Garage/Barn find

[merbesfield]

PS jack post area.

[djporsche]

Nice work.

[merbesfield]

Big day at the shop. Started at 6 am and left at 8pm. Car is now ready for pans to go in. Finished the last few rust items along the pan perimeter and got the heater tubes fabricated and installed. My idea for custom heater tubes worked very well. I do still have some minor work to be done, detail welding, but all the fabrication of the heater tube is completed and they are in the car. They actually have to come back out bc I have to paint the rust stop in the areas up under the tubes. Here are the latest pics.

[merbesfield]

Custom heater tube fabrication. Started with 2.5" muffler tubing. Wrapped with high temp. insulation material, then foil tape. Cut opening for cabin heat, fabricated extension tube to mate muffler to heater slide openings. Exactly how the factor did it, basically. When I removed the original heater tubes, I very carefully removed the sheet metal that was welded to the opening. I fabricated new and will re-weld like the factory. Original heater slides will go back in place. This was a lot of work but the results are great. No rust and they will last at least another 40 years.


Tubing with hole to match slider outlet.

View into opening before re-welding.

Space between tube and slider opening.

Oval material fabricated to mate opening with heater tubing.

Oval material after fitting to tubing and opening.

Wrapping heater tubes with high temp blanket material.

Wrapped with foil tape.

Clamping method. I will weld this tight so it will never come loose.

[merbesfield]

A couple more.

[merbesfield]

Got the heater tubes finished and the rockers are now painted with POR15 so that is done. Next step is to reinstall them and weld the hot air openings.


Center tunnel is completed and awaits all new parts. Package from Pelican arrived today with all new goodies so center tunnel can be sealed up.

Also completed the rust repair of the Right rear shock tower. Did one half at a time so the position would not shift. No more rust.

[merbesfield]

I removed the rusted rear package tray. Looked like swiss cheese. There was really very little of it worthy of keeping so in the end I decided to remove the entire unit as a whole so I could reproduce it if needed. I started fabricating the piece. It is going well but will take some work to complete. If anyone has a good one please save me untold hours that it will take for me to reproduce this piece. Here are the pics of what I accomplished with a few hours time last night.
Swiss cheese out.

Started by removing all the little pieces so that I could use the original as a pattern.
Custom light weight hinges



Take some measurements. Bend some metal.

Start pounding the sand bag.


Great exercise and stress release. Tomorrow I will continue pounding. I can't believe no one is making this part yet. I realize some pics have been floated around, but no production or delivery. The part does not appear to be that complicated given the use of a large press. But what do I know.

[Tim K]

I believe someone was making these (SWB shelf) in small quantities using a rubber die of some kind. Does anyone remember the details?

Keep up the good work.

Tim K

[merbesfield]

Originally Posted by Tim K

I believe someone was making these (SWB shelf) in small quantities using a rubber die of some kind. Does anyone remember the details?

Keep up the good work.

Tim K

I remember reading about that as well, but there was some issue and they were not available? I would love to buy one from someone. I really don't want to have to build my own.

[azzarule]

911/912 Chassis: Restoration Design

Have a look at this site restoration design in canada they have repro pans and rear prcel shelf, rear seat wells etc. The only one I have found.

[azzarule]

I have just about finished cutting our the rear seat wells as one panel wheel to wheel, and then the parcel shelf, almost finished preparing the donor pieces and the sites for welding, so much seam sealer and gunk to remove around the rear parcel shelf rear corners, very complicated section. Left the rear seat back section for strength didn't want to take out the whole piece, although had it as a whole piece from a donor car.

[merbesfield]

Originally Posted by azzarule

911/912 Chassis: Restoration Design

Have a look at this site restoration design in canada they have repro pans and rear prcel shelf, rear seat wells etc. The only one I have found.

Last time I inquired about the rear parcel and seat panels they were still in "production" and they were having issues. Does anyone know anything different? I have sent another email request to Mike deJong.

[merbesfield]

I received an email today from Mike at RD. They are just now beginning the dies for the rear shelf, then testing then ...... It will be a while unfortunately. He put that on the web to test the waters I guess. Seems to me he should not have put it on the site if it were not really ready for sale, but hey it is not my company. Anyone have a package tray they want to sell?

[robmog]

try marek, it might be available now.
NEW swb Parcel shelf! - Early 911S Registry Bulletin Board

[djporsche]

Originally Posted by robmog

try marek, it might be available now.
NEW swb Parcel shelf! - Early 911S Registry Bulletin Board

I cant reply on that site or send him an email. If anyone has any info on the parts in the link please post up. I would like all 4 panels. Thanks

[merbesfield]

I have sent Marek an email, but no reply to date.

[merbesfield]

Today I concentrated on engine tin and other misc. pieces. Got them all blasted and painted. I am waiting for a rear package tray to arrive that one of our fellow car guys was so nice to sell me.


Got my Bat Wing blasted and painted as well.

And the rockers are now at the machine shop getting re-ground and will be ready on Monday. After I have them, there should not be any hold ups with engine assembly.

[merbesfield]

Thanks to John Schaefer aka jpnorthwood, I have a rear package shelf headed my direction.

[merbesfield]

I have checked my floor pan that I bought from RD and for some reason it is too narrow in width. I am about 1/4" short on both sides. See pics. I called RD and they checked the dimensions of my pan against others in stock and they are the same. So not sure why my car is wider, but I am almost positive that the car did not bow out while working on it. Before cutting the pan out I welded a cross bar from L to R and the hump. Also, if you look at the sides of the car, the doors and the gaps appear to be good. I know these cars where all hand made so is it possible for them to be off this much? Others have said the RD pans fit well. The gap is too large to just ignore, I will have to cut and fabricate to widen it. Let me know what others have done if this has happened before. Thanks

[merbesfield]

A friend of mine gave me these docs that belong to someones 1965 SC. If anyone knows the owner send them my way.

Delivery date: 11/19/1964 Bill Spreen, Atlanta, GA
Chassis SN: 219524
Engine SN:812810