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914World.com _ 914World Garage _ EX-BUILD-OFF-CHALLENGE ‘17: Project 2.4

Posted by: Dion Sep 9 2016, 10:27 AM

Well I've started the process of preparing for
my 2056 GT to 2.4L six "rallye tribute" auto.
Tearing into the interior I discovered some rust mites have been eating for a while.
Doesn't look too extensive but will be probing some more. The exterior left long was
patched a long time ago, albeit incorrectly. This was done by shop
that wasn't fully up to speed on these cars and I was still a novice, well
still am. I'll be doing some exploratory surgery on this left side inside and out. So I'll get this addressed before any engine install takes place. Would like to
have it buttoned up for Hershey 2017. Wish me luck.
"


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Posted by: Dion Sep 9 2016, 10:28 AM

E brake area top:
Exterior long near door sill bottom pic


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Posted by: mepstein Sep 9 2016, 11:16 AM

Doesn't look bad. Grab a multi tool and get rid of the floor tar once and for all.

Posted by: 914dave Sep 9 2016, 11:47 AM

QUOTE(mepstein @ Sep 9 2016, 01:16 PM) *

Doesn't look bad. Grab a multi tool and get rid of the floor tar once and for all.


I was going to suggest , contact cement heavy duty aluminum foil in place and new carpets. Good as new. Wasn't sure how that would be received. shades.gif

Posted by: Dion Sep 9 2016, 12:16 PM

I intend to Mark.
As always Dave has my back!
I rely on his Jedi knowledge.

Posted by: rgalla9146 Sep 9 2016, 12:25 PM

QUOTE(914dave @ Sep 9 2016, 01:47 PM) *

QUOTE(mepstein @ Sep 9 2016, 01:16 PM) *

Doesn't look bad. Grab a multi tool and get rid of the floor tar once and for all.


I was going to suggest , contact cement heavy duty aluminum foil in place and new carpets. Good as new. Wasn't sure how that would be received. shades.gif


License plate ( aluminum kind , easy to bend, more 'professional') and bondo.
1/2 hour max. Finish with duct tape to prevent further rust.

Posted by: mepstein Sep 9 2016, 12:32 PM

QUOTE(rgalla9146 @ Sep 9 2016, 02:25 PM) *

QUOTE(914dave @ Sep 9 2016, 01:47 PM) *

QUOTE(mepstein @ Sep 9 2016, 01:16 PM) *

Doesn't look bad. Grab a multi tool and get rid of the floor tar once and for all.


I was going to suggest , contact cement heavy duty aluminum foil in place and new carpets. Good as new. Wasn't sure how that would be received. shades.gif


License plate ( aluminum kind , easy to bend, more 'professional') and bondo.
1/2 hour max. Finish with duct tape to prevent further rust.

It's a VW. The proper method is to steal some street signs and fiberglass them in. Construction adhesive would also work.

Posted by: Dion Sep 9 2016, 12:49 PM

At what point do I go to Earl Schreib & Zeibart?
After the foil is in?

Posted by: 914dave Sep 9 2016, 01:10 PM

Right after the foil. If you want it proper.

Posted by: mepstein Sep 9 2016, 01:43 PM

All you need to do a pro repair- no metal work!


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Posted by: Dion Sep 9 2016, 02:54 PM

I knew this club would payoff in its wealth of knowledge. dry.gif
Thanks boys!
Stay tuned.... welder.gif

Posted by: flippa Sep 9 2016, 04:22 PM

QUOTE(mepstein @ Sep 9 2016, 11:32 AM) *


It's a VW. The proper method is to steal some street signs and fiberglass them in. Construction adhesive would also work.


What, no pop rivets? huh.gif

Posted by: bretth Sep 9 2016, 05:14 PM

QUOTE(flippa @ Sep 9 2016, 06:22 PM) *

What, no pop rivets? huh.gif


Yeah one pop rivet over a 4 inch hole in the frame is all it took to hold my car together.

Brett

Posted by: wndsnd Sep 9 2016, 05:23 PM

QUOTE(flippa @ Sep 9 2016, 06:22 PM) *

QUOTE(mepstein @ Sep 9 2016, 11:32 AM) *


It's a VW. The proper method is to steal some street signs and fiberglass them in. Construction adhesive would also work.


What, no pop rivets? huh.gif



Leave it to an engineer to overcomplicate this repair!

Posted by: Dion Sep 9 2016, 05:30 PM

You guys are great. This is gonna be fun. beer3.gif

Posted by: jmitro Sep 9 2016, 07:56 PM

looks like you got a little work to do. Good luck with it!

Posted by: rgalla9146 Sep 10 2016, 03:25 AM


Paint it Red.
Very important.

Posted by: cary Sep 10 2016, 08:10 AM

The problem your going to run into is the degradation of the inner stiffening layer too. Which is the layer where the seat belt anchor starts it spot welds. sad.gif

Jeff did an extensive rebuild/patch in that area in his thread.
http://www.914world.com/bbs2/index.php?showtopic=76791&hl=dead

Hopefully yours won't be that extensive. Was the jack point replaced on the prior repair ?

Posted by: Dion Sep 10 2016, 10:25 AM

Hey Cary,
The jack point was completely cut out. They just welded up "patch".
However unbeknownst to me they never joined the top of the patch to where it meets
the door sill area. I will cutting out that whole area to see what's what.
Yeah it will be a nice challenge with that seat belt anchor area. We'll get it done.
Also need to address front of long next to front left wheel well/fender.
Purchasing cut off wheels and a new grinder/ die grinder. I'll add to this thread as I make progress
Thanks guys.


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Posted by: Dion Oct 2 2016, 05:27 PM

Ok, tar all scraped out. Door braces in place.
Time this week to start cutting and removing the
offending rust areas on the longs.


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Posted by: Dion Oct 4 2016, 06:01 PM

Well did more exploratory surgery and it's ugly. Beauty on
the left side was in fact only skin deep. Consulted with my
bro Dave ( 914Dave ). So time to cut out the outer long complete.
To the kickup and replace the metal accordingly. Inside the cabin
area can be fixed with a few patches. Floor is in good shape remarkably.
I should just enter the buildoff at this point biggrin.gif
Stay tuned...


