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A small celebration of a milestone: getting the rhd sill reconstruction into primer.
Still some crafting to do but having the repairs all nicely covered in epoxy primer feels like progress! Now at least when I look at how much there is still to do, I can narrow my field of vision and focus on this part of the car and think of what it used to look like! Before: (June 2013) http://forums.pelicanparts.com/uploa...1416209766.jpg http://forums.pelicanparts.com/uploa...1416209806.jpg During: http://forums.pelicanparts.com/uploa...1416209935.jpg http://forums.pelicanparts.com/uploa...1416210311.jpg http://forums.pelicanparts.com/uploa...1416210338.jpg http://forums.pelicanparts.com/uploa...1416210384.jpg After (November 2014) http://forums.pelicanparts.com/uploa...1416210448.jpg http://forums.pelicanparts.com/uploa...1416210485.jpg http://forums.pelicanparts.com/uploa...1416210521.jpg http://forums.pelicanparts.com/uploa...1416210628.jpg Quite a bit more flatting to do, and a few places that need a skim with filler. Once the door is patched and primed, the rhd side will officially be done. 18 months left until deadline so I had better up my work rate! |
Final patch on the rhd door.
Tricky one. In hindsight I could have made life easier for myself. ... http://forums.pelicanparts.com/uploa...1416822678.jpg http://forums.pelicanparts.com/uploa...1416822705.jpg http://forums.pelicanparts.com/uploa...1416822741.jpg Front and rear are welded in. Now job I have been dreading: getting this door to appear smooth, and mate with the door lock post and the door hinger post. Which means filler. http://forums.pelicanparts.com/uploa...1416822785.jpg http://forums.pelicanparts.com/uploa...1416822875.jpg The newer batch of the Luxor Ultralight is snot yellow. Slightly more attractive than snot green. http://forums.pelicanparts.com/uploa...1416822900.jpg Top of the door is in pretty good condition. http://forums.pelicanparts.com/uploa...1416822956.jpg http://forums.pelicanparts.com/uploa...1416823008.jpg Sand until your back aches then test fit, remove and repeat. http://forums.pelicanparts.com/uploa...1416823044.jpg Gaps still pretty good. Bit of an overbite on the corner, but I'll cut a relief cut in the edge and knock it in a bit. http://forums.pelicanparts.com/uploa...1416823085.jpg |
The summer rains have come. (The second since I rescued the car)
So the end of a weekend means covering up all the exposed steel spots until next weekend. Still have a lot of flatting to do on the door, followed by another skim of filler. Sense of progress when 2/3rds of the one side is in the same colour primer. http://forums.pelicanparts.com/uploa...1416823321.jpg http://forums.pelicanparts.com/uploa...1416823482.jpg The door gaps look decent...a minor miracle to be honest. http://forums.pelicanparts.com/uploa...1416823542.jpg Really happy with the rear quarter. If I can get the door to look anything like the quarter I'll be well chuffed. Particularly considering that there is not that much filler on the panels....far less than I thought I would need. http://forums.pelicanparts.com/uploa...1416823675.jpg http://forums.pelicanparts.com/uploa...1416823708.jpg The 'indents' are the hastily applied primer, not imperfections. After 400 wet it will be gorgeous. Glaciers move master than I do, but they are not as smooth. http://forums.pelicanparts.com/uploa...1416823739.jpg |
This door is killing me.
About to have a go at the fourth round of filling and sanding on account of highspots! In working in new steel and trying to remove a large indent in the centre of the door I clearly pushed some bits out.....AAARRRGGHHHH! Need to spend some time with an old school sheet beater. "The last 10% takes 90% of the time".... Enough of this. Time to let something else frustrate me. http://forums.pelicanparts.com/uploa...1417678733.jpg |
Cue Hitchcock soundtrack..
