Puma's '68 Resto

Puma · 08:38 AM

Howdy!

I've got no idea what I'm doing but that never stopped me before. Here's my '68 912 resto project. I sincerely welcome any and all advice and criticism. She's a basket case but I wanted something I could completely rebuild. I've already started tearing her down in anticipation of media blasting to bare metal.

Parts I need:

Driver front fender (side markers not required)
Passenger front fender (side marker holes not required)
S bumper- think I've found one!
Control arms- got 'em!
Bilstein struts
Passenger sun visor (can be a basket case)
Engine (haven't decided which way to go)
Fuchs (I'm going to try to fit 7x15's)
Front hub (912)

Should you have these parts please contact me.

I know you guys like pictures so here ya' go...

Car as found

At home in my garage

Engine compartment almost clean

Puma · 05-20-2016, 05:54 AM

And now the bad

Front pan is shot

Transport driver bent the front with tow strap

Discseven · Discseven's Garage

Diving off the deep end Puma... way to go! Will follow your progress.

Cory M · 05-20-2016, 12:20 PM

I hope you are a good welder...

Fixer · 05-20-2016, 12:39 PM

Quote:

Originally Posted by Cory M

I hope you are a good welder...

He will be when done.

Only area to watch out for is door to rocker and lock post fitment when done.

Get her blasted, pick a spot and start. We'll all help motivate and guide.

Good luck, -Matt

Cory M · 05-20-2016, 01:21 PM

Pick your blaster carefully. A friend just told me about a mustang that got destroyed by a careless media blaster. Unfortunately he took them the car after spending hours and hours on rust repair. The roof, quarterpanels, etc are totally stretched and mishapen.

Puma · 05-20-2016, 09:00 PM

Thanks guys!

I figure if a human can do it, I can do it. Thanks for the encouragement!

I scored gas, steel and few odds and ends for welding today and my pro welder friend got on the phone and he talked me through setting my gas and wire speed. I practiced and while I'm not saying it's easy, I don't think it's rocket surgery either. I'll practice some more before I build Matt's tilting dolly. So here's a public thanks to Matt for sharing his dolly design.

I started disassembling the driver door today and that's going well.

The media blaster guy I know and the first thing he talked about was being careful not to warp panels. This guy is the salt of the earth and I trust him completely.

Until next time...

mickey356 · 05-20-2016, 09:50 PM

"If a human can do, I can do it".....atta boy Puma!!

I'll be following closely. Can't wait to see your progress. So many great projects going on here now. I can't wait to get mine back and get to work.

Fixer · 05-21-2016, 04:36 AM

Puma and I have spoken a little by phone and in my opinion he has what it takes because this work will require 90% enthusiasm to complete. Puma [Justin] is also bright as they come.

BTW, his late father was a real-deal NASA man so there's more to the story..

Do it for you and for your late Father Justin, he'll be riding in the passenger seat with you when your done.

Puma · 05-21-2016, 05:51 PM

Quote:

Originally Posted by Fixer

Puma and I have spoken a little by phone and in my opinion he has what it takes because this work will require 90% enthusiasm to complete. Puma [Justin] is also bright as they come.

BTW, his late father was a real-deal NASA man so there's more to the story..

Do it for you and for your late Father Justin, he'll be riding in the passenger seat with you when your done.

Wow, thanks for the vote of confidence and the compliment. You're spot on, this is my first project without my Dad. He was a walking encyclopedia of engineering, mathematical, and general know-how. I miss him dearly so you got it right, I'm doing this with him in mind. Thanks again Matt!

Mickey, I also can't wait to see your car. I'll be cheering you on. When do you think you'll have her back? What color are you thinking? Details man, details!

So today I spent fixing problems with my welder. I had to rebuild the gun wires because the feed would just keep going. There were other little issues but they're not worth mentioning. So I practiced on scrap for about an hour, laid out my dolly frame, double checked my measurements and went after it. I wouldn't say my welds look good but the dolly is solid. I learned a lot today with my friend Eric talking me through the process via telephone and just doing it.

Some thoughts if you're going to try welding: don't wear tennis shoes, molten junk inside the tubes sometimes flies off and lands on your shoe, instantly burns through your shoe, sock, and skin. Do not ask me how I know this.

Take the time to remove stickers from castors. I thought "I'll just burn through 'em!" Nope, stickers make a mess of sputtering and coughing welds.

So here's the base of the dolly I made today. I dropped it, jumped on it, yelled at it and it appears solid.

