2.2E restoration progress - Day 3

[nick-moss]

Not a lot achieved today as I had to visit the chiropractor so sort out my back after manhandling the car out of it's garage and round to the trailer on Saturday.

I struggled to get the bolts out of the front suspension mountings, some broke, some had to be ground off, there is al lot of work to do here.
The rest of the heater assembly came out and then the front fenders. Don't you just hate when the PO has tacked the bottom edges on then covered the fixing with bondo?

The good news is that the fenders and the tops of the inner fenders are perfect.



I will update the website later, Arsenal are playing Liverpool right now.

[dtw]

Nick,
You're making great progress! Did your fender look something like the first picture in this thread?

Slicing & Dicing the new '72: Good & Bad News

I just found a nasty little bodge job this week as well.

[nick-moss]

Dave,

No not nearly as bad as yours, just a small tack weld at the bottom of the back edge, enough to make me think "I'm sure I've got all the bolts out, what is still holding it."

[skinnerd]

Mooseman:
Enjoying the pics and progress. Please keep us posted, and put as many pics out there as you can stand. Looks like a great project, and makes me want to get out in the garage and work on my beast.


does it rain as much in the UK as it does in Portland in the winter? I'm off to have a pint....

[nick-moss]

I don't think it rains anywhere as much as it does in Oregon :-) It is snowing here right now. See more picyures by following the 1970 2.2 911E link below

[nick-moss]

Pictures of day 3 progress here

Has anyone seen cracks like these before? Identical 40mm cracks on each inner wing top:

[Adam]

You're moving really fast! How's the MFI Carrera coming along?

[nick-moss]

Adam, the Carrera is still in the body shop. It has required far more remedial work than had first been anticipated, and indeed more than the 2.2E will require (I hope). And of course it seems that every specialist takes far longer to get ant work done than they should. That's why I intend to do all the work on the E, apart from the paint. myself.

[nick-moss]

I thinks it's day 7 now. There wasn't much to show in the last couple of days, just scraping off underseal and floor sound deadening.

Now starts the serious remedial work. The right rocker looked fine before I removed the aluminium kick plate, one thing led to another, then an angle grinder and a drill. The outer and inner rocker were shot, as well as the bottom of the door hinge post.
So much for rust-free Californian cars. As Chuck Moreland said recently:

There are exactly two types of early 911 - those with rust, and those whose owners haven't yet found the rust.

More pictures here

[dtw]

Nick,
This is amazing - the work on our respective cars on each side of the Atlantic is progressing at near identical intervals. I was going to suggest a wager on who would win out with the least damage, but per your latest update it appears I'd win. The coupe should appreciate the thorough attention you're giving to those sills. Mine (inner rockers) turned out to be rock solid, except for the jack tube area which I've prepared patches for.

A question: jpnovak and I have been kicking around the best approach to removing the outer rocker, where it forms an "elbow" with the sill and is spot welded on both the horizontal and vertical. If I am interpreting your pictures correctly, you drilled out all spot welds. Is this right? How did you prevent deformation of the joint? My thought was to shave down a section of wood and clamp it under the joint for support. Your thoughts are appreciated.

[nick-moss]

Dave

I drilled out all the welds on the top join, it's easy here as you can drill all the way though, the new rocker will privide the new metal to wels to.

I didn't worry about the shape that was left, it can easily be tapped back into shape and the the new metal will create a former.

[dtw]

Nick,
Great pic, thanks. What about the vertical joint?

Your rocker/lock post joint looks bodged about as badly as mine. I should have pics up in the next several weeks detailing my repairs to this section. I'm interested to see how you do it, too.

[jpnovak]

Ahh this looks familiar. I think I have done that before.

http://home.mindspring.com/~iluvlucy/rockers.html

look familiar?

Yes, Dave and I have been pondering this project. I tried to drill them out and mad a huge mess of that upper seam with the inner rocker. I decided to cut next to it and then grind it away. There was less mess to clean up.

Jamie

[nick-moss]

I have learnt all this by watching my bodyshop guy do the work on my '74, which was in a much worse state than to '70 2.2E, having spent all it's years on salty European roads.



More photos of that mess

[Glasgow 911SC]

Nick,
A restoration like this looks like it could be a very frustrating but satisfying project. All that rust is a touch sickening though.

[nick-moss]

Loads of progress today.

I got hold of the repair section for the right door hinge panel (and the left one as well, along with a pedal floor repair section)

So a nasty hole



was plated



and the new part of the hinge post welded in



Things go so much faster when one does all the work oneself! Now the inner rocker panel is ready for welding.

More pictures here

[nick-moss]

It must be day 10 now.
Not much progress over the last couple of days as I have been building a spit to make working on the underside much easier.



I have now cleaned off all the underseal and primered the bare metal of the inner wings.



And the right hand inner sill is now being tacked into place



Now I am waiting for the boot floor repair sections to arrive

[maxnine11]

i must say, i'm impressed by your stand and your rate of progress!! keep the pictures coming!! max

[Glasgow 911SC]

This has got to be 1 of the fastest moving restorations ever!