Perhaps the thread evokes the same human behaviour as a car wreck on the freeway: people can't help but slow down to have a look!

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!;)

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!

Thanks Peter.
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.