Started on the body.
Used a sponge roller to get the first coat on, on the outside.
Sandblasted steel gives a great surface for the paint to bond to.

http://forums.pelicanparts.com/uploa...1403777600.jpg

Then broke out the spray gun to do the interior and underside.

http://forums.pelicanparts.com/uploa...1403777667.jpg

http://forums.pelicanparts.com/uploa...1403777703.jpg

http://forums.pelicanparts.com/uploa...1403777722.jpg

http://forums.pelicanparts.com/uploa...1403777740.jpg

http://forums.pelicanparts.com/uploa...1403777766.jpg

Indicator housings were remarkably intact.

http://forums.pelicanparts.com/uploa...1403777789.jpg

Then some sanding and a second coat of primer.
Changed colour to help with cutting through.
Lovely stuff to sand.
180 then 400 wet and dry.

http://forums.pelicanparts.com/uploa...1403777931.jpg

http://forums.pelicanparts.com/uploa...1403778019.jpg

http://forums.pelicanparts.com/uploa...1403778051.jpg

And more sanding....and more sanding.

180
400.
800.
1200.
Repeat.
Getting ahead of myself but the roof and quarters come up beautifully when you spend the time with the sand paper. But lots of rust to sort before we get close to getting the primer smooth.

http://forums.pelicanparts.com/uploa...1403796054.jpg

The bottom of the car looks a bit like a sieve in places.
Some places will need to be cut out and patched, but the repairs don't give me access to places that will no doubt have surface rust: suspension tube, bottom of the rear wheel house below the torsion tube, transmission tunnel, the box section in the engine bay, behind the heater tubes and in the cavities behind the lower suspension pan.

So my plan involved a petrol sprayer and water-based rust converter.
Dilute the rust converter 2 to 1 and use the petrol sprayer to blast the stuff into every cavity until it drips out the various rust holes. Then cover with a rust converter primer (similar to red oxide but without the etch aspect)

http://forums.pelicanparts.com/uploa...1403796896.jpg

http://forums.pelicanparts.com/uploa...1403796912.jpg

Bottoms of the doors are rotten (to be expected) but the rest is solid.

http://forums.pelicanparts.com/uploa...1403796965.jpg

http://forums.pelicanparts.com/uploa...1403797026.jpg

http://forums.pelicanparts.com/uploa...1403797112.jpg


http://forums.pelicanparts.com/uploa...1403797203.jpg

New steel is a little pricy with a 10 to 1 exchange rate, and transcontinental shipping!
But now have all I need...or rather the minimum.
Have avoided ordering a front slam panel and the floorboard clip helps....two very expensive parts (considering no-one does a rhd replacement floorboard).

http://forums.pelicanparts.com/uploa...1403797614.jpg

The floorpan involved the now familiar hand stripping with torch, scraper and then 3M wheel. A nasty job. But considering the saving......

http://forums.pelicanparts.com/uploa...1403797473.jpg

The parts have been a mix of RD and Sportwagon Eckhart . SE is a bit cheaper on account of there being a few direct flights a week from Germany to SA. Both have been great to deal with.

You got mail.
http://forums.pelicanparts.com/uploa...1403797717.jpg

964 outer rockers very kindly 'loaned' to me. Indents will have to be flattened.

http://forums.pelicanparts.com/uploa...1403797758.jpg

http://forums.pelicanparts.com/uploa...1403797818.jpg

http://forums.pelicanparts.com/uploa...1403797849.jpg

These replacement lower hinge post patches are great.
Decent gauge and a nice fit.
From Sportwagon Eckhart.

http://forums.pelicanparts.com/uploa...1403797881.jpg

My only criticism are RD's rear window corners. They have no gutter lip. Will have to fashion some. A tricky little piece of work despite paying 120 $ for 2 parts.

http://forums.pelicanparts.com/uploa...1403798028.jpg

http://forums.pelicanparts.com/uploa...1403798060.jpg

Interesting idea for the rear parcel shelf that needs the corners done.....like they all do. Smuggler's box pressing is the same as the parcel shelf on the swb cars. So I reckon I can sacrifice this spare cover to make two patches.

http://forums.pelicanparts.com/uploa...1403798143.jpg

Now all I need to do is get all these bits welded in!
Simple.....when you know how.