Puma · 05-21-2016, 07:54 PM

And we're mobile!

pors1968 · pors1968's Garage

Good luck with your projet will follow your progress.

Fixer · 05-22-2016, 10:16 AM

Hey Justin,

I know you want to paint the car Ossi blue but that Polo red is classic and if original you may consider keeping it. [i'm Not a red car guy btw]

When welding, i always use a vise grip to clamp and bite into my chassis or tub to get a really good ground rather than rely on the welder's ground clamp. Be sure to wire brush the contact jaws of the welder's ground clamp. Be sure you have the correct MIG gas, 75% Argon, 25% co2

When welding think of yourself as Neo [from the Matrix movie], stay calm and really see the weld happening as you're weaving the two pieces of steel into one.
I know it sounds corny..

Take your time and enjoy the process. -Matt

Puma · 05-23-2016, 02:31 AM

Matt,

I definitely need to improve the ground situation so I'll use your advice. Thanks! I absolutely had to get the cart up and working Saturday so I just went for it. I will practice a lot more before actually welding the car. I've got a lot to learn. Corny, nah, just a known reference that's recognizable.

My car is originally sepia brown and I do actually like that color. I owned a sepia Volkswagen Scirocco and the color really grew on me. I do need to see an Ossi car in person before I decide but from pictures I've seen it really moves me. my inspiration is actually from the job I did with restoring a vintage road bike that's kinda Ossi blue with brown leather and it looks so good. Btw I'm really into bicycles. I figure a medium blue makes the car lines easiest to see, too light and it blinds, to dark and the car is a blob. Know what I mean?

So here's where we are so far: glass, headliner, gauges out and the battle of the wiper mechanism has been won. I've only got three bolts that have to be drilled out and they're tiny trim bolts. Some pictures:

Puma · 05-23-2016, 02:34 AM

I can't figure out how to remove the knee pad. Is it just vinyl covering foam that has to be peeled off? I haven't seen or felt any screws. Any tips? I'd rather not destroy it.

slow&rusty · 05-23-2016, 04:44 AM

Amazing! I will certainly keep checking into the progress and wishing you the best of luck with the journey ahead.

It never ceases to amaze me, how passionate 911 air cooled owners are about restoration and DIY....truly inspiring.

mickey356 · 05-23-2016, 08:47 AM

Here ya go Puma. Knee pad removal in a 67

Can't imagine it's much different in a 68. Though it may have been taken off and reattached, incorrectly, at some point.

Sent you a PM, by the way. Keep up the good work.

Puma · 05-29-2016, 08:22 AM

Alrighty, here's where we are this morning,

I got the wiring harness out, complete in one piece. I'd read where people cut it in half but I really didn't want to do that so I took my time and gently coaxed her out. I'm kinda shocked at how much wire is there for such a little car.

Engine compartment is devoid of everything.

Trunk is done with exception to steering shaft.

I cut out some cancer. Basically it was in the way and just wanted to get rid of it.

A few odds and ends left in the dash: steering, ignition, headlight switch, trim, and a mystery switch. I'm kinda wondering if I can remove the stalks and leave the steering rack in because it's a lot to remove it. What do you think?

And lastly, the rear suspension is out. It's amazing how easily 48 year old bolts came out with a two foot breaker bar. I don't know how to remove the rear torsion bars or spring plates so any advice here is greatly appreciated. Okey dokey, I'm back at it. Hoping to get the car completely disassembled today!

Puma · 05-29-2016, 08:26 AM

Quote:

Originally Posted by slow&rusty

Amazing! I will certainly keep checking into the progress and wishing you the best of luck with the journey ahead.

It never ceases to amaze me, how passionate 911 air cooled owners are about restoration and DIY....truly inspiring.

Thanks for the encouragement! I really like the diy nature of these cars and the opportunity to learn new things. I wouldn't have it any other way.

Puma · 05-29-2016, 08:29 AM

Quote:

Originally Posted by mickey356

Here ya go Puma. Knee pad removal in a 67

Can't imagine it's much different in a 68. Though it may have been taken off and reattached, incorrectly, at some point.

Sent you a PM, by the way. Keep up the good work.

Mickey, my knee pad ended up being different for some reason but it eventually came out. It was the single most rusted part of the car. The metal under it is perfectly fine but whatever Porsche used for the knee pad basically crumbled away. I was hoping to use it for a template to create a new one but I don't know how viable that is now. I'm still going to try. Thanks for the link.