"The Parcel Shelf" Nasty one this. Properly rotten. I have been scheming this one for a while. http://forums.pelicanparts.com/uploa...1417678859.jpg I really want to try and keep as much of the original SWB pressings and those lovely drilled holes in the channel support....hence the complicated patch. Here's some more of the 80s "just leave the rust and braize a patch over the top" http://forums.pelicanparts.com/uploa...1417678983.jpg There is a spot of rotten metal further up the channel, so I'll have to drill the spot welds and cut out a piece to get at it. Oi Vey. http://forums.pelicanparts.com/uploa...1417679446.jpg http://forums.pelicanparts.com/uploa...1417679007.jpg Here's the donor. (71 Targa) http://forums.pelicanparts.com/uploa...1417679121.jpg http://forums.pelicanparts.com/uploa...1417679139.jpg Over sized to give me room to manoeuvre. In one or two places I might use a lapp weld. We'll see. Some of the rot that came out. http://forums.pelicanparts.com/uploa...1417679177.jpg http://forums.pelicanparts.com/uploa...1417679256.jpg There is quite a bit of patching to be done. http://forums.pelicanparts.com/uploa...1417679291.jpg The trick is going to be figuring out the order of repair. I'm thinking as follows: - patch the inner and outer fender skin. - patch the upper part of the windscreen channel. - weld in parcel shelf patch, leaving seam against inner fender unattached to allow correct positioning of windscreen frame. - weld in outer corner patch Any wisdom out there with regards this repair? Porsche Pointer http://forums.pelicanparts.com/uploa...1417680175.jpg |
Started cutting away the rot.
It was a while until I stopped. http://forums.pelicanparts.com/uploa...1417972332.jpg It really would help a lot if Restoration Design added two inches onto the ends of their rear window corner patch. On these older cars the rot is seldom only in the corner. it extends up into the frame, down into the engine bay and across into the lower windscreen channel. (Will send Mike and his team a note....the rain channel would also be nice) Kept the rotten pieces to help me figure out how all these panels come together. This didn't look too bad on the outside. http://forums.pelicanparts.com/uploa...1417972831.jpg http://forums.pelicanparts.com/uploa...1417972853.jpg http://forums.pelicanparts.com/uploa...1417972900.jpg http://forums.pelicanparts.com/uploa...1417972466.jpg http://forums.pelicanparts.com/uploa...1417972492.jpg First step is to make a patch that can replicate the pinch seam. http://forums.pelicanparts.com/uploa...1417972600.jpg I reckoned the best way to do this is to use the existing seam as a buck http://forums.pelicanparts.com/uploa...1417972733.jpg http://forums.pelicanparts.com/uploa...1417972949.jpg |
Next cut out the rotten pinch seam.
http://forums.pelicanparts.com/uploa...1417973058.jpg http://forums.pelicanparts.com/uploa...1417973111.jpg Cutting down into a beautifully smooth panel always turns my stomach...but the rot must go. Some much accumulated muck up here where these panels come together it gives me a chance to do some cleaning. The fabricated seam profile looks pretty good. http://forums.pelicanparts.com/uploa...1417973229.jpg http://forums.pelicanparts.com/uploa...1417973267.jpg I'll trim and tack and pinch the excess once the outer corner patch is aligned and in place. Using slightly thinner gauge steel should help me get the seam nice and snug. Thinking of adapting a pair of vice grips with the form of the seam, kind of like a pair of flangers. Can't afford for the seam to have any imperfections. http://forums.pelicanparts.com/uploa...1417973328.jpg Next step is to fix the rot on the inside wheel arch. A piece of the donor targa came in handy. http://forums.pelicanparts.com/uploa...1417973536.jpg http://forums.pelicanparts.com/uploa...1417973591.jpg http://forums.pelicanparts.com/uploa...1417973620.jpg Now the tricky bit. Where the inner fender panel comes up and joins with the corner and the parcel shelf. http://forums.pelicanparts.com/uploa...1417973686.jpg http://forums.pelicanparts.com/uploa...1417973736.jpg |
Once I have figured the exact line of the outer piece, I'll bend and trim the excess to meet the inside of the outer corner. Easier said than done.
http://forums.pelicanparts.com/uploa...1417973809.jpg http://forums.pelicanparts.com/uploa...1417974066.jpg http://forums.pelicanparts.com/uploa...1417974109.jpg These are the ingredients. Going to need to do some clever bracing to ensure that all the pieces align on the outside. Such an important visual part of the car. In my opinion the most beautiful. |
Taken me a while to get back into the project. Already the end of March.