Shiny new metal, nice! How do you plan on flattening the indentations on the rocker panels?

As far as I recall the way to do it is to make two vertical cuts on either side of the indent and then flatten them out with the aid of a buck and a hammer. Then weld and fill. Some guys weld in a little patch. Will see when I get to item #647 on the list!

A few bits and pieces I have been playing with while waiting for some real progress.
Colour scheme is an organic process...I call it spray can photoshop....

http://forums.pelicanparts.com/uploa...1404201803.jpg

Satin black engine lid works quite well...imho.

http://forums.pelicanparts.com/uploa...1404201854.jpg

With some gold pin striping tape

http://forums.pelicanparts.com/uploa...1404202032.jpg

Like the idea of going with black anodised window trim

http://forums.pelicanparts.com/uploa...1404202082.jpg

And some DIY grilles. Cymbal for colour reference.

http://forums.pelicanparts.com/uploa...1404202162.jpg

http://forums.pelicanparts.com/uploa...1404202218.jpg

http://forums.pelicanparts.com/uploa...1404202241.jpg

Centre filler....I remember a little chemistry

http://forums.pelicanparts.com/uploa...1404202293.jpg

http://forums.pelicanparts.com/uploa...1404202311.jpg

And the Momo Monza Steering wheel. Something different, with a little R influence.

http://forums.pelicanparts.com/uploa...1404202507.jpg

Time to start with the welding.
After getting numerous quotes and trying to puzzle different ways of paying for the body to get sorted, I decided to do the metal work myself.

Short of a broken shackle on a wind pump, I've never welded anything before. I've digested a lot of theory from this forum and from the tube. We'll see how reality compares.

I've borrowed a little machine from a mate. Clarke 90 Amp. 25/75 gas and .8mm wire. Lots of practise on different gauge scrap to get the wire speed sorted......and some muscle memory.

http://forums.pelicanparts.com/uploa...1406529789.jpg

http://forums.pelicanparts.com/uploa...1406529811.jpg

http://forums.pelicanparts.com/uploa...1406529840.jpg

The first real project is to patch two rust spots at the front and rear of the longitudinal.

http://forums.pelicanparts.com/uploa...1406530015.jpg

http://forums.pelicanparts.com/uploa...1406530048.jpg

http://forums.pelicanparts.com/uploa...1406530071.jpg

Steel behind the lower door post corner is not great. Looks worse on camera than it is. If it weren't in such a tricky spot I would cut it out.

http://forums.pelicanparts.com/uploa...1406530145.jpg

http://forums.pelicanparts.com/uploa...1406530241.jpg

Rear Patch
http://forums.pelicanparts.com/uploa...1406530093.jpg

And a coat of paint over the rust converter before it all gets covered up.

http://forums.pelicanparts.com/uploa...1406530367.jpg

Also drilled a hole at the top of the door hinge post to allow me to spray rust converter in the top...and wax when the time comes. Plan is to drill quite a few of these through the chassis: rear box sections, wheel house corners etc.

http://forums.pelicanparts.com/uploa...1406530479.jpg

Next step the inner sill.
Clean off the factory black, drill, fit.

http://forums.pelicanparts.com/uploa...1406530703.jpg

http://forums.pelicanparts.com/uploa...1406530732.jpg

http://forums.pelicanparts.com/uploa...1406530771.jpg

http://forums.pelicanparts.com/uploa...1406530802.jpg

There is a Porsche in there somewhere.....
http://forums.pelicanparts.com/uploa...1406530831.jpg

Had a few goes to make sure the welds were penetrating. Drilling out dodgy welds are school fees I guess.
http://forums.pelicanparts.com/uploa...1406530879.jpg

http://forums.pelicanparts.com/uploa...1406530992.jpg

http://forums.pelicanparts.com/uploa...1406531036.jpg

Not going to win any prizes, but it's solid and straight.

Jack tube support plate. I'm sure there are better / smarter ways to do this but this seemed to make the most sense to me, with my limited skills.