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Posted by: Dion Oct 4 2016, 06:02 PM

Ugly


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Posted by: Dion Oct 4 2016, 06:03 PM

blink.gif


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Posted by: Dion Oct 4 2016, 06:05 PM

dry.gif


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Posted by: Dion Oct 5 2016, 09:34 PM

Opened up whole of left longitudinal today. I'll be ordering some metal
for the U-boat. I'll be replacing the sill,door jamb, rocker outer cover,
the rear jack donut and inner rear lower firewall.
Dave lent me his spot weld remover bits so that's where I'll begin.
Then I'll address a "hatch" for the six to adjust the timing. Lots of work ahead.
Many of you guys have been here before. Wish me luck.
This will be going at the same time as reassembling Dave's GT. So little time!


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Posted by: altitude411 Oct 6 2016, 11:48 AM

Your going to need a few more license plates and possibly another roll of duct tape... popcorn[1].gif

*subscribed*

Posted by: Dion Oct 6 2016, 12:25 PM

QUOTE(altitude411 @ Oct 6 2016, 09:48 AM) *

Your going to need a few more license plates and possibly another roll of duct tape... popcorn[1].gif

*subscribed*


Hahahah. Yeah pretty much!
What has the collective done with regards to the door jamb
sticker? Is it salvageable? Do you even bother.
Being it's an "Antique" here in PA, the car doesn't get inspected.
Just wondering what you have done.
Thanks

Posted by: Dion Oct 17 2016, 08:50 PM

So the build challenge is on. Happy to say I've obtained a nice heater tube from
Rich (rdauerhauer). So that's a relief as the original was a little cut into.
My supply of spotweld cutters is here, so hope to post more pics soon of progress.
Goal for this time frame till January is to remove rear quarter panel and lower firewall
driver side. As well as weld up the many numerous holes in the firewall that were used for running wires. Parts have been ordered from Restoration Design as well as 914rubber. Carry on.

Posted by: mepstein Oct 17 2016, 08:59 PM

QUOTE(Dion @ Oct 6 2016, 02:25 PM) *

QUOTE(altitude411 @ Oct 6 2016, 09:48 AM) *

Your going to need a few more license plates and possibly another roll of duct tape... popcorn[1].gif

*subscribed*


Hahahah. Yeah pretty much!
What has the collective done with regards to the door jamb
sticker? Is it salvageable? Do you even bother.
Being it's an "Antique" here in PA, the car doesn't get inspected.
Just wondering what you have done.
Thanks

Take a picture of it for your records and then order a new one from Andy ( I forget his screen name on this site but someone will chime in)

I guess the lift purchase is paying off.

Posted by: Dion Oct 17 2016, 09:07 PM

Mark, I don't think I'd go this deep into "hell" if it wasn't for this lift. Heheheh
I'll keep checking on the sticker. For some reason "car-bone" comes to mind regarding
odd,one off stickers and such. Thanks.

Posted by: Larmo63 Oct 17 2016, 09:15 PM

SoCalAndy makes the stickers.....


Posted by: altitude411 Oct 17 2016, 09:28 PM

Socalandy. His awesome six build is in the restoration forum

Posted by: Dion Oct 18 2016, 07:13 AM

Thanks for the info on the stickers. I'll give him a shout. Yes I have his build bookmarked. It's excellent.

Posted by: mbseto Oct 18 2016, 07:53 AM

I would say you have your work cut out for you. But really, your work is cutting everything out. :-)

Posted by: Dion Oct 25 2016, 06:31 PM

Still cutting away. Parts from Restoration Design on the way. Time to break out
the kerosene heater soon. Hitting 38*F tonite.
Drilling out spotwelds is certainly a test of wills. Progress is
slow but it's progress.


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Posted by: JmuRiz Oct 25 2016, 07:07 PM

After knowing and talking with ScottyB enough, he says that even the nice looking ones have rust...looks like you got lucky and hit the motherload icon8.gif
I guess it's good restoration design is a sponsor. Best of luck on the fixn', your progress thus far shows you are going to be able to handle it just fine.

Posted by: theleschyouknow Oct 25 2016, 08:04 PM

keep up the good work

somebody I think in the 2016 build off had an alternate method of drilling out the spot welds using regular bits
sorry can't remember who it was or the details like bit sizes but basically it involved drilling just thru the first layer with a larger bit and 'exposing' the weld then drilling a thru hole large enough to remove most if not all of the weld then, if necessary, he reported it was easy to pry/pop the panels apart
kinda sounds like 2 steps to do 1 to me but he seemed to like the results

looks like you have your hands full but also that it is in good hands, have fun!

beerchug.gif
cjl

Posted by: Dion Oct 25 2016, 09:28 PM

Thanks guys. Appreciate the confidence.

Posted by: DirtyCossack Oct 26 2016, 10:57 AM

QUOTE(theleschyouknow @ Oct 25 2016, 09:04 PM) *

keep up the good work

somebody I think in the 2016 build off had an alternate method of drilling out the spot welds using regular bits
sorry can't remember who it was or the details like bit sizes but basically it involved drilling just thru the first layer with a larger bit and 'exposing' the weld then drilling a thru hole large enough to remove most if not all of the weld then, if necessary, he reported it was easy to pry/pop the panels apart
kinda sounds like 2 steps to do 1 to me but he seemed to like the results

looks like you have your hands full but also that it is in good hands, have fun!

beerchug.gif
cjl


Doesn't sound exactly like my technique, but I use a cut off (so it only sticks out about 1/4" from the chuck to prevent breaking bits) 1/8" bit to start a pilot hole (aids a big bit's bite), then use something like a 3/8" bit to only go through that top layer before carefully using a seam buster tool to separate. The technique allowed for welding separate panels back together.

Then again, you could be talking about somebody different...