After staring at the gaping hole regularly for the last 3 months, I finally ran out of excuses and jumped back in. My measuring and cutting skills have got a little rusty. Two patches didn't fit right, leaving gaps between the old original parcel shelf and the new steel = high probability of burning through and numerous four-letter expletives. So cut the tack welds and started again. http://forums.pelicanparts.com/uploa...1427963694.jpg Finally managed to get the corner patch welded in. http://forums.pelicanparts.com/uploa...1427963910.jpg http://forums.pelicanparts.com/uploa...1427963939.jpg Made life very difficult for myself by trying to keep the original drilled out look of the brace between parcel shelf and window channel. Didn't quite line up. Will have to go back and patch that at a later date. Next step was to replicate the edge of the parcel shelf that joins with the underside of the corner piece and runs through to form the rain channel at the edge of the engine lid opening. The RD piece unfortunately doesn't include this part of the pressing. http://forums.pelicanparts.com/uploa...1427964027.jpg http://forums.pelicanparts.com/uploa...1427964121.jpg |
The only solution to rain gutter lip seemed to be to make a tool.
I traced the curve of the original piece and cut it out of 4 mm steel. http://forums.pelicanparts.com/uploa...1427964228.jpg Then used it as a buck to beat the edge up to form the lip. Seems to work pretty well. Now I just need to figure out how to get the horizontal part of the lip done - perhaps the negative part of the tool? http://forums.pelicanparts.com/uploa...1427964385.jpg http://forums.pelicanparts.com/uploa...1427964413.jpg http://forums.pelicanparts.com/uploa...1427964451.jpg Will trim the excess once I've figured out how to shape the horizontal lip |
Now the bit I've been dreading; the window corner.
Considering what these cost me, I spent at least an hour slowly making sure I trimmed it to perfection. http://forums.pelicanparts.com/uploa...1427964981.jpg http://forums.pelicanparts.com/uploa...1427965100.jpg http://forums.pelicanparts.com/uploa...1427965123.jpg http://forums.pelicanparts.com/uploa...1427965143.jpg Finally. Starting to look like progress. http://forums.pelicanparts.com/uploa...1427967697.jpg Now I need to finish the crimping on the rain gutter....and then start on the rhd side of the parcel shelf! |
Quick job to cut out the dodgy patch over the original 912 engine mounts.
The po left the original rusted steel pressing and welded piece dover the top - just like the rest of the car. Cut out the bad steel and welding. Also gave access to the box section and a chance to clean up and rust protect. http://forums.pelicanparts.com/uploa...1427967971.jpg http://forums.pelicanparts.com/uploa...1427968025.jpg Shape a two piece patch and weld it all closed again. http://forums.pelicanparts.com/uploa...1427968090.jpg http://forums.pelicanparts.com/uploa...1427968135.jpg |
Well done sir!;)
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Thanks Steve.
A little bit here and there, slowly, adds up to real progress! |
Started to attack the rhd side of the parcel shelf / window corner.
Because I'm not that smart and like to make life difficult for myself, I have decided to try and keep as much of the original shape and style of the pressings. My vision far exceeds my ability, but that's never stopped me before. Life with a bend brake and a guillotine would be be so much easier. Not to mention a shrinking, flanger etc etc. But for now a plank with a narrow channel cut into it, a chisel and a few clamps will have to suffice. Replicating the brace between parcel shelf and window channel. http://forums.pelicanparts.com/uploa...1429172221.jpg http://forums.pelicanparts.com/uploa...1429172308.jpg The homemade anvil has been a life-saver. http://forums.pelicanparts.com/uploa...1429172345.jpg http://forums.pelicanparts.com/uploa...1429172400.jpg And there it is. Pretty chuffed with that. http://forums.pelicanparts.com/uploa...1429172535.jpg The rot that came out of the corner http://forums.pelicanparts.com/uploa...1429172589.jpg The new steel that will replace it http://forums.pelicanparts.com/uploa...1429172656.jpg |
The LHD side is almost done.
Need to clean up the welds and finish the rain channel. Not too bad. http://forums.pelicanparts.com/uploa...1429173265.jpg |
Great work Matthew. You'll be finished before you now it.
