A little more progress.
The front slam panel corners need to be rebuilt/replaced.
Rather than wait for the parts from Europe, I decided to have a go at fabricating my own. Not having a stretcher / shrinker makes the jobs a little trickier but you never know unless you try.

http://forums.pelicanparts.com/uploa...1464008630.jpg

Enter the trusty stove cap and the I-Beam.

http://forums.pelicanparts.com/uploa...1464008713.jpg

Flatten the flanges.

http://forums.pelicanparts.com/uploa...1464008740.jpg

http://forums.pelicanparts.com/uploa...1464008771.jpg

Step one complete.

http://forums.pelicanparts.com/uploa...1464008789.jpg

Cut the piece in half to make the two corners.

http://forums.pelicanparts.com/uploa...1464008815.jpg

Now for the tricky bit: working the second edge.
The inside radius of the stove cap seems to be the right radius.

http://forums.pelicanparts.com/uploa...1464008856.jpg

http://forums.pelicanparts.com/uploa...1464008903.jpg

A bit of planishing and a few welds and they may just work!
Or at worst, the second set will be better.

http://forums.pelicanparts.com/uploa...1464008952.jpg

Trim the edges and weld in a captive nut for the lower fender bolt.

Tremendous amount of good work going into this car.

Keep going!

OMG! That is just a whole lot of work you have accomplished there. I can't wait to see more pictures.

Thanks very much for the encouragement. Nice to know there are others out there enjoying this as much as me!

A whole bunch of small jobs start to add up over time! Thanks for support. I'm afraid you'll have to wait for more pictures as I only work on weekends...some weekends. But stay tuned, at this rate I'll be busy doing this for a few years yet.

Quick update on the front suspension pan and fuel tank carrier.
This has been an ongoing saga for a while.
Wife very generously gave me the a whole Saturday.
So decided to tackle it and get it done.

All prepped and ready to be covered up for another 50 years.
Seams sealed, battery support patch welded-in and a final coat of paint just for safety.

http://forums.pelicanparts.com/uploa...1464024454.jpg

http://forums.pelicanparts.com/uploa...1464024583.jpg

Mid-surgery always looks a mess, but it's all solid and reasonably neat underneath the primer / paint/ sealer.

http://forums.pelicanparts.com/uploa...1464024603.jpg

Just to be safe I stripped away all the epoxy primer to bare steel, and then hit it with etch primer.

http://forums.pelicanparts.com/uploa...1464024974.jpg

And then the really hard behind any decent welding job: the endless fitting, removing, tweaking, fitting etc etc.

http://forums.pelicanparts.com/uploa...1464025003.jpg

http://forums.pelicanparts.com/uploa...1464025057.jpg

Especially when you bend your 6'2" frame into the spot where the fuel tank should go, only to discover you've left your side-cutters next to the kettle in the kitchen!
When you get back from retrieving the aforementioned side cutters and your left hand welding glove is where the side-cutters were......

And as you start to plug weld, that local chap with the racing / road-legal SC arrives for the visit he has been promising for months....not really complaining

http://forums.pelicanparts.com/uploa...1464025187.jpg

http://forums.pelicanparts.com/uploa...1464025244.jpg

http://forums.pelicanparts.com/uploa...1464025277.jpg

Got to love an SC. One day the world will appreciate just how fantastic they truly are. Anyway, that's a different soapbox...I might be slightly biased.

http://forums.pelicanparts.com/uploa...1464025330.jpg

I lost count at 52 plug welds.

http://forums.pelicanparts.com/uploa...1464025686.jpg

http://forums.pelicanparts.com/uploa...1464025703.jpg

http://forums.pelicanparts.com/uploa...1464025721.jpg

Too late for a grinder so a wire brush and a coat of etch primer will suffice until next weekend.

http://forums.pelicanparts.com/uploa...1464025738.jpg

And just to make sure (even though I measured a hundred times) the fuel tank fits perfectly with some room to spare.

http://forums.pelicanparts.com/uploa...1464025804.jpg

And that's another job crossed off the list.

http://forums.pelicanparts.com/uploa...1464025857.jpg

Quick update.
A few stolen hours.