Posted by: theleschyouknow Oct 26 2016, 11:17 AM

QUOTE(DirtyCossack @ Oct 26 2016, 11:57 AM) *

QUOTE(theleschyouknow @ Oct 25 2016, 09:04 PM) *

keep up the good work

somebody I think in the 2016 build off had an alternate method of drilling out the spot welds using regular bits
sorry can't remember who it was or the details like bit sizes but basically it involved drilling just thru the first layer with a larger bit and 'exposing' the weld then drilling a thru hole large enough to remove most if not all of the weld then, if necessary, he reported it was easy to pry/pop the panels apart
kinda sounds like 2 steps to do 1 to me but he seemed to like the results

looks like you have your hands full but also that it is in good hands, have fun!

beerchug.gif
cjl


Doesn't sound exactly like my technique, but I use a cut off (so it only sticks out about 1/4" from the chuck to prevent breaking bits) 1/8" bit to start a pilot hole (aids a big bit's bite), then use something like a 3/8" bit to only go through that top layer before carefully using a seam buster tool to separate. The technique allowed for welding separate panels back together.

Then again, you could be talking about somebody different...


yep that was you nice work!
I got it kinda backward in my explanation
re reading my post it I think it might sound critical but no offense was meant in fact I was impressed with your ingenuity and hoping to pass it on
keep up the good work!


beerchug.gif
cjl

Posted by: Dion Oct 28 2016, 03:04 PM

Fed ex truck dropped off some goods today.
Thanks to the guys at Restoration Design.
These parts are gonna make life a lot easier
in the coming months.


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Posted by: porschetub Oct 28 2016, 04:13 PM

QUOTE(Dion @ Oct 26 2016, 01:31 PM) *

Still cutting away. Parts from Restoration Design on the way. Time to break out
the kerosene heater soon. Hitting 38*F tonite.
Drilling out spotwelds is certainly a test of wills. Progress is
slow but it's progress.


Good skills on the bodywork,clever to see you covered the dash....amazing how those little chips of steel go so far and stick/burn to stuff.
Keep up the good work.

Posted by: tygaboy Oct 28 2016, 04:30 PM

QUOTE(Dion @ Oct 28 2016, 02:04 PM) *

Fed ex truck dropped off some goods today.
Thanks to the guys at Restoration Design.
These parts are gonna make life a lot easier
in the coming months.


You're probably OK, but you may want to double check that rear jack point piece to be sure the donut is welded on in the correct orientation. I just got around to fitting mine, only to find out it was put on backwards. It causes the jacking surface of the donut to be "way not parallel" to the ground.
It was a known error but a few parts did get out there.

Posted by: Dion Oct 28 2016, 04:40 PM

Thanks Dean, the whole dash is out. Have a nice NOS to put in there.
I'll be covering more of it with thicker plastic when it's time for paint.
Cutting around the door brace on the jamb side till I can weld a triangular
plate near the floor and long and firewall then I'll remove the jamb.
Goal for tomorrow is removing all of rear left quarter panel. "Tyga" I'll check the donut thanks.


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Posted by: Dion Nov 5 2016, 07:15 PM

Ok finally removed rear quarter. It's really amazing what you can find hidden
underneath nice paint. A complete chunk missing beneath the left rear light housing.
Popped right out when I flexed the panel while removing. Next up left inner lower firewall. Oh and my "fresh air" elbow was half bondo!?! So this car had issues
back before 1986. I purchased it March 1986. I never would have known till I took on the task of
putting the six in.


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Posted by: Dion Nov 5 2016, 07:17 PM

Panel off


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Posted by: Dion Nov 5 2016, 07:22 PM

So this will get fresh paint


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Posted by: tygaboy Nov 6 2016, 07:43 AM

QUOTE(Dion @ Nov 5 2016, 06:22 PM) *

So this will get fresh paint


I love pics like the one above! It's like the 6 is patiently waiting, hiding under the bench. Here it's peeking out and saying "Hey car, I see you! We are gonna have some kinda fun!!"

Keep up the great work!

Posted by: Dion Nov 13 2016, 04:13 PM

So with the rear panel off was better able to access the work at hand.
Cleaned up a lot of undercoating.
Found a decent sized hole on the left susp. console.
So I'll be ordering a bit more steel. I want to next remove
the lower inner firewall , to clean up and cut out around and including
the seatbelt anchor.



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Posted by: Dion Nov 13 2016, 04:14 PM

Deterioration


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Posted by: tygaboy Nov 13 2016, 07:43 PM

Dion - I have a '72 donor car that is virtually rust free. I've been slicing off the handful of pieces that I'll need but feel free to contact me if you need any sheet metal parts that you can't find. It's got solid consoles on both sides.
I'd love to see it help a fellow Build-Off Challenger!
Keep up the great work!
Chris

Posted by: Dion Dec 1 2016, 01:29 PM

Cut away the remainder of the sill panel.
Surface rust on the extra panel in front of heater tube.
No issues there. Will make patch panel for lead edge of the long that you
see just inside the wheel well.


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Posted by: Dion Dec 1 2016, 01:37 PM

Removed more of the door jamb except for brace area.
Cut open seatbelt anchor region to take care of that and prepare for
placing in new steel.
I removed the left half of inner firewall just before
tunnel overlap. The tunnel is sound from what I can tell on probing and
scraping. Test fit the new panel of firewall. Should be real nice when complete.
The bronze brazing mixture on those E brake tubes are a bugger. Did my best
not to destroy them.
I'm at the point now that I'll be sandblasting all these
areas. I'm awaiting a call from Lowes for my new
compressor (Christmas gift). Then that will be the next
coming weeks chore.


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Posted by: Dion Dec 1 2016, 01:41 PM

Pics


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Posted by: Dion Dec 1 2016, 01:43 PM

Pics


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Posted by: Dion Dec 1 2016, 01:44 PM

New firewall panel test-fit & de-brazed E-brake tubes.


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Posted by: tygaboy Dec 1 2016, 01:46 PM

I'm amazed at the level and extent of sawzall-smiley.gif surgery you're taking on! Impressive.

I always thought R&R was short for "Rest and Relaxation", but your work has me thinking it's really "Remove and Repair"!

Keep up the great work.

Chris

ps. I should be able to get you that suspension console by around year end. Let me know if there are any other pieces you need.

Posted by: Dion Dec 1 2016, 02:01 PM

Thanks for that Chris. I'm the one that gets slack jawed seeing the other builds.
The tube frames & carbon fiber stuff. Just incredible.
Hats off to all you guys.
Cheers all, Dion

Posted by: Mitox Dec 1 2016, 08:15 PM

Ok, I'm an idiot. I moved my post to the official challenge thread. Sorry.

