suspension pan replacement

[BK911]

Hello!

I am preparing to replace the front suspension pan in a 73T. The pan and gas tank support are completely rusted through. I searched the archives and found some useful info, but I need more! Is there a tech article somewhere explaining how to? Such as how to remove old pan, how to align new pan, which types of welds to use in what location, etc.. I’ve never welded but figured something as trivial as a front suspension pan would be a good place to learn! I have the pieces from restoration design and am ready to begin! I would also like recommendations on a welder purchase. Something around $300?? I could probably step up a little more if needed.

Thanks!
BK

[dtw]

Front pan...trivial...$300 welder...yeeeesss...

I would say this is not a good learner project if you've never done this type of work...but just my opinion.

Jamie? Care to field this one? (I've "sat in" on this procedure, but he's one of the resident experts on it.)



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Dave
'72 911T to '73 RSR Replica Project

[GIBSON]

There have been previous posts on this topic, you might do a search and find some good info. I replaced this pan on my 67S and found it to be a somewhat difficult but enjoyable job.
I'm sure others can give you better advice on welders, spend enough to get something good. Then, practice- a lot! Weld up some similar thickness metal, get the settings on the welder right so you don't burn through. If you have the welder matched to the metal thickness you won't be fighting the welder to produce good, even welds. There is no substitute for experience, you have to get this by practicing. If you can watch someone weld something similar you'll be ahead as well.
My opinion is to try it. It will give you confidence to try other procedures in the future. To be able to weld up jigs and tools for other projects is a real plus.

Bruce Herrmann

[BK911]

Yea, I was joking about the front pan being trivial. I do intend on practicing welding before I touch my car. Anybody else need a pan welded in so I can practice?

I have 100% confidence in my abilities to perform any task, given the right tools and proper guidance. I'm not too smart, but I'm smart enough to realize I'm not too smart! That's why I research everything before taking the plunge.

I've seen welders for ~$300 with the regulator, which were capable of welding up to 3/16" steel. No good? I can bump it up a little if necessary. Please advise!

[cds72911]

Hi, as others have said an archive search will turn up some good info. That said, I can recommend the welder I purchase - a lincoln SP125. It was a bit more than your budget, but a good product.

From my research I found that Lincoln, Hobart and Miller are the big three names in small welders. Century also makes some okay stuff, they private label some of it to other stores (like Sears).

If you can afford it get a gas shielded setup rather than a gas-less setup. The fluxed wires in gas-less setups leave nasty slag and the welds tend to be less clean.

My biggest piece of advice I can offer is to go to a local technical school and take a short welding course where you cover arc, gas, mig and tig welding - then after the class and some hands on experience decide what to purchase. You may find that your decision is different after getting some hands on experience.

Charlie

[Hatari]

Just did this on a 70' 911S. I don't recommend buying a welder if you do not have decent welding experience. I had my brother-in-law install the pan and brace. He welds for a living and still had some challenges such as in the tight spots with thin or deteriorated original metal that didn't show signs of rust on the surface. We did reinforce those areas with additional sheet metal and I am satisfied that the integrity in those areas is fine. Welding is a craft which requires experience especially with thin sheet metal. I bought a $300 110 volt wire feed welder a couple of years ago and even with the argon gas attached, I did a great job of burning holes in sheet metal.

By the way, the sequence is to drill out the fty. spot welds in the original pan (in the area where it is spot welded) and with a cut-off wheel, cut out the remaining material after tracing the replacement pan with a grease pencil or marker. You then spot weld the new pan in along the original spots and lower body creases. We did the entire job in one day (about 7 hours start to finish), but my brother-in-law knew his business with the MIG.
Jack McAllister

[Andrew Luu]

Hi BK,
I am in the process of garthering informations on floorpan and gas tank supports restoration for my 72 911T also. I have decided to enroll in the Northern Virginia Comunity College autobody class. They will be teaching autobody welding this spring semester. The plus part is that you get to practice with their equipments and I am trying to find out if they allow me to take my car there and work on it. I have already emailed the teacher and asked if the course will cover floorpan and gas tank support welding but have not gotten the reply back. Maybe you can look into the Baltimore county community college to see if they offer auto body classes. It is a 4 credit class and cost $40/credit. So I may have some money left to buy the replacement parts from restoration design. Does not answer your questions but I hope it will help you in some small way. Andrew.

[Andrew Luu]

BK
After I finish with the welding class (this comming summer) I will start on my car. If you have not done your car yet, you are welcome to come by and watch how I mess mine up :-). Also, good luck on your roof this weekend. Andrew

[Rot 911]

BK, you,as the new owner of my 72 911, know that I did the suspension pan myself. I had done arc and gas welding, but this was my first time MIG welding. I purchased a Craftsman welder from sears on sale for $400. It is a Century welder. I got the one that is 110 volt, but uses a 20 amp circuit which allows up to 1/4 inch welding. It has adjustable wire speed and heat range. Most importantly it is set up to be used with gas and comes with the regulator. I would also advise you to get one of the "instant" darkening helmets, which makes the start of the weld so much easier. I got mine on sale from Harbor Freight for $80. Makes sure you get one that is for MIG welding. Mine has two darkness settings, one for arc and one for MIG. I found a couple of old sheet metal real estate signs and practiced welding on them before I started on the suspension pan. Welding thin metal is much harder than welding plate steel.

Kurt V

[BK911]

Gentlemen!

Thanks for all the input! I think I am going to hold off on my PlayStation 2 purchase and step up to a better welder! Too bad I'm single because I'm sure my wife would love PS2 for xmas!

Taking a class sounds like an excellent idea. Unfortunately I don't have time. I am packing up and moving to Orlando near the first of the year. I just got accepted into a Precision Engineering masters program with a concentration on High Performance Engine Optimization. So it's off to Florida trailering my thesis project behind me!

Andrew... If I read your post correctly, you are volunteering to help me with my roof? And I can practice on your suspension pan? Good deal, I appreciate your generosity! So you'll drive a little sideways, at least you're driving in a 911!

Mr. McAllister! You've started what I was looking for. I was basically looking for a tech article explaining the procedure. Similar to the format in Wayne's awesome new book.

[Rot 911]

Me at work on the suspension pan

Kurt V