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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.



Enter the trusty stove cap and the I-Beam.



Flatten the flanges.





Step one complete.



Cut the piece in half to make the two corners.



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





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



Trim the edges and weld in a captive nut for the lower fender bolt.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 05-23-2016, 05:09 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #201 (permalink)
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Tremendous amount of good work going into this car.

Keep going!
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"I started out with nothin and I still got most of it left...."
83 911 SC Guards Red (now gone)
And I sold a bunch of parts I hadn't installed yet.
Old 05-23-2016, 05:23 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #202 (permalink)
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OMG! That is just a whole lot of work you have accomplished there. I can't wait to see more pictures.
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Old 05-23-2016, 05:32 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #203 (permalink)
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Quote:
Originally Posted by billybek View Post
Tremendous amount of good work going into this car.

Keep going!
Thanks very much for the encouragement. Nice to know there are others out there enjoying this as much as me!
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 05-23-2016, 09:25 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #204 (permalink)
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Quote:
Originally Posted by Cairo94507 View Post
OMG! That is just a whole lot of work you have accomplished there. I can't wait to see more pictures.
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.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 05-23-2016, 09:26 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #205 (permalink)
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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.





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



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



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





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







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.

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 05-23-2016, 09:45 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #206 (permalink)
 
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I lost count at 52 plug welds.







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



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



And that's another job crossed off the list.

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 05-23-2016, 09:51 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #207 (permalink)
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Quick update.
A few stolen hours.

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









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





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



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

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-05-2016, 10:49 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #208 (permalink)
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Alu bootlid in all its glory.
Lovely piece of Porsche jewellery.
Nice detail for the whole lightweight theme.



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



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!







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







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

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-12-2016, 10:59 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #209 (permalink)
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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.



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



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.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-12-2016, 11:02 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #210 (permalink)
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The kidney is done.



Lower door hinge post patch is in and sealed up.



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



Here it is in action...



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.



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.



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.

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-17-2016, 02:19 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #211 (permalink)
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Looking good Barnes, keep the momentum!!
Old 06-17-2016, 02:30 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #212 (permalink)
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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.



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.



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.



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





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



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



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.



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.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-19-2016, 08:56 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #213 (permalink)
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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.





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....










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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
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Old 06-26-2016, 09:26 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #214 (permalink)
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After that little adventure, time to do some actual work.
The LHD door.



All the rot cut out.



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



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



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



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



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.



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.






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

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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
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Old 06-26-2016, 10:10 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #215 (permalink)
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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.



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



...now to find a decent replacement MIG.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-26-2016, 10:14 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #216 (permalink)
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Lower door patch.
Cut and shape using the template I made.



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.







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



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



Cleaned and primed.



Now all I have to do is try and get the MIG working again.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 06-30-2016, 07:55 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #217 (permalink)
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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 .

Willem
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Old 07-01-2016, 12:45 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #218 (permalink)
 
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Quote:
Originally Posted by Willem Fick View Post
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 .

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!
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 07-07-2016, 10:44 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #219 (permalink)
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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.





Cleaned and etch primed.



Strut brace needed to be trimmed.





And a little seam sealer. Done.





Tick another job off the list.
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Don't buy a Porsche until you can afford two.

1980 SC - sold
1983 SC
1967 912.5 in DIY build
Old 07-07-2016, 10:52 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #220 (permalink)
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