Posted by: Dion Dec 1 2016, 10:04 PM

QUOTE(Mitox @ Dec 1 2016, 06:15 PM) *

Ok, I'm an idiot. I moved my post to the official challenge thread. Sorry.


Heheheh no worries Mike! beerchug.gif

Posted by: Dion Jan 9 2017, 04:06 PM

Since PA has been hit with the 20*F temps for a while now and
snow is on the ground. It's been slow progress. My kerosene heater
is having a hard time keeping up. I'm also waiting for my electrician
to be available to run a dedicated line for my new compressor.
So doing some other jobs.
Obtained some "past it" Fuchs to roll the car around for when
the weather breaks and commence with the sandblasting.
Also working on front struts. They are renewed and painted.
Proceeding with placing new bearings in the 911 hubs so I can
have the front suspension done and ready to bolt in.
Have some minor work to do on the six engine as well.
I'll update accordingly.
Cheers!




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Posted by: Dion Jan 9 2017, 04:07 PM

Bilsteins


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Posted by: 914dave Jan 9 2017, 05:45 PM

The weather and electrician have conspired against Dion making progress. To my benefit as he helped me fish the wiring harness and hang the dash in my car yesterday. Thanks D! beerchug.gif I guess it pays to have proper heat in the garage

Posted by: tygaboy Jan 9 2017, 06:17 PM

Your Bilsteins are making me green with envy... biggrin.gif

Our cold can't rival yours but we're in the 30s, which is uncomfortable enough.
I got a 220V electric heater and put in on a roll around stand. I just point at where I'm working and it makes all the difference.

Keep up the great work!

Posted by: Dion Jan 22 2017, 09:26 PM

Tackling front suspension work. Replaced hub bearings and installed new
vented rotors.


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Posted by: Dion Jan 22 2017, 09:28 PM

Baked the hubs at 250*F for 25 minutes to coax the
races out.


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Posted by: Dion Jan 22 2017, 09:29 PM

Clean hubs


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Posted by: Dion Jan 22 2017, 09:30 PM

Repacked


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Posted by: Dion Jan 22 2017, 09:35 PM

New ball joints installed. Pay attention to the type of pinch bolt
you have. Torque slowly. Some have reported snapping but must have
"drawn" the bolt through with nut instead of hammering in flush first.


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Posted by: Dion Jan 22 2017, 09:36 PM

Rotors


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Posted by: Dion Jan 22 2017, 09:38 PM

Front calipers will be sent to PMB soon.
Time to get back to the chassis rust repair.


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Posted by: tygaboy Jan 22 2017, 10:50 PM

Nothing like a little brake and suspension porn on a Sunday evening!
Looking good, Dion.

Posted by: Garland Jan 22 2017, 10:58 PM

Looks great,

Posted by: jmitro Jan 22 2017, 11:00 PM

great work; the bilsteins look very nice

Posted by: Dion Jan 26 2017, 04:23 PM

Some garage time this afternoon.
Started prepping trunk area. Removed a chunk of JB weld from trunk I patched
years ago. Needless to say hole enlarged. Learned my lesson. So cut out around it.
This will get a patch.


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Posted by: Dion Jan 26 2017, 04:27 PM

Also some body filler escaped proper contouring from way back in 2004.
Popped it off to find a strange upward dent. No idea how
that would ever happen since it behind the rubber cap of bumper top.
So hammered it back to more appropriate shape.


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Posted by: Dion Jan 26 2017, 04:27 PM

Hammered.


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Posted by: Dion Jan 26 2017, 04:31 PM

Curious? Anyone have a "proper" hole on right side of rear of car near bumper mounts?
Looks like it's a mirror placement for tow eye bolt on left minus the tube and bracing.


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Posted by: Dion Jan 26 2017, 04:32 PM

Tow hook spot?


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Posted by: altitude411 Jan 26 2017, 04:49 PM

QUOTE(Dion @ Jan 26 2017, 03:31 PM) *

Curious? Anyone have a "proper" hole on right side of rear of car near bumper mounts?
Looks like it's a mirror placement for tow eye bolt on left minus the tube and bracing.



Yes. SOP

Posted by: 914dave Jan 26 2017, 04:49 PM

Mine has the same hole. No idea what it's for.

Posted by: tom.esh Jan 26 2017, 06:29 PM

My replacement pan has that hole. I don't think it was on my 73.

Posted by: Dion Feb 5 2017, 10:26 AM

Bodywork has come full stop for now.
Temps are in 20's to 30's and I've come down
with a major sinus infection. Uggh! Been battling it since New Years,it comes and go
but has come back with a vengeance. Being an RN we are the last
ones to see a doctor. Ok enough of that.
I'm updating with older pics here since it is my build thread. So it
serves as a great history.
So first is the 2.4 when I first purchased it nearly 2
years ago. I then cleaned it up and began replacing items




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Posted by: Dion Feb 5 2017, 10:28 AM

Took the carbs off for cleaning and replaced all the seals.


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Posted by: Dion Feb 5 2017, 10:30 AM

Found the ball that was supposed to be on the spring was missing.
Glad I dug into these Zeniths.
I found a great thread about the Zenith carb being rebuilt on the bird site:

http://forums.pelicanparts.com/porsche-911-technical-forum/797607-zenith-rebuild-my-first-carby-project.html

I read it about 10 times before I had the nerve to dig in.


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Posted by: Dion Feb 5 2017, 10:43 AM

Replaced the alternator and painted the fan and shroud.


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Posted by: Dion Feb 5 2017, 10:47 AM

Shroud


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Posted by: Dion Feb 5 2017, 10:51 AM

Fan installed


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Posted by: Dion Feb 5 2017, 11:00 AM

So the upper valve covers that I did in silver paint were done over
in black since the silver didn't adhere very well. Must have had
remnants of oil on them. So after I adjusted the valves this past week
i cleaned the covers up again and did them in black.
Doing the valves with the motor out has to be the way to go.
If you have a lift. It took me over just 2 hours. First time doing a six.
I did it using the standard method as well as the "backside" method mentioned on the
bird site. I prefer the standard method honestly. As I found variations using the backside method. But that's me.