Finishing up the front slam panel repair.
It's the small jobs that take the most time.

http://forums.pelicanparts.com/uploa...1465195565.jpg

http://forums.pelicanparts.com/uploa...1465195584.jpg

http://forums.pelicanparts.com/uploa...1465195600.jpg

http://forums.pelicanparts.com/uploa...1465195614.jpg

And the inner kidney repair...repairing a bad repair.

http://forums.pelicanparts.com/uploa...1465195654.jpg

http://forums.pelicanparts.com/uploa...1465195674.jpg

And a nice piece from a trade: an oe alloy engine lid.

http://forums.pelicanparts.com/uploa...1465195716.jpg

I swear it's lighter than the fibreglass lid I already have!

http://forums.pelicanparts.com/uploa...1465195745.jpg

Alu bootlid in all its glory.
Lovely piece of Porsche jewellery.
Nice detail for the whole lightweight theme.

http://forums.pelicanparts.com/uploa...1465800811.jpg

Back to the LHD sill reconstruction.
First is the lower door hinge post.

http://forums.pelicanparts.com/uploa...1465800826.jpg

After spending a day reconstructing the lower fender joining panel, I've finally come to terms with the fact that it has to go.
Marginal in places and badly repaired.
There is no way that it will take a weld and to make such little patches will be a pain.
Add another 4 hours to the work list!

http://forums.pelicanparts.com/uploa...1465800868.jpg

http://forums.pelicanparts.com/uploa...1465800933.jpg

http://forums.pelicanparts.com/uploa...1465800948.jpg

Last small jobs on the outer sill: fill the holes and strip to bare steel for etch primer.

http://forums.pelicanparts.com/uploa...1465800997.jpg

http://forums.pelicanparts.com/uploa...1465801045.jpg

http://forums.pelicanparts.com/uploa...1465801063.jpg

And in goes the kidney. With a fair amount of fitting to match the contour of the repaired lower section.

http://forums.pelicanparts.com/uploa...1465801080.jpg

Quick test fit of the sill to check gaps was positive.
The rear will come up once I have finished cutting and fitting the rear to get it snug up against the kidney and the jacking tube.

http://forums.pelicanparts.com/uploa...1465801234.jpg

Some work to do on the door...obviously!
But the gaps are uniform, so happy there.

http://forums.pelicanparts.com/uploa...1465801247.jpg

Everything is drilled and primed and ready for the little MIG.
Progress. And another 5 jobs off the list.

On its wheels by the end of July is still possible.....maybe.

The kidney is done.

http://forums.pelicanparts.com/uploa...1466158383.jpg

Lower door hinge post patch is in and sealed up.

http://forums.pelicanparts.com/uploa...1466158406.jpg

And now for my patented sill flange alignment tool.
I-Beam, ribber bands and a hammer.

http://forums.pelicanparts.com/uploa...1466158436.jpg

Here it is in action...

http://forums.pelicanparts.com/uploa...1466158509.jpg

Having no helpful assistant, this helped ensure the outer sill sits as close to the face of the already welded-in inner sill. The I-Beam acts as a dolly, the spade head o the hammer sits against the outer rocker, and with the help of a heavier hammer, the two metal surfaces are persuaded to sit nice and snug together.

http://forums.pelicanparts.com/uploa...1466158641.jpg

The first few plug welds are in and things are looking good. I'm welding in the outer rocker from the inside as getting the MIG shroud nice and close to the surface is difficult from the outside with the U-Shaped profile of the outer rocker.

And alignment is good.

http://forums.pelicanparts.com/uploa...1466158720.jpg

The gaps are nice and uniform, but I'll probably use shims in the hinges to close the gap at the rear of the door, against the door lock post.

http://forums.pelicanparts.com/uploa...1466158780.jpg

Looking good Barnes, keep the momentum!!

http://forums.pelicanparts.com/uploa...1466354172.jpg

Definitely heading out of the woods now.
Progress.
Having all the steel done will be major achievement.
A slight pause and celebration, followed by the black hole of hours know as bodywork.
Anyway.

