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I would rather be driving
 
jpnovak's Avatar
 
Join Date: Apr 2000
Location: Austin, TX
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So, today at lunch I bought some square tubing. I should have a body dolly fabricated and welded in the next day or two. It should not take long to get the suspension dropped and the tub on the rolling cart. I am excited to get to that point so that the repairs can really start.
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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
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Old 02-10-2015, 11:59 AM
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Quote:
Originally Posted by jpnovak View Post
Today I started the process of adding weight back to the car today. What? No, I am not bolting new parts on the car. In fact, I removed some rusty metal. Below is the result of 25 minutes and 5 cut-off wheels in my grinder. I have a feeling I need to go buy stock in an abrasives company the way I am going to go through consumables.

.....
Something I heard recently is that stainless cut-off wheels far outlast the standard abrasive wheels and more than make up for the cost premium. Something I intend to try for myself.

Watching with great interest!

Tim K
Old 02-16-2015, 09:04 PM
  Pelican Parts Technical Article Directory    Reply With Quote #22 (permalink)
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Jamie, are you a professional welder? I am watching this project with a mixture of terror and fascination. How do you get everything to fit the way it should? How do you keep the unibody square?

Talented folks like yourself amaze me. I can do a bunch of mechanical stuff, but bodywork looks to me like Black Magic.

Keep up the good work, and keep us posted. Thanks so much for sharing.
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Old 02-17-2015, 07:09 AM
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Get a Plasma cutter. It's way more fun then cutting disks.
Old 02-17-2015, 07:25 AM
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Quote:
Originally Posted by MJHanna View Post
Get a Plasma cutter. It's way more fun then cutting disks.
Plasma Cutter + severely rusted metal is usually a recipe for frustration from my limited experience. Cutting discs and the occasional reciprocating saw are more consistent though probably "just a little" more mess.

I went by and visited Jamie this weekend to take a look. Once you get past obsessing about what is rusted, and look at what is solid, you can see that other than some reasonably easy to replace and readily available parts, the tub is solid and will come back about 80% or more with just the rear seat pans, floors, and front suspension pan. The rest Jamie already has solid plans to correct.

Go Jamie, go!
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Old 02-17-2015, 08:32 AM
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Well done so far
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Old 02-17-2015, 10:38 AM
  Pelican Parts Technical Article Directory    Reply With Quote #26 (permalink)
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Week 2:

So despite some work travel I managed to get some progress done. First I will address a few questions.

Currently the tub is not connected with additional bracing. Why you ask? The structural parts of the tub are not rusty and the entire outer "cage" is fully supporting the tub. The tub is sitting level on my lift without any additional load of suspension or drivetrain. These cars are pretty stout and I have not yet cut out any part of the tub that I consider to be structural in any way. There will be a time for bracing but now is not the time. I could not get my panels in place if I closed the passenger compartment with bracing.

Plasma Cutter. Mark, I used to have one. I never used it. I think the cut-off wheels are more precise except for tight corners. Mine also left a ragged edge that I still had to clean up with a grinder. That was 14-15 years ago. Maybe the home use versions are better now. Bring your's down in March and I can borrow it for a few weeks.

Time for a little game of "what is this?" or "where does this go?"







































Give up? Let's see. Three holes, one larger than the other. One stud. Lots of crust. Well. It came out of this...





Yes, that is the pedal cluster. Err, I guess I should say this was the pedal cluster. Its a bit rusted. I have NEVER seen anything like this. Oh, the part in the first pic? That was the back edge of the pedal cluster. The stud attached to through the tunnel to the master cylinder. It went into the trash. Add that to my list of parts to buy. Oh yeah, that sheet metal part sticking forward? That is the floor reinforcement for the pedal cluster. It also locates the gas pedal. This is what you get when you cut this out of the car. This was the third dustpan. Morrie was there to help sweep up the pile.




Scarey!!! Well to some. I expected it on this project.

So Saturday I kept cutting. I took out the front pan and also the heel panel. These are currently rough cuts needed before I start fitment.





Why did I cut these out? Well besides the rust I finally have something shiny to take pictures of. New sheet metal! Thanks to Mike at Restoration Design for quick packing and shipping. They arrived while I was away for a work trip. Thanks to Fedex for having routine Saturday delivery.



At lease the new panel looks much better than the old. You can see how bad the heel panel was in the comparison.



This is the first test fit. I will have to massage a few corners and work the top edge where it ties into the seatpan but first impressions are positive.

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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
classicautowerks.com - EFI conversion parts
Old 02-18-2015, 04:14 PM
  Pelican Parts Technical Article Directory    Reply With Quote #27 (permalink)
I would rather be driving
 
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Sunday was spent drilling spot welds. If you look at previous pictures in the post you will see that I Have a cut panel from another car. This is great except for one thing. There are a gazillion spot welds around the perimeter and I had to drill out every single one of them. That really sucked. You have to pay attention to what side of the flange you are drilling such that you can weld the panel in correctly.

My method was to clean off undercoating, seam sealer and paint to locate the spot welds. Then I center punch with a prick punch. I do not use a spring loaded punch here as they just don't have enough force to make a nice divot. Then I used a $4 HF special spot weld cutter. I bought several of them because the last time I used one I broke off a lot of teeth. This time was different.

