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

Time to start the project thread. I had intended to rebuild the suspension, make the exhaust legal, fix a coupe rust bubbles and a few small while I'm there tasks.

That was before I found this..
http://forums.pelicanparts.com/uploa...1285447721.jpg

and this..
http://forums.pelicanparts.com/uploa...1285447773.jpg

and this..
http://forums.pelicanparts.com/uploa...1285448245.jpg

And some other ugliness.

So the project has grown. In addition to the tasks listed above, this thread will cover an windows out repaint, the addition of an IROC style whale tail, a refresh of the interior and some fancy front and rear bumpers (haven't decided what style yet) and probably a lot more while I'm in there stuff.

I'm going to need to learn a lot on this one. Definitely stepping outside my comfort zone.

I feel ya, one of my own personal cars is being torn down bare chassis.
I have a trickle or little bit of rust I had found. It's important to go over things with a methodical and sharp eye. No where to the same extent as you have, but the trickle could mean more. I can't risk it.

Good luck man.

This was the tip of the iceberg, so to speak.

http://forums.pelicanparts.com/uploa...1285449789.jpg

I knew there would be more but geeez...:eek:

Any time you have rust like that in your last pic, you have to know it's the tip of the iceberg. At least you'll know what you have after you're finished. Good luck.

Ah, so familiar, the feeling of being sucked into a Black Hole. The whole first half-year of my project was a series of unfortunate discoveries. But now, two years later, there's definitely light at the end of the tunnel. If you've got the will, the time, and the money, you can deal with whatever you find. Enjoy it, and good luck.

Mike

Glenn,
Good luck! you'll get through this!

If any one is interested...
 

I am detailing my adventures in rust repair in a different thread in the Paint and Bodywork Forum.....here

Shopped around a bit and have ordered a MIG welder. Should be here in a couple days. Waiting for control arms to come back from rebuild service at ER. Gotta source some body parts and buy a couple more small tools.

So today I installed the turbo tie rods. Actually a pretty easy job.

http://forums.pelicanparts.com/uploa...1285612123.jpg

Poke around the front wind-shield as well in the lower corners as this area also tends to rust and then drips water into the cabin behind the dash right where all the electrics are located!

I'm in the same boat and love it! I bought a Lincoln 140 last year and have been scraping and prepping, replacing bits and pieces. There never is enough time to work on it.

Good luck!

I think I found the front valance I will use. This is a TRE product and uses the stock bumper.

http://forums.pelicanparts.com/uploa...1285633606.jpg

This one is on a wide body but there is a version to fit my SC as well.

^Hehe, I took that picture when I used to work for Dave. Yeah, he can set you up with that valence. It's a replica of the NLA Kremer valence from the '80s (also used by Ruf).

Small world, huh?

I do remember the Kremer Porsches of way back. Not sure about the grill in the middle but I think it will work on a yellow car, good contrast. I'm going to have an IROC whale tail so I'm mixing decades.....

Basically, I need a valance that allows me to keep the stock bumper and fits an SC with stock fenders. This was the only one I found.

DaddyGlen-

I feel your pain. My car was about at your point 2 years ago. I bought a MIG welder and jumped in. It was actually fun once the anxiety wore off. Just be slow and careful and measure 8 times before cutting and recognize that the replacement panels almost never fit properly out of the box. The tough part now, once I have the body essentially sorted, is getting those outrageous estimates for painting the car. I have the feeling that painting is not as easily learned as metalwork.

Spent about 10 minutes and removed the windshield this morning. Pretty simple job.

I used a plastic thread gauge to push back the trim connectors and then slid the gauge under the trim. Pushing firmly and moving slowly all the way around freed the trim without any damage.

http://forums.pelicanparts.com/uploa...1285685117.jpg

Then using a razor knife with a new blade I cut the seal off the top of the glass.

http://forums.pelicanparts.com/uploa...1285685194.jpg

Then peel the rubber off and the glass is free to be pushed out from inside.

http://forums.pelicanparts.com/uploa...1285685247.jpg


After lifting out the glass and removing the rest of the seal I was greeted with good news. I had a few rust bubbles and expected the worst but it appears that it isn't too bad and I'll be able to get by with some clean up and POR-15. :)

That's exactly the right way to remove the glass so it does not break. I'm glad you found no major damage in those corners as this would be a tough job to fix.

Christmas came early. Several items I bought arrived today.

Couple used Corbeau seats. I will recover the blue in a yellow plaid.

A fiberglass IROC style whale tail. Very rough shape so I will be building my bodywork skills even more. (I knew the shape when I bought it and paid accordingly)

And a new Millermatic 140. Let the welding begin!

http://forums.pelicanparts.com/uploa...1285805399.jpg

Go Glenn Go! I am sorry to see the rust but know you will do just fine repairing the yellow 911. My hats off to you for tackling the welding repair but know you are the kind of guy to get it done!

good luck. i don't have nearly that much rust on my car but its going to be nice seeing how u go about fixing yours. good choice in the miller unit. both my welders are millers never had an issue with either in 10+yrs of use.

I would dump that body and get a rust free roller to swap everything over. It will be less time consuming, likely more cost effective and on top of that more durable. That rust you have there will come back out unless you cut it all out to the bone.

George