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Posted by: Dion Feb 5 2017, 11:04 AM

Put the carbs back on. Added the surrounding sheet metal.
Fan side will have to come back off to place motor mount on.
Momentarily felt bad as I had to cut into original 914/6 tin to
Make it fit the 2.4 engine. Oh well. Sorry purists!


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Posted by: Dion Feb 5 2017, 11:06 AM

Engine tin


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Posted by: Dion Feb 28 2017, 11:37 AM

Weather finally gave me a window to sandblast the left side of chassis.



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Posted by: Dion Feb 28 2017, 11:39 AM

Sandblasted


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Posted by: Dion Feb 28 2017, 11:44 AM

Cut out the firewall to make my life easier in the future.
I know there's plenty of opinions on this.
Rest assured it will be covered with a steel door made from another
firewall courtesy of Garold. I will be welding nuts to engines side to secure it. Add appropriate rubber seals,etc.
That's a way down the list. Nevertheless that's the plan


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Posted by: porschetub Mar 19 2017, 02:37 PM

Nice work on the motor Dion,what history do you have on it ?,bet the can't wait to get it in.
You did a better job of the firewall cut than I did,mine was a bit of a hack job headbang.gif ,it was great to have it open to do timing etc.
I see you have the ''holy grail'' Bosch cast iron distributor ,is it a ''06'' off the "S" model ?.
Keep up the good work beerchug.gif

Posted by: Dion Mar 19 2017, 03:41 PM

Hey Dean, thanks for the compliments. I can't wait to be up and running like yours!
The distributor is a 0231-159-001 cast iron from a '67 T. I think they might also have
been used on the "S".
The 2.4 has an aluminum '67 case, counterweight crank, rods were checked and
balanced by Ray Litz. New Mahle pistons and cylinders.
Heads have 46 intake and 40 exhaust.
The Zeniths are configured similar to Webers and have the emission circuit eliminated.
The engine looks tired on the outside when I first purchased it. It was used for
about 20,000 miles in a VW Vanagon project for the fellow I Purchased it from.
He's a fellow 914 racer down in Texas. He was going to put it in his
vintage racer but decided to stay 4 cyl. He was happy in his class. Didn't want to deal with different specs and rules that the six would entail. Besides he has
a 356 project looming. Been on the phone and email a couple times with him.
Good guy. He's waiting for me to fire this thing up as well!

Posted by: Dion Mar 19 2017, 03:45 PM

So it's sort of warming up here. Did a little but necessary project today.
Late start, wasn't in the mood to weld. Took care of the oil tank today.
Cleaned up, prepped, primered & painted. Prolly help Dave this week further
his. Hershey closing in. beer3.gif


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Posted by: Dion Mar 19 2017, 03:46 PM

Primer & paint.


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Posted by: porschetub Mar 19 2017, 06:18 PM

Cool sounds like a nice engine with great mods,you will get good power with the carbs,the dizzy is from memory used on the "S" there were 3 types used over the years of that model which were all 2 litre motors 001, 003 and 006.
The dizzy you have has a fairly aggressive advance curve but was made to work with carbs however ,but the ''S'' had aggressive cams to suit,had a friend with one (68 ''S ") and he said the power came on late like an old 2 stroke motocrosser he said it was a very quick car on the open road.
Do you have stock cams?,what spec was the motor to start with?
I just guessing cause I'am the late stages of final tune with my zeniths but you would have 32mm vents,55-60 idles and mains around 130-135 or at least close,you will certainly have the setup to run the larger vents with your valve size.
Nice stock oil tank good score,mine has an PITA leak at the suction hose thread no matter how tight I do it up it leaks,only had it out 3 times so Iam fairly quick @ it now headbang.gif headbang.gif headbang.gif .
Keep up the good work on your car ok.



Posted by: Dion Mar 19 2017, 06:53 PM

Dean, I wish I could say E cams but alas it's a T cam.
It started life with a magnesium case with hi-comp Forge-true Pistons with crank and rods from a 2.7.
It was a 2.5L essentially. Then it was rebuilt as the 2.4 with aluminum case.
with 2.7 crank & Rods, and then the 2.4 Mahle P&C with the Zeniths to suit.
Thanks for the info on Zeniths and distributor.
Keep at Dean I know you'll tame the oil leak!

Posted by: porschetub Mar 19 2017, 08:37 PM

All good,you are on the right track without me sticking my nose in ,however,we have same coloured car,both our engines came from a VW bus,and we have same coloured engine fan ,we are miles apart but maybe not lol-2.gif lol-2.gif lol-2.gif lol-2.gif .

Posted by: Dion Mar 19 2017, 09:27 PM

beerchug.gif my brother in the South Pacific!
Heheh that is funny!

Posted by: Dion May 22 2017, 06:33 AM

Been a while. Time to update.
Removed both front suspension spindle/brake/strut assemblies. They will be replaced by
the 911 assemblies I renewed earlier.
I was also able to get on with the welding. First up was a small area on the left inner wheel well, beginning of the left long. It was right at the corner where it gets pelted with debris and water.
My goal is to get some welding done every week. See what outside influences will disrupt that! dry.gif . welder.gif welder.gif



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Posted by: Dion May 22 2017, 06:34 AM

Patch:


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Posted by: Dion May 22 2017, 06:50 PM

This evening, welded all my "ventilation" holes in the firewall.
Holes were for previous harnesses and electrical "clothes lines" dry.gif as my bud Dave
termed them. Heheh. All wires will now be routed properly through tunnel.
Not the best pics but I'm pleased with my amateur work.
The smell of seam sealer burning is quite distinctive.
Hope to work on "timing" access door for firewall soon.
Getting the little things done while Dave finishes his car.
I'll need his assistance taking the trailing arm suspension console out.
He has a "buck" to form the additional metal I'll need to fix that area.


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Posted by: Dion May 22 2017, 06:53 PM

Closed holes:


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Posted by: Dion May 27 2017, 04:26 PM

Added some self etching primer to the recently repaired hole on
Left front long radius.
I also repaired a similar hole on right front long.


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Posted by: Dion May 27 2017, 04:27 PM

Right front side long:



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Posted by: Dion May 27 2017, 04:29 PM

"Green" frame coating, and welds.