I used ONE and only ONE spot weld cutter on the entire panel. I could not believe it. The only thing I don't like is that the cutter is too large. btw, keep the center pin lubed so that it is free to move in and out. Then you make sure to use a corded drill. My cordless battery power did not last very long here.

After a while you end up with a pile that looks like this. This is only half of the pile. The smaller bits are the remains of what used to be the rear inner fender well. The large section is the external sheet metal across the engine bay that also contains the lower rear window seal lip.



Here you can see the edge of the panel. Yes, I will have to plug weld every one of those holes. That will suck. Not as bad as finishing all the welds though.



Interesting to note that the center of the rear deck panel has a box section to give rigidity. I knew this was there but its good visual aid for those who did not.

To rest my hands from drilling spot welds I got out the grinder and cleaned up the flanges from cutting out the old rusty rear deck panel. Then, Of course I had to test fit the new one.

Like a glove.







I still have to clean up the flanges on the green panel but I am only come clecos and spot welds from having it attached. That will have to wait a few weeks while I organize some mobile wet blasting on the tub. I can't wait for clean shiny metal on the whole tub.

Next step is to trim and fit the front pan.
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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
classicautowerks.com - EFI conversion parts
Old 02-18-2015, 04:16 PM
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Gotta luv the 72s. I'd oil system in car when u found the car? That's a big one. I have my eye on one like it right now. Can I drop it off next month? Lol. Congrats and good luck with her.
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Old 02-18-2015, 04:39 PM
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Jamie, this project is looking great! Can't wait to see it. When will it be out of intensive care and taking visitors?
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Old 02-18-2015, 05:00 PM
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I would rather be driving
 
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Yes, the oil system is in the car.

Mark, the 904 is welcome to come visit and pay its well wishes. Let's hope its not to pay final respects. You are welcome to come see it anytime.
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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
classicautowerks.com - EFI conversion parts
Old 02-18-2015, 05:15 PM
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I thought I had a lot of projects on mine! Wowzer, lots of metal work.

How about a stock compression 3.2 with low boost? Have a newly remanufactured Holset HX40 that spools quick lying around. Torque on the low end with 300+ reliable hp!

Sounds juicy to me!

I can cut a new turbine housing "P" trim in a couple of hours on a lathe. Will your lathe swing a turbine housing?

Just a thought.

Last edited by Tippy; 02-18-2015 at 10:15 PM..
Old 02-18-2015, 10:12 PM
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Great work Jamie! You have once again motivated me. I got the pan in on "Blu" the other night. I will have to pick your brain (more pickin' than I can hold in my basket) about bracing as I do more pan replacement.

I have a couple small turbos in the crate as you saw...hint,hint.

When do you think you may get to the point of someone to blast the car? I think I am going to go that route for all the areas except for the roof and rear qtrs. I want to put the car on the rotisserie first.
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Old 02-19-2015, 04:00 AM
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I would rather be driving
 
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Cory, I think the 3.2 might be a bit much for Minne. That torque level is more than I want in the car. HMM Make that more than I NEED. I always WANT such things. Besides, I don't have a 3.2 in the garage.

John, If all goes well next weekend they will blast the car. Still trying to work out the schedule. It is supposed to rain and that will not work since I can't dry out the tub before it flash rusts. I will keep you posted. I am concerned that the process will not remove the undercoating. That is the reason I am trying the process. I don't have hours to spend with the wire wheel and grinder.
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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
classicautowerks.com - EFI conversion parts
Old 02-19-2015, 05:57 AM
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very ambitious....... very cool, high reward project.........
Old 02-19-2015, 08:52 AM
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Looking forward to following this Jamie, love your very detailed descriptions of what you are doing.

On a separate note, can you overnight some Franklin brisket? I might have some parts you need in trade.
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Old 02-19-2015, 08:55 AM
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Following... I need to get re-motivated to tackle my 72 tub but it'll have to wait till it gets above freezing.
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Old 02-19-2015, 09:10 AM
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Shaun,

I could send you some brisket if you want. However, it usually does not make it home before it ends up in my belly. That is the same for Franklin's, Stile Switch, Rudy's, Iron Works, etc. So many good choices. The worst part about Franklin's is waiting in line for hours. Yes, that's right. Get there early, wait in line and hope they don't sell out before you get your share.

Oh, you probably want to sausage links too. Now I am making my self hungry for lunch.
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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
classicautowerks.com - EFI conversion parts
Old 02-19-2015, 09:49 AM
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Would a set of deep 6s be worth it? No need to stand in line, someday I'll have to get down there to try it, for now, it's Mr. Winters in NC, which might be as good.

But yes, sausage links too.

There is no BBQ up here, I really want to start a food truck based on brisket and pork shoulder alone.
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Old 02-19-2015, 09:57 AM
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Yes. Eastern NC based pork is still my favorite. I need to get Dave to send me some too.

Come on out and I will be happy to help you sample. We might even take a trip down to Lockhart for Black's. Better yet, wait until Minne is finished and we can take her down.

Or The Salt Lick. MMM. Salt lick.
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Jamie - I can explain it to you. But I can not understand it for you.
71 911T SWT - Sun and Fun Mobile
72 911T project car. "Minne" - A tangy version of tangerine
classicautowerks.com - EFI conversion parts
Old 02-19-2015, 11:11 AM
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