On with the show.
Checking alignment and finishing the lower plug welds.
You have to be careful. Assume nothing.
As the lower flange mates up against the inner sill, the gap to the door widens.

http://forums.pelicanparts.com/uploa...1466353956.jpg

Whoever invented the octisserie is a genius.
Seriously.
It makes working on the car a pleasure.
There really isn't an area you can't get up to eye level.
Welding a set of castors onto the uprights makes life even easier.

http://forums.pelicanparts.com/uploa...1466354127.jpg

The last tricky fabrication job (that's right, 'the last') is the lower piece of the fender / rocker / door lock post. Mine is properly rotten; at least 3 laters of rotten steel.

[img]http://forums.pelicanparts.com/uploads25/IMG_18691466354313.jpg[/img

The old vs the new.
Everything gets stripped for etch primer.

http://forums.pelicanparts.com/uploa...1466354422.jpg

The old corner was properly rotten.
And it didn't look that bad when I bought the car.

http://forums.pelicanparts.com/uploa...1466354479.jpg

http://forums.pelicanparts.com/uploa...1466354546.jpg

The rocker end gets etch primer.
And the kidney; the seam sealer got a coat of paint.

http://forums.pelicanparts.com/uploa...1466354608.jpg

The lower door lock post patch needs lengthening, to replace the rotten piece above.
For once, there are no curved flanges to deal with!

http://forums.pelicanparts.com/uploa...1466354684.jpg

In she goes.
You can see how high up the door lock post the rot climbed.
And inside of this - the inner kidney - was all gone.

http://forums.pelicanparts.com/uploa...1466354768.jpg

Interesting how it all moves.
Pressing the patch hard up against the door frame pushes the inner edge of the lower
rear fender in bu about 10mm.
Some kind of fulcrum going on.

I've joined it up but I'll leave the plug welds until the lower patch is on.
I learned a lot from the other side.
But there is a whole bunch of potential movement when each of the seams starts to get welded. I'll need to concentrate and take my time.

Another job off the list.
Progress.
Only a few sessions from having the whole body done.
All the steel.
In just under 3 years.

Then I'll clean up and paint the underside.
The interior, the engine bay and the boot.

Then another major phase begins: bodywork.
Having a lot of FBG panels, there will be a whole bunch of working and building edges to get the panel gaps right.

Oh,and then there is that other thing:
The engine.

As luck would have it, the MIG gave up the ghost.
This time the wire is getting snagged somewhere in the sleeve at the base of the gun.
The time has come to buy my own.

In the meantime, a piece of jewellery arrived from Portugal.
A set of Cibie's with the perfect amount of rust and old paint and well-used lenses.
[Thanks Vasco].

Rushed home to mock them up.

http://forums.pelicanparts.com/uploa...1466961441.jpg

http://forums.pelicanparts.com/uploa...1466961557.jpg

Look great against the primer grey.
I'm sucker for spray can photoshop (especially when the MIG is out of action)

And so an idea turns into masking tape, a can of gloss black and some gold pin-stripe I've been playing with....

http://forums.pelicanparts.com/uploa...1466961708.jpg


http://forums.pelicanparts.com/uploa...1466961849.jpg


http://forums.pelicanparts.com/uploa...1466961930.jpg


http://forums.pelicanparts.com/uploa...1466961982.jpg

After that little adventure, time to do some actual work.
The LHD door.

http://forums.pelicanparts.com/uploa...1466964048.jpg

All the rot cut out.

http://forums.pelicanparts.com/uploa...1466964088.jpg

Making a patch with the right profile is pretty easy.
The trusty anvil with a piece of 3mm plate welded to it.

http://forums.pelicanparts.com/uploa...1466964148.jpg

Making the step is simple with the help of a couple of c-clamps and two hammers.

http://forums.pelicanparts.com/uploa...1466964186.jpg

Hold the smaller one with the spade in position and give it a decent whack with a bigger hammer.

http://forums.pelicanparts.com/uploa...1466964221.jpg

And a then a spare bracket from our fireplace comes in handy.

http://forums.pelicanparts.com/uploa...1466964262.jpg

A good whack all along the edge evens out individual strike marks from the little hammer. A coal chisel with a spade blade, the edge rounded with a grinder, would work even better.

http://forums.pelicanparts.com/uploa...1466964316.jpg

The curve below the step is also simple; using the vice to hold it, you can get the curve started by hand, then smooth it with a dolly.