I like your sig "Don't buy a Porsche until you can afford two" |
An excellent example of a true labor of love. I applaud your tenacity and fabrication skills, sir!
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I'm not where I want to be, but I sure am a long way from where I was :) Would love to take credit for the quote but I stole it from someone else. Pretty much sums up this addiction we all share. |
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Thanks for the compliments. In truth, I had never welded when I started. But reading through the threads here and watching every youtube video on welding and fabricating is about all the education you need. Patience also helps. Cheers. |
A month or two and I have made some progress.....
Stripped and etched the patches. http://forums.pelicanparts.com/uploa...1435409293.jpg Glaciers move faster. |
The jigsaw puzzle comes together.
http://forums.pelicanparts.com/uploa...1435409733.jpg http://forums.pelicanparts.com/uploa...1435410380.jpg http://forums.pelicanparts.com/uploa...1435410395.jpg http://forums.pelicanparts.com/uploa...1435410413.jpg http://forums.pelicanparts.com/uploa...1435410429.jpg Aside from the lip on the rain channels in the corners (RD corner patches have no lip), I'm done with the $%^&* parcel shelf / corners repair! |
The dreaded LHD sill / door slam post.
This side looked worse than the other. Appearances were not deceiving. http://forums.pelicanparts.com/uploa...1435410578.jpg http://forums.pelicanparts.com/uploa...1435410606.jpg http://forums.pelicanparts.com/uploa...1435410619.jpg The floorpan directly under the seat rail support is not good. http://forums.pelicanparts.com/uploa...1435410638.jpg Properly rotten inside http://forums.pelicanparts.com/uploa...1435410694.jpg Seat rail support will have to be patched. Hopes of a quick patch fade away.... http://forums.pelicanparts.com/uploa...1435410748.jpg |
Jack support tube is rotten.
Unfortunately the steel of the floorpan all along the sill looks like its too far gone. http://forums.pelicanparts.com/uploa...1435410844.jpg http://forums.pelicanparts.com/uploa...1435410946.jpg The inside edge of the kidney area is also beyond repair....mainly thanks to previous repairs. This will have to all come out. Another tricky repair. http://forums.pelicanparts.com/uploa...1435410968.jpg http://forums.pelicanparts.com/uploa...1435411089.jpg Enough of that. Decided to make a tactical retreat and save what little optimism I have left. I needed to take my frustration out on something, so I decided to cut! The utterly rotten and equally appallingly repaired front slam panel. http://forums.pelicanparts.com/uploa...1435411213.jpg http://forums.pelicanparts.com/uploa...1435411240.jpg http://forums.pelicanparts.com/uploa...1435411277.jpg The sense of purpose that comes with committing to a cut line often fades with realities of the patch that has to be hand made, with hand tools, and half a brain. |
Here we go.
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Here we go.
Step One: Hand bend a piece to the vertical shape of the panel. http://forums.pelicanparts.com/uploa...1435411546.jpg Make relief cuts along the horizontal curve lines and bend in the bottom. http://forums.pelicanparts.com/uploa...1435411576.jpg http://forums.pelicanparts.com/uploa...1435411674.jpg http://forums.pelicanparts.com/uploa...1435411698.jpg 45 cuts seems to line up well. Sometime you get a little lucky. http://forums.pelicanparts.com/uploa...1435411755.jpg http://forums.pelicanparts.com/uploa...1435411820.jpg Weld up and clean. http://forums.pelicanparts.com/uploa...1435411947.jpg http://forums.pelicanparts.com/uploa...1435411918.jpg Now to bend and shape the flanges, and the battery support plate. |
Onwards with the front suspension pan.
