Hi Brian,

I am glad you like the thread. I hope it has been educational and will be used as a reference for others going down the same path.

Day 77: Today I was able to clean up the vin plate, overriders, and door sill plates. The plan is to install all of this stuff on Sunday.

VIN plate before

http://forums.pelicanparts.com/uploa...1352127957.jpg

VIN plate after. There is a little bit of patina left on there which is fine with me:)
http://forums.pelicanparts.com/uploa...1352128012.jpg

Rear bumper trim correctly installed

http://forums.pelicanparts.com/uploa...1352128045.jpg

Overrider before

http://forums.pelicanparts.com/uploa...1352128088.jpg

Overrider after

http://forums.pelicanparts.com/uploa...1352128116.jpg

Test fitting door sill plate
http://forums.pelicanparts.com/uploa...1352128152.jpg

Day 78: Today was an epic day in the rebirth of the Rat. Peter was able to come over for about 4 hours and we were able to install the rear bumpers, license plate panel, overriders and front passenger fender. We also got the rear lights in. We were also able to rivet in the vin plate and door sill plates because Peter brought over his rivet gun. Peter who is a sticker fiend also did the engine compartment stickers for me. These turned out absolutely perfect. Fitting the fender using the WD-40 trick on the Terostat was excellent. Here are some pics of a great day

Cleaning for stickers

http://forums.pelicanparts.com/uploa...1352128414.jpg

With stickers

http://forums.pelicanparts.com/uploa...1352128449.jpg

VIN plate riverted in

http://forums.pelicanparts.com/uploa...1352128484.jpg

Door sill plates riveted in

http://forums.pelicanparts.com/uploa...1352128585.jpg

The rear end all put together
http://forums.pelicanparts.com/uploa...1352128621.jpg

http://forums.pelicanparts.com/uploa...1352128654.jpg
http://forums.pelicanparts.com/uploa...1352128685.jpg
http://forums.pelicanparts.com/uploa...1352128711.jpg

It amazes me to see what you started with and where you are now. Amazing work!! Outstanding!!!

Thank you for sharing the journey.

Day 77 cont: I was able to finish up the assembly of the driver side fender for installation later this week. This involved fitting the fuel door and the latch mechanism. Installing the latch mechanism which needs a 6 mm allen wrench in a very tight spot was quite the pain!

http://forums.pelicanparts.com/uploa...1352128952.jpg

http://forums.pelicanparts.com/uploa...1352129020.jpg
http://forums.pelicanparts.com/uploa...1352129044.jpg

Kristoph,
Very good to see the progress. Looking great! Please keep the pictures coming. Gives a small glimmer of hope to all of us whose projects are languishing.
David

I have all sorts of random parts for sale that I will not be needing to finish the Rat.

Please PM me if you are interested in any of the following:

A set of fair door stays
928 male hood latch complete
strut tube dust cover
strut tube front upper mount
body covers for sway bar holes
male hood latch (no cup)
male trunk latch (no cup or spring)
male trunk latch (complete) - this is from a 912 but it is the same latch
trunk carpet in fair shape with a few holes

Looking great.

Glad the WD40 trick worked well for you.

It did indeed. I think moving around the fender without it would have been very difficult. I am planning on using seam sealer in the wheel well in addition to the Terostat to insure that no water gets into any cracks. I will then spray a final layer of the rudderized undercoating in the wheel well.

PM Sent...

No progress for the last couple of days due to grading and other work related obligations. I am hoping to get the driver fender on this weekend and start working on the doors. I also hope to get the bumper mounted. I might also be able to put in the Thermocoustic sound deadening material and maybe start on the carpet. If all goes according to plan it will be another breakthrough weekend. Last night I was able to get the Rat started and ran the engine for about 15 minutes. I can't wait to be driving around with the beautiful sound of an air cooled flat six in my ears again!! My last major obstacles include:

Headliner
Carpet Install
Door Reassemby
Dash
Glass Install
Getting all the lights to work correctly
New Batteries

Any tips or tricks for these tasks would be greatly appreciated!

The final tasks will be an alignment and bleeding the brakes

Headliner - never done it, but threads here indicate it is time consuming and troublesome

Carpet Install - there is a diagram floating around hre; post if you can't find it
- also, in a recent thread, a guy found a non-toxic glue that works well

curious to hear what you will use for Thermocoustic sound deadening

I've done or helped do the following:

Headliner:
Go invest in a ton of binder clips for the headliner. They will be your best friend when bonding it at the edges. There wasn't really any rocket science to it but it was somewhat tedious. When I helped Jason do his (non-sunroof car), we used the binder clips to clamp the edges of the headliner prior to glueing so that we could see where it was going to want to wrinkle and bunch. Then we just adjusted the material and reclamped as necessary. IIRC, he applied the adhesive in small sections at a time, only removing the binder clips in the section he was working on. There are probably other ways to do it, but that seemed to result in a pretty decent finished product.

Door reassembly:
Fairly simple... the big trick is just figuring out the order of operations and solving the puzzle to get the window back in the track on the regulator. I don't have pictures but I remember there being openings in the regulator track (horizontal) where, if you took the window regulator to the bottom limit with the window guides (vertical) removed, the window would come out of the track. Installation should be reverse. Sorry if my terminology is off. I'm assuming the '69 is the same as or similar to the '71 and IIRC correctly, the door latch and lock mechanism went in first, then the window regulator. I would order new plastic clips that retain the linkage rods for the door openers and lock button. The old ones get really brittle.

Hope that helps at least a little...

A couple of threads that might be useful for the headliner install...basically covering the description by 95avblm3.

Early 911 registry:
71E resto....headliner DIY

And another discussion on Pelican with a link to a youtube video:
http://forums.pelicanparts.com/porsche-911-technical-forum/666633-part-1-headliner-install-dont-scared.html

Hopefully they're helpful...since I'll be using your thread as a reference when I install my headliner. :)

Here is a link for a youtube video of a guy installing a headliner in a 68.

911 68 headliner fitting with Gary Cook.wmv - YouTube

This guy also has videos up for just about everything else on your list.

Hope this helps.

For whatever reason I haven't posted on this thread even though I check every week or so. I can't hold back anymore, it's just so cool to see it going together with such a great new color! Congrats on the progress so far and best of luck as you continue to go forward!

Ahh... Peter Morgan from the UK... I didn't realize he had added more videos of his project. His are very detailed, maybe a little slow at times but overall a very good resource.

^^^Sorry it is taking me multiple posts to spit it all out but...

Kristoph: before you attempt your headliner, I strongly suggest your watch the video that SC-Alfa posted. My suggestion of the binder clips worked well for us but Gary Cook gives some very valuable tips in the video that we didn't even think of... like marking centerlines, only attaching the underside first so that you have adjustment before wrapping the flange, etc.

Good job! Everything is coming together nicely...you are on the 10 yard line!

Thanks to everyone for their great suggestions, especially Jeremy, and Von. Thanks SC Alfa for the link to the video. I have watched it and it will be most useful especially doing the headliner. The plan for this evening is to do the front driver fender and maybe mount the front bumper!