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Posted by: Dion May 27 2017, 04:30 PM

Primered


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Posted by: Dion May 28 2017, 01:47 PM

Well after watching a decent Monaco F1 race,
headed into garage to get dirty. I'm taping Indy for later and
to have a beer3.gif . I'm gonna need it after playing with the welder.
I'm slowly improving. I have a lot of admiration for you guys doing it so well.
Trunk hole had to be made even larger cause there was a nice mix of filler and steel combined. Yeah and filler doesn't weld so well. Stinks like hell to. The metal was very thin in this area. I'm guessing because of previous repair and grinding away of the steel.
So here is what was done today.


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Posted by: Dion May 28 2017, 01:48 PM

Welded piece. Will primer later. Thanks for lookin'


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Posted by: Dion Jun 4 2017, 05:39 PM

I had a very nice phone call recently with Keith Von-Laws,
we were discussing my welding skills or lack of.
I've been working with a mig welder machine that is prolly over 20 yrs old.
Keith (who has welded for a living) was noticing a few things when checking out my
build. The settings on my welder may no longer be what it says on the
rotating dials. He suggested a "newer", If not , new welder.
Keeping in mind we have budgets. Also discussed what settings would be used for
difference situations. Talked about this also with my bro Dave.
All in agreement that a newer one could make life a wee bit easier.
I'm going to try and pick up an Eastwood model that will not kill the budget.
Looking forward to see if this helps me improve. Need a refill on the mig bottle anyway
I'll treat it to a new machine.
Thanks Keith for the pointers and encouragement.
Dave did say that with the new welder he was able to make noticeable
cleaner work. Thus improving the skills. Practice,practice right? Thanks Dave.
Having the right tools should help. Stay tuned.

Posted by: Dion Jun 11 2017, 05:31 PM

Alright picked up a new Mig! Early Father's Day gift!
Keith you were right. Life became much easier with the new welder. Thanks for the pointers.
Now I can improve on technique.



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Posted by: Dion Jun 11 2017, 05:34 PM

Made a patch for the spot where the old "snorkel" was for fresh air and pressure relief.
That area was rotted. I'll be adding a new snorkel later.


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Posted by: Dion Jun 11 2017, 05:35 PM

Also repaired the ratty edge of inner sail panel.


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Posted by: Dion Jun 11 2017, 05:37 PM

Closed the holes on the old insignia spot.
I'll be mounting the 914-6 emblem here.
This area had a lot of filler on it.


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Posted by: Dion Jun 17 2017, 12:17 PM

Some fresh paint for these items.
Added some "lightness" for the wiper arms ala
"Colin Chapman" style for laughs.


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Posted by: mb911 Jun 17 2017, 02:43 PM

Grinder skills will improve with time but blend down a biy more and it won't look as apparent of a repair area. I teach this for a living at the college level..

Posted by: mb911 Jun 17 2017, 02:44 PM

Finish with a blending wheel or a softpack with 120 grit.

Posted by: Dion Jun 17 2017, 03:42 PM

Thanks, Ben. Appreciate the feedback. I do need to get more supplies. I'm
Finding out how much more I need the more I'm getting into repairing the
metal. This is all new territory for me.
So grind welds down "better",then flap disc.
Is that better than using a wire wheel when cleaning up the welds?
Thanks.

Posted by: Dion Jun 19 2017, 09:41 AM

Ok so not much gonna get done over the next couple of weeks.
Family vacation time. Heading out west to see some of the National Parks including Yellowstone & Bryce as well as the Grand Canyon. So...
Forgot to share this neat silencer I obtained. Can't wait to hear it. NOS! Pretty neat.
May not make the greatest HP gains but I thought it be cool.


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Posted by: Dion Jun 19 2017, 09:45 AM

Original advertisement came with it.


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Posted by: mb911 Jun 19 2017, 09:50 AM

QUOTE(Dion @ Jun 17 2017, 01:42 PM) *

Thanks, Ben. Appreciate the feedback. I do need to get more supplies. I'm
Finding out how much more I need the more I'm getting into repairing the
metal. This is all new territory for me.
So grind welds down "better",then flap disc.
Is that better than using a wire wheel when cleaning up the welds?
Thanks.



The best advise I can give anyone when grinding is to just grind the high spots pf the weld down until it is flush with the Parent material. then use a blending disk, Soft pack, Flap disk. Wire brushes are only for removing paint, and rust etc.

I like to to use a die grinder with a thick abrasive wheel on it to bring all high spots down then I use a soft pack which is a glorified sanding disk with a rubber backing that flexes to the contours 36 grit then 80.. this allows it to look virgin..

Posted by: Dion Jun 19 2017, 09:57 AM

Thank you Ben. Going to head to the local hardware store and get some supplies.
Get to some finishing work tonite. I'll post pic, hopefully see improvements.
As you said, it takes time. Hopefully my skills will be improving.
Thank you again.

Posted by: tygaboy Jun 19 2017, 11:52 AM

Go Dion - You're making good progress (unlike some of us...)
LOVE that exhaust! And that advert is very cool. It's great to have those sorts of goodies to go along with the parts.

Posted by: Dion Jun 19 2017, 12:41 PM

Progress is a strong word Chris! Hehehe
Thanks though. It be nice to button this car by
the challenge's allotted time. But....
Yeah I grabbed the silencer cause of its rarity.
I've only seen one on a racing 911. So I thought it was cool.
The fella in Holland could only give me an estimate on decibels
and HP changes. It is literally NOS. A neat find.

Posted by: porschetub Jun 19 2017, 02:09 PM

QUOTE(Dion @ Jun 20 2017, 06:41 AM) *

Progress is a strong word Chris! Hehehe
Thanks though. It be nice to button this car by
the challenge's allotted time. But....
Yeah I grabbed the silencer cause of its rarity.
I've only seen one on a racing 911. So I thought it was cool.
The fella in Holland could only give me an estimate on decibels
and HP changes. It is literally NOS. A neat find.


Hi mate ,like that muffler,it will be load and fun aktion035.gif aktion035.gif .
Good score on the welder ,I think for rust repair you need the advantage of a better welder,hope you have more luck than I did with my new 180....crapped out after a week and they give me a replacement headbang.gif ,new one seems fine.
Keep up the good work beer.gif .