The patch under the battery tray doesn't line up exactly, so I'll have to add a lip to mate with the suspension pan lip. http://forums.pelicanparts.com/uploa...1435728495.jpg http://forums.pelicanparts.com/uploa...1435728568.jpg The rhd side is pretty good and solid....luckily. Just the front section needs to be patched. At least my welding is getting better! http://forums.pelicanparts.com/uploa...1435728639.jpg Now the tricky bit. My octisserie is mounted to the front suspension tube bolt holes, so the front of the frame has to come off.... And the bracing has to come out to test fit the petrol tank. http://forums.pelicanparts.com/uploa...1435728873.jpg Cue balancing, cursing, a jack balanced on old wheels etc etc. Additional lower patch and flange welded in. http://forums.pelicanparts.com/uploa...1435728950.jpg The test fitting and removing the pan with multiple clamps and stubborn flanges, and taking the a-arms in and out is exhausting. Luckily I had a set of new bushes so everything was tight. But hell on the lower back for a 6'2" frame. And then it was in! Some alignment along the front lip height to be done, but a major job ticked off the list. http://forums.pelicanparts.com/uploa...1435729115.jpg http://forums.pelicanparts.com/uploa...1435729155.jpg http://forums.pelicanparts.com/uploa...1435729185.jpg http://forums.pelicanparts.com/uploa...1435729210.jpg |
And now for the rhd fuel tank support patch.
Start with the old one. http://forums.pelicanparts.com/uploa...1436081563.jpg Mark up all the flanges and cuts. http://forums.pelicanparts.com/uploa...1436081619.jpg Cut and bend. http://forums.pelicanparts.com/uploa...1436081647.jpg Trace the curve of the forward part of the support, and then weld in the vertical section. I have found that leaving the excess helps control heat. Once it's all welded, I grind back the excess. http://forums.pelicanparts.com/uploa...1436081726.jpg With a bit of hammering the fit isn't too bad. (As Gary Player said "The more I practise, the luckier I get") http://forums.pelicanparts.com/uploa...1436081755.jpg Considering that the outer flange was pretty tired, I laid a bead between the two panels to add strength. Then hit the cavity with etch primer and the bead with seam sealer. I'll most likely drill a hole in the top of the support so I can get in there with cavity wax. http://forums.pelicanparts.com/uploa...1436081815.jpg Test fit and align the edges of the patch. Tack weld and ready tho go. http://forums.pelicanparts.com/uploa...1436081905.jpg All done. Looks pretty good. Quite proud of that! http://forums.pelicanparts.com/uploa...1436081961.jpg Tank gap is exactly to spec (to the mm).....even a blind squirrel finds a nut! And the tank support aligns perfectly (although the edges are going to need some persuading) http://forums.pelicanparts.com/uploa...1436082088.jpg Next step, the LHD side. |
That ALMOST looks like fun!
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.....almost!
When it all goes to plan then it is fun. |
On to the lhd tank support.
Had to cut out more rot on this side so getting the patches all aligned with the fuel tank support was a bit trickier. Start with a cardboard template. http://forums.pelicanparts.com/uploa...1436730190.jpg Cut, bend and drill. (Top tip: drill the holes before you bend the flanges) http://forums.pelicanparts.com/uploa...1436730220.jpg Same procedure with the lower half of the patch. Took a lot of time to get the two pieces aligned. Cut a relief cut in the top of the patch to get the flanges to sit in and tightly against the inner fender. http://forums.pelicanparts.com/uploa...1436730269.jpg Tack weld and check for fit. http://forums.pelicanparts.com/uploa...1436730384.jpg The fuel tank support panel is needs a few relief cuts to fit...don't they all. http://forums.pelicanparts.com/uploa...1436730470.jpg |
Finish the welds.
http://forums.pelicanparts.com/uploa...1436730597.jpg Just to be sure I played a bead on the other side. http://forums.pelicanparts.com/uploa...1436730633.jpg Cleans up pretty well. So much easier to weld when you can weld on a bench! Clean steel, good earth and no more than 50 amps with 1mm wire in an old MIG. Not bad. http://forums.pelicanparts.com/uploa...1436730684.jpg Etch primer and in she goes. Pretty good fit. http://forums.pelicanparts.com/uploa...1436730767.jpg Need to stitch in the lower suspension pan, seam seal and prime before i weld this patch in. Also need to find a suitable pipe to weld in for the headlights / indicator harness. By the time I'm done with all these patches, I'll hopefully have enough cash for the new front slam panel. One weekend at a time. |
Decided to leave the front slam panel for a while.
