Reassembly Begins (now I could use some help)

[TC911e]

There's still a long way to go, but I've finally gotten to a point where I'm facing putting something on instead of just taking pieces off. Which just raises another set of questions. The question of the hour, and I'm sure more will follow, is about how to deal with bare sheetmetal that's sandwiched together for spot welding.

The car is a '69 911e. I've rebuilt the right front corner in front of the battery box where the previous owner apparently crunched it, which was poorly repaired, which trapped enough water that it rusted to nothingness. I'm now about ready to attach a new front seal lip. The original one is rusted away in the corner, and it was pretty rusty between the front lip and the front partition panel.

(Before)

(Almost to after)





What should I do to the lip and the front partion beyond cleaning the rust off the front partition and treating it with PickleX? Strip the black primer/paint off the new part or leave it on? Give everything a coat of weld through primer to get some coverage at least where it doesn't burn off?

I plan to come back an give everything a shot of epoxy primer, but there will be places it won't be able to get to. The new lip looks like it's built to drain better, but....

(Old lip and New Lip)


Any recommendations would be appreciated.
Tim

[Bob Kontak]

Clean and scuff the rails before priming.

Spray at odd angles to get primer between the welded panels. Don't worry about runs, etc. Just get paint in there. Make sure it is as clean and dry as can be before painting. 80 grit the runs off on the visible surfaces after drying.

Inject some Gravitex between the welded panels the best way you can after the "crevice" priming. I am thinking something like an old fashioned oil can may do the trick and even drill some small access holes where you cannot squirt it in from the sides. Trim off the drippings after it sets up. Then spray the Gravitex or Wurth product giving a uniform bumpy finish (you need the gun) and go over all with epoxy again before color.

This is not a conventional repair so unconventional methods are ok. :-) You can buy a cheap sand blaster to knock some of the rust off before coating.