Posted by: Dion Jun 19 2017, 07:23 PM

Ok per Bens advice. Obtained some flap discs. Trying to correct my sins. Welded some pin holes and reground, then flapdisc the area again. No one will see the amateur job but it's giving me practice. This patch will get cut open again for the snorkel tube.
At least it's a rust free and solid area. Not the prettiest.


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Posted by: Dion Jul 17 2017, 01:41 PM

For your viewing pleasure and critiquing:
Heeding the advice of the experienced on this board, I went back to my trunk floor repair. It improved a little. I'll need some body filler to smooth out for better aesthetics
and then paint. I know it gets covered by the mat and carpet. My concern is being watertight. I do like summer but working with the safety equipment on when it's 85F and
90% humidity , whew! A new appreciation for those that do this for a living.


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Posted by: Dion Jul 17 2017, 01:42 PM

Top:


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Posted by: Dion Jul 17 2017, 01:42 PM

Bottom:


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Posted by: tygaboy Jul 17 2017, 06:13 PM

Dion - It's hard to tell from the pics but it looks like you may have the repair piece not quite aligned / in level. It looks like you're ending up with a step where your weld is.

I know I've got it "right" when I can use a 1/4" grinding wheel to knock down the majority of the weld bead and not get into the parent material of either side.
I use the grinder to get close then hit it with a 2" or 3" abrasive wheel on an air angle grinder (depending on the available clearance) to take it almost to the parent material level.
If I have the room, I then do 80 grit on a d/a sander. If no room, 100 grit on the 2"/3".

On the water tight: get a powerful light and shine it on one side of the weld while viewing from the other side. You'll see pinholes where there are, well... pinholes!
buzz them closed and check again til they're all gone.

And remember: It's only metal!

Keep up the great work.

Posted by: Dion Jul 17 2017, 06:52 PM

Chris, you are correct. Slowly getting there. Yes I have a halogen work lamp under the car shining up. Pinholes revealed themselves. Closed them, found another after I hit the area with some primer. Yep it's only metal. I'll still need to address it. But it's way better than my previous attempt. Thanks for the encouraging words.

Posted by: Dion Jul 31 2017, 08:38 PM

Rescuing an early bumper. Rusty backside. Sandblasted, some flap disc work. Rust encapsulater from Eastwood. Then some paint. Chrome side is.... well it's better than
my scratched and dented one. This one has a few dimples but less obvious than my previous bumper. Took a buffer to it. It's a 10 footer. Good for my driver. It has built in
patina biggrin.gif


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Posted by: mb911 Aug 1 2017, 06:05 AM

QUOTE(tygaboy @ Jul 17 2017, 04:13 PM) *

Dion - It's hard to tell from the pics but it looks like you may have the repair piece not quite aligned / in level. It looks like you're ending up with a step where your weld is.

I know I've got it "right" when I can use a 1/4" grinding wheel to knock down the majority of the weld bead and not get into the parent material of either side.
I use the grinder to get close then hit it with a 2" or 3" abrasive wheel on an air angle grinder (depending on the available clearance) to take it almost to the parent material level.
If I have the room, I then do 80 grit on a d/a sander. If no room, 100 grit on the 2"/3".

On the water tight: get a powerful light and shine it on one side of the weld while viewing from the other side. You'll see pinholes where there are, well... pinholes!
buzz them closed and check again til they're all gone.

And remember: It's only metal!

Keep up the great work.


agree.gif

Posted by: Dion Aug 1 2017, 06:28 AM

Polished


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Posted by: mb911 Aug 1 2017, 07:26 AM

Looks nice way better then what I had ..

Posted by: tygaboy Aug 1 2017, 07:26 AM

Looking good, Dion! smilie_pokal.gif

And slightly hijacking but: I'm with you on "driver quality". I plan to drive my car, do an occasional track day, park it near other vehicles, even leave it outside sometimes.
I look at some of the fantastically wonderful work being done by folks like 914dave (and his helpers!) and wonder if I'd ever really want something that nice. I'd be worried sick about every little thing. Heck, just working on my car with the new seat in it is nerve wracking.
It's also a convenient excuse for not spending a ton on paint!

Sorry to distract but this is just my way of supporting you in not obsessing about a bumper that isn't perfect!

Keep on posting - you're helping keep me motivated.

Posted by: Dion Aug 1 2017, 08:53 AM

Chris your too funny man! I have to agree. Mine is a driver for sure.
I'll never have the level of finish some of these builds have because....
Yes I'd prolly be paranoid! I told Dave that first rock chip is gonna hurt
real bad. Heheheh Hell I get nervous about of his tools in the garage near
his ride.
I'll be getting back to welding shortly. Like melting the metal.
Thanks guys!


Posted by: 914dave Aug 1 2017, 12:40 PM

Chris and Dion, enough talk about stone chips!!!! Hahaha

Posted by: Dion Aug 1 2017, 01:22 PM

QUOTE(914dave @ Aug 1 2017, 10:40 AM) *

Chris and Dion, enough talk about stone chips!!!! Hahaha

slap.gif beerchug.gif beer3.gif

Posted by: Dion Aug 13 2017, 02:43 PM

Rear "boot" repair part 2
Went back to rear trunk repair to seal up pin holes from welding. Upon grinding more metal away found some more weak metal. Repairs ensued.
Cut, removed and replaced the original patch panel.
Followed that with an adjacent area repair. Used "all metal" for the pinholes I could not
seal up. Still working on sanding technique. But it's a trunk floor. Not concours worthy
but rust free and strong. I'll add seam sealer later when the primer dries. Working on smoothing the bottom of this area next.


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Posted by: Dion Aug 13 2017, 02:44 PM

Pic


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Posted by: Dion Aug 13 2017, 02:45 PM

Pic


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Posted by: Dion Aug 13 2017, 02:46 PM

Pic


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Posted by: Dion Aug 15 2017, 07:32 PM

Primer & seam sealer for trunk patch area. Topside and muffler side.
Onwards and upwards. Slowly getting the hang of this.
Unbelievable how many items one needs to purchase to complete certain tasks.
Didn't really know how many grades of sandpaper existed until I entered
this realm of bodywork. It's far from the best repair.
Constantly learning from experience of what is proper and what was a bad decision as most things in life. One obvious lesson is be patient!!! Don't rush things.
Thanks for looking in.