Lots of little patches to be made on the lhd boot lip. http://forums.pelicanparts.com/uploa...1441557397.jpg http://forums.pelicanparts.com/uploa...1441557459.jpg Amazing how many little corners have rust in them. Replacing the bigger rusty panels is easier than all these little patches. http://forums.pelicanparts.com/uploa...1441557516.jpg http://forums.pelicanparts.com/uploa...1441557599.jpg And the lip along the front of the scuttle was badly repaired. So that will have to be done as well. Going to try and weld the patches from underneath to minimise grinding in a tight spot. That'll have to wait until the car is on its side. http://forums.pelicanparts.com/uploa...1441557693.jpg http://forums.pelicanparts.com/uploa...1441557717.jpg |
And again, a change of scenery.
The driver's side footwell. http://forums.pelicanparts.com/uploa...1441557828.jpg Helps to have a later targa pan. Unfortunately it was cut out short of the rockers. So I'll have to be a 2 part patch. http://forums.pelicanparts.com/uploa...1441557851.jpg http://forums.pelicanparts.com/uploa...1441557905.jpg http://forums.pelicanparts.com/uploa...1441557928.jpg http://forums.pelicanparts.com/uploa...1441557955.jpg http://forums.pelicanparts.com/uploa...1441557977.jpg Decided to to plug and lap weld the new section into the old steel. Some of the old steel is pretty tired and I can't face fabricating the footwell. It won't be as pretty as I'd like but it will be strong. http://forums.pelicanparts.com/uploa...1441558011.jpg |
http://forums.pelicanparts.com/uploa...1441558214.jpg
Fit and shape. http://forums.pelicanparts.com/uploa...1441558232.jpg Getting there. Plug and stitch. I'll weld the lower lip of the lap weld when the car is on it's back. http://forums.pelicanparts.com/uploa...1441558322.jpg |
Looking good Barnes
Just noticed how much it looks like swiss cheese in that colour ;) Keep the momentum!! |
Thanks Ducatisti.
A good Parmesan. God knows it costs about as much! |
The rear floorpan on the rhd side is toast. Thin with loads of holes.
Must have had wet carpets under the seat for years. The donor floorpan to the rescue once again. http://forums.pelicanparts.com/uploa...1442162528.jpg By using the lhd side, and flipping it, I could get the whole patch in one piece. I cut it much bigger than I needed just in case. http://forums.pelicanparts.com/uploa...1442162736.jpg http://forums.pelicanparts.com/uploa...1442162809.jpg After lots of test fitting and double checking the fit, I cut the galvanised patch to size. http://forums.pelicanparts.com/uploa...1442162850.jpg Tack weld, bliksem (Afrikaans for 'hammer'), repeat. Slow going. http://forums.pelicanparts.com/uploa...1442162910.jpg Welding is pretty good these days. More good than bad. Consistent penetration and a neat bead. Another few years and I'll be half decent. http://forums.pelicanparts.com/uploa...1442163088.jpg Clean up and etch prime topside and underside. No plan to grind the welds down, but they'll get seam sealer and a fresh coat of satin something...still not sure what colour to eventually paint it....oxblood red is starting to grow on me. http://forums.pelicanparts.com/uploa...1442163397.jpg |
The Octisserie is a marvellous thing.
I had a spare set of castors lying around and welded them to the one side. Means I can flip the LO over and still move it about. The minimum amount of effort to get set up and put away is important when you are stealing hours. http://forums.pelicanparts.com/uploa...1443366824.jpg Can now do a whole bunch of jobs. Like lay a bead along the lower edge of the outer rocker. http://forums.pelicanparts.com/uploa...1443366893.jpg And reinforce the plates on the bottom of the front suspension pan...but then the MIG packed up. So while I wait for spares I'll do some patch fabrication. The bottom of the smugglers box is pretty rotten. Inside and out. http://forums.pelicanparts.com/uploa...1443367024.jpg I had to cut out a lot more than the rot to make room to get in there with a grinder. http://forums.pelicanparts.com/uploa...1443367091.jpg The underside was also toast. http://forums.pelicanparts.com/uploa...1443367133.jpg A couple of places here where two skins come together. Going to have to plan the welding carefully. All the rot. Including the brace for the steering column inside the smuggler's box. http://forums.pelicanparts.com/uploa...1443367505.jpg |
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