I really didn't want a project this big....yet...

[DaddyGlenn]

Headed out to get some shielding gas for the welder and some metal to practice on today.

Found a little more rust when I pulled the dash out. I'm kinda getting used to the fact that there is serious rust repair in my future. If others can do it, why not me?



Biggest problem I have now is that, mentally, I am slipping down that slope. Thinking about wider fenders, which means new wheels. Also thinking about a roll bar and other time and cash consuming ideas.

Control arms are on the way back from Chuck. Replacement metal for the front bumper shock mount areas is also on the way.

[Wil Ferch]

Funny....I'm looking at a lot of lower-priced ( than the "norm") SC's and 3.2 Carreras...for a project I have in mind....and a LOT of nice sounding/looking cars had this very same lower rocker-to-latch plate area rust show up. Some very badly. What the heck is goin' on?. Is this a place that "packs" with crud and decays rapidly? It is ending up much too common to feel comfortable about.

[DaddyGlenn]

Originally Posted by Wil Ferch

{snip}... Is this a place that "packs" with crud and decays rapidly? It is ending up much too common to feel comfortable about.

I've scoured the forums and it seems to be common. I think it is the design of the front end of the rear wheel wells. Traps all kinds of junk and rots its way forward.

Here is a picture of mine. You can see how crud would build up there.

[aigel]

There are no inner fenders on these cars. None of the German cars of that era had them. A real shame, it isn't that the inner plastic fender wasn't invented by then. You get some salty mud in there during the winter time and it will be the gift that keeps on giving all year long.

Nowadays rust prevention by manufacturers include avoiding any traps like that. Even metal lips and edges are sealed off with body sealer. If the customers would not have gravitated towards the companies offering the best rust protection / warranty, we'd still have the car companies sell us self-destructing rust buckets.

George

G

[Wil Ferch]

Porsche at some levels is a company of contradictions. Electrical fuses are another area that was well known by the 80's in industry... and Porsche was stuck in the stone ages and continues with flawed electrical circuit designs. Can't even call that late-news....just simply bad design known all along.

And yeah...lack of plastic fender liners.....the thickness of maybe plastic milk carton jugs could have done the trick. Pretty cheap to incorporate into the build/design.

Think of the many threads that speak to packing the crud "really and truly" well into the car into the various collection points.

- LF fender area by the water bottle for mid 80's Carrera's
- tail-light housing assemblies...if you ever take them out, you'll see the tons of crud that accumulates.
- now seeing "this" latch plate area.
- I'm sure many others. The top-edge seam where the body meets the front fender longitudinally on the top ledge and leads to the cowl...( you know the area I'm talking about), that area is exposed to view whenever a front fender is removed. I've never seen an SC or Carrera *without* rust on this body "ledge", although the cars are galvanized.

Porsche introduces galvanized steel and doesn't finish the job for the simple lack of thin, cheap, plastic sheathing.

Amazing.

[DaddyGlenn]

I may make some design modifications as I make repairs or after.

[wildcat077]

Glenn,

How do you like your auto set Miller welder ? Seems like you will have your hands full.I just picked up a Millermatic 212 with auto set in replacement of my smaller Lincoln unit and i can't wait to try it !
Hopefully not on MY car ... lol

Just waiting to pick up 10 Meters of 8/3 SOOW cable to wire into my machine ...

Cheers !
Phil

[Tom '74 911]

Originally Posted by DaddyGlenn

Biggest problem I have now is that, mentally, I am slipping down that slope. Thinking about wider fenders, which means new wheels. Also thinking about a roll bar and other time and cash consuming ideas.

I know EXACTLY how you feel and think!

Tom

[DaddyGlenn]

Not much done lately but here is a quick update.

I've chosen fabric for the seats. Yes, I'm going to use a yellow plaid. the yellow is a pretty good match for Talbot Yellow. I just can't decide if I should cover the cushions in the plaid and leave the rest of the seat black or cover the seat in plaid and do the cushions in black.



Also sourced some metal for the front and did some practice welding this weekend.

[wayner]

Any updates on the metal work?

[911Maverick]

Love'n that yellow plaid. Awesome.

[DaddyGlenn]

I posted a metal work update here.

http://forums.pelicanparts.com/paint-bodywork-discussion-forum/565023-talk-me-through-rust-repair-please-3.html#post5649370

[DaddyGlenn]

Got some more work done. Here is the driver's side front shock mount, replaced with a coat of POR-15, primer and several coats of Wurth's rubberized undercoat. The undercoat builds very nicely.

[DaddyGlenn]

It has been slow going. All the metal replacement on the front of the tub is done and I'm working on the area around the door/rocker panels. I've got to replace the kidney bowls on both sides and the lower 2/3 of both door lock posts. Here is a shot of the left side while I await the arrival of new metal.

[gregwils]

Looks good. You have a lot going on. I'll try to stop by in a few months to introduce myself. My motor is out and so is the front suspension - new rubber bushings, inserts and regrease the rack, plus some other small WYIT stuff. Still, will be back on the road in 6 to 8 weeks.

Are you planning to doing the welding on the rear fenders yourself?

[DaddyGlenn]

Originally Posted by gregwils

Looks good. You have a lot going on. I'll try to stop by in a few months to introduce myself. My motor is out and so is the front suspension - new rubber bushings, inserts and regrease the rack, plus some other small WYIT stuff. Still, will be back on the road in 6 to 8 weeks.

Are you planning to doing the welding on the rear fenders yourself?

Hey Greg. This project isn't the half of it. Got a ton of stuff going on in the other aspects of life, too.

Yes, I plan on doing all the welding myself. I also plan to do the interior and as of right now, the strip and repaint, too. I am comfortable with the mechanical stuff but the metal and paint work is pushing my skills to new limits. Wish I only had 6-8 weeks.....

I am now living in Upper St. Clair. It would be nice to meet a local Pelican.

[DaddyGlenn]

Progress photo.

Caption: "Dear Lord, what have I done?!"

[KNS]

Daddy,

Good work, thanks for keeping another one on the road!

[fastfredracing]

You sir, are a madman with the sheetmetal, great work. Not to hijack this thread, but have we met before? Did you ever hang around the north park swimming pool at the NHSCC autocrosses? I remember talking to a guy a few times with a yellow 911 that he had just repainted himself, looked pretty nice. Seems like you fit this description pretty good. I was there every weekend with a red 911 sc.

[will hung]

Good job Glenn, keep up the momentum. If the Pittsburgh Pelicans ever organize a get together, I'd like to see it.