Step 1.
http://forums.pelicanparts.com/uploa...1406531189.jpg

Step 2.
A mate gave me a great tip: I-Beam scraps as an anvil. A piece of railway track is ever better, but haven't managed to find a piece yet.
http://forums.pelicanparts.com/uploa...1406531281.jpg

Step 3.
http://forums.pelicanparts.com/uploa...1406531411.jpg

Step 4.
I need to get a mini cutting disk for the air grinder. A mini grinder with a 4 inch disk makes cutting accurately quite tricky.
http://forums.pelicanparts.com/uploa...1406531452.jpg

Step 5.
http://forums.pelicanparts.com/uploa...1406531517.jpg

Step 6.
http://forums.pelicanparts.com/uploa...1406531538.jpg

Step 7.
Backing plate. I welded a piece of round bar scrap to the I-Beam to make a buck / anvil. Radius is perfect for the bottom curve of the body.
http://forums.pelicanparts.com/uploa...1406531568.jpg

Step 8.
http://forums.pelicanparts.com/uploa...1406531727.jpg

Step 9.
http://forums.pelicanparts.com/uploa...1406531754.jpg

Step 10.
http://forums.pelicanparts.com/uploa...1406531846.jpg

Step 11.
http://forums.pelicanparts.com/uploa...1406531866.jpg

Step 12.
Drilled and ready for welding.
http://forums.pelicanparts.com/uploa...1406531907.jpg

Quite proud of this.

Strip off the factory black and etch prime.

http://forums.pelicanparts.com/uploa...1406532049.jpg

http://forums.pelicanparts.com/uploa...1406532070.jpg

That was about 12 hours of work.
Next steps:
- lower door hinge post
- rust patch behind kidney
- kidney
- outer sill
- door lock post patch into outer sill
- lower flare cut welded back on....

And then the same on the other side.
And the front, and the floor pan, and the parcel shelf, and the rear window corners.

The trick is to focus on what you have done, and not what is still to be done. A lot like life I guess.

To plug these holes later, pop in at Skiffy in Midrand. They stock a great selection of plastic caps and plugs. As far as I can recall any quantity under 10 is considered a sample and come at no cost. Their catalogue can be browsed at Skiffy plastic parts, Skiffy metal parts, components.

Nice progress! I really like your solution to a jacking tube, and the welding looks just fine!

Nice work.

Next step: closing up the indents on the 964 sills.
Good practice for welding and grinding.
These things are filled with holes.

http://forums.pelicanparts.com/uploa...1407741383.jpg

http://forums.pelicanparts.com/uploa...1407741413.jpg

A makeshift anvil. Round tube welded to a piece of I-Beam scrap.
http://forums.pelicanparts.com/uploa...1407741453.jpg

http://forums.pelicanparts.com/uploa...1407741479.jpg

Welded up and ground down. Not the prettiest but a thin skim of filler will finish it off.
http://forums.pelicanparts.com/uploa...1407741505.jpg

http://forums.pelicanparts.com/uploa...1407741590.jpg

Stronghand Tools. Good quality and a good price...even when imported with a silly exchange rate. Can never have too many clamps.

http://forums.pelicanparts.com/uploa...1407741640.jpg

Lower door hinge post patch.
Restoration Design.
Pretty good fit.

http://forums.pelicanparts.com/uploa...1407741797.jpg

http://forums.pelicanparts.com/uploa...1407741818.jpg

And the dreaded shut lines.
Doors from a 71 targa.
Sills from the 90s.
Shell from 67.

Have been terrified of this step - combination of how much filler and fiberglass there was in the old patchwork of rusted, layered steel that were pretending to be outer sills, and my lack of skill / experience working steel. I hoped that somehow, by some miracle, I would be able to fit everything back together with the minimum of hammering, shaping and four-letter words.

http://forums.pelicanparts.com/uploa...1407742020.jpg

http://forums.pelicanparts.com/uploa...1407742037.jpg

http://forums.pelicanparts.com/uploa...1407742060.jpg

http://forums.pelicanparts.com/uploa...1407742087.jpg

All credit to Porsche. Their bits really are made properly.
Usually a fair amount of lead, but mine was fairly unleaded.
Unlike the FBG front wings.
Has anyone, ever, in the history of car construction received FBG panels that fit?
I doubt it.
But at least they are FBG so working them will be relatively painless.

http://forums.pelicanparts.com/uploa...1407742208.jpg

http://forums.pelicanparts.com/uploa...1407742230.jpg

Next step: patching the lower door lock post.......