The profile is pretty good.
Some dolly work between tack welds and it will be perfect.


http://forums.pelicanparts.com/uploa...1466964531.jpg

http://forums.pelicanparts.com/uploa...1466964563.jpg

With a shrinker getting the curve would be straight forward. Pity I don't have a functioning shrinker.

http://forums.pelicanparts.com/uploa...1466964619.jpg

I made a template out of 4mm steel a while back.
This is will help line up the door skin.

With the outer sill / lower door lock post profile I should be able to get the curve bang on.

http://forums.pelicanparts.com/uploa...1466964695.jpg

The original edge is in decent shape, so that will also help.

http://forums.pelicanparts.com/uploa...1466964803.jpg

...now to find a decent replacement MIG.

Lower door patch.
Cut and shape using the template I made.

http://forums.pelicanparts.com/uploa...1467301010.jpg

Scribing the line of the bend with a dremmel helps keep the bend crisp. Be easier with a bead roller.....a shrinker would make the edge much cleaner.

http://forums.pelicanparts.com/uploa...1467301126.jpg

http://forums.pelicanparts.com/uploa...1467301253.jpg

http://forums.pelicanparts.com/uploa...1467301295.jpg

A bit of hammer and dolly work and the result is not too bad.

http://forums.pelicanparts.com/uploa...1467301961.jpg

Nice clean edge.
I'll trim down the flange to match the original width once it's welded in.

http://forums.pelicanparts.com/uploa...1467302001.jpg

Cleaned and primed.

http://forums.pelicanparts.com/uploa...1467302093.jpg

Now all I have to do is try and get the MIG working again.

Matthew,

It's most likely the sleeve that's worn on your torch. To get a new one chat to the guys at e-weld.

If you are intent on a MIG, have a look at the TradeWeld 200M.

It can do both 0.6 and 0.8 wire (not 1mm as it says in the online specs), run as low as 20A, and you can hook a spool gun to it if you want to do aluminium. It costs around R7000 (also at e-weld), but if you have a pensioner to take with you on a Wednesday you get 10% off on the same unit at Builders' Warehouse :D.

Willem

Thanks Willem.
The sleeve is knackered. And I have a spare from the UK. But getting the fittings off the existing sleeve is proving too much for me. They seem to made of two halves that are pinched together.

The irony is that I have only a day or two's worth of welding left to do! Will see if I can jury-rig it to get the remaining work done. Thanks for the e-weld tip, they have some really nice machines. A decent MIG would be great, but I'm leaning towards a TIG. Envious of your set-up with both machines. I see they also sell a hand-held spot welder which I would invest in if I was starting from scratch. A TIG, a MIG AND a spot welder would be perfect!

Finally for round to getting the strut braces done.
An engineer mate with proper skills (and access to the right machinery) made me these rsr braces. Laser cut and cleanly bent. Took a while to get them lined up and straight.

http://forums.pelicanparts.com/uploa...1467917323.jpg

http://forums.pelicanparts.com/uploa...1467917346.jpg

Cleaned and etch primed.

http://forums.pelicanparts.com/uploa...1467917381.jpg

Strut brace needed to be trimmed.

http://forums.pelicanparts.com/uploa...1467917418.jpg

http://forums.pelicanparts.com/uploa...1467917454.jpg

And a little seam sealer. Done.

http://forums.pelicanparts.com/uploa...1467917500.jpg

http://forums.pelicanparts.com/uploa...1467917537.jpg

Tick another job off the list.