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Posted by: Dion Aug 31 2017, 07:12 PM

Ok here's an update for August. Obviously not going to make it for the
deadline of 9-14. I must admit I have been a bit distracted as I just sold
my 1992 VW GTi of which I owned since new on BaT. So that will fund the rest of this
resto. Sad to see it go but I can't afford to maintain a fleet. Especially with my daughter in college. Ok I digress.
I worked on the left long that had a hairline crack in it and also a hole that was adjacent to the seat rail on drivers side rear. Trying to heed advice from the experts here.
I'm getting there! Slowly but getting there.
I ground the welds down and then smoothed them a bit with the "all metal" aluminum
"bondo". Will coat with primer next.


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Posted by: Dion Aug 31 2017, 07:14 PM

Pix


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Posted by: Dion Aug 31 2017, 07:16 PM

Seat rail area, sorry pics loaded in reverse order.


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Posted by: Dion Sep 13 2017, 06:21 AM

Well it's the day before 9-14-17 challenge.
Figure I'd update today as I'm nowhere near done.
Worked on removing rear brakes & trailing arms.



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Posted by: Dion Sep 13 2017, 06:22 AM

Pic


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Posted by: Dion Sep 13 2017, 06:24 AM

Rear console will be cut out and replaced.


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Posted by: Dion Sep 13 2017, 06:27 AM

Engine bay side is nice and clean (rust free?)
Reconditioned arms courtesy of Jayman.


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Posted by: Dion Sep 13 2017, 06:33 AM

After the work on Sat. had a visit from Dave (914Dave) on Sunday.
Hopefully the good karma from his car will transfer to my U-boat.
He needed a "more flat" floor than his garage had to set up camber/caster measurements.
Before he goes to a final setting at a "pro" shop.
His car is stunning.


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Posted by: jmitro Sep 13 2017, 10:10 AM

that's awesome; what size wheels/tires in the rear?

Posted by: Dion Sep 13 2017, 10:25 AM

Hey Joseph, 225/50/15. 8 up front, 9 in the back.
Daves rims are repops from Group4 of the Campagnolo rims.
Just like the Lancia Stratos ran. They're very,very cool.

Posted by: Dion Sep 25 2017, 07:00 PM

Right so Build off challenge is on the simmer. I actually feel less
pressure working on this car now.
Changed gear from body work to working on mechanical
bits. First up removing rear brake lines and "ABS" device.
Will send that bugger of to PMB for an overhaul along with the
front S calipers.


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Posted by: Dion Sep 25 2017, 07:01 PM

Brake line layout


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Posted by: Dion Sep 25 2017, 07:07 PM

This evening removed front control arms to replace all the bushings
and give it a good cleanup. The rust that poured from the torsion tubes, unreal.
Makes no sense to have fresh brakes and lines and not freshen the front end.
Getting those arms are a bugger. Took the whole assembly out
and used the "heavy" lift to keep all still while a nice sized hammer
helped tap out the arms from cross member. Felt good to make mechanical progress.


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Posted by: Dion Sep 25 2017, 07:08 PM

Assembly and control arms removed


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Posted by: porschetub Sep 25 2017, 09:04 PM

Yes correct you switch jobs to something else for a while and you come back to the other better focused....has always worked for me.
Cheers mate.

Posted by: 914dave Sep 26 2017, 08:10 AM

QUOTE(porschetub @ Sep 25 2017, 11:04 PM) *

Yes correct you switch jobs to something else for a while and you come back to the other better focused....has always worked for me.
Cheers mate.


He's waiting on me to help with the inner drains rail patch. He's been patient. He's done a lot of the crap work. The going back together should go fast.

Posted by: tygaboy Sep 26 2017, 08:16 AM

QUOTE(914dave @ Sep 26 2017, 07:10 AM) *

QUOTE(porschetub @ Sep 25 2017, 11:04 PM) *

Yes correct you switch jobs to something else for a while and you come back to the other better focused....has always worked for me.
Cheers mate.


He's waiting on me to help with the inner drains rail patch. He's been patient. He's done a lot of the crap work. The going back together should go fast.


Dave - It's great that you and Dion are there for each other. Having another set of eyes and hands is (nearly!) always a good thing. I most appreciate the way Martin, my build co-conspirator, helps talk me off the ledge when I start to get overwhelmed by whatever the latest challenge happens to be. Having someone there who isn't so emotionally attached to the car really helps me maintain perspective.

So... Good on you both. Now get back to work. I want to see the replacement rear suspension console go in! popcorn[1].gif

Posted by: Dion Sep 26 2017, 08:26 AM

QUOTE(914dave @ Sep 26 2017, 06:10 AM) *

QUOTE(porschetub @ Sep 25 2017, 11:04 PM) *

Yes correct you switch jobs to something else for a while and you come back to the other better focused....has always worked for me.
Cheers mate.


He's waiting on me to help with the inner drains rail patch. He's been patient. He's done a lot of the crap work. The going back together should go fast.


Well yeah, waiting for your expertise. You've been a busy lad.
Not that I don't have enough to do that I can get into trouble with. Heheheh

Posted by: Dion Sep 26 2017, 08:31 AM

QUOTE(tygaboy @ Sep 26 2017, 06:16 AM) *

QUOTE(914dave @ Sep 26 2017, 07:10 AM) *

QUOTE(porschetub @ Sep 25 2017, 11:04 PM) *

Yes correct you switch jobs to something else for a while and you come back to the other better focused....has always worked for me.
Cheers mate.


He's waiting on me to help with the inner drains rail patch. He's been patient. He's done a lot of the crap work. The going back together should go fast.


Dave - It's great that you and Dion are there for each other. Having another set of eyes and hands is (nearly!) always a good thing. I most appreciate the way Martin, my build co-conspirator, helps talk me off the ledge when I start to get overwhelmed by whatever the latest challenge happens to be. Having someone there who isn't so emotionally attached to the car really helps me maintain perspective.

So... Good on you both. Now get back to work. I want to see the replacement rear suspension console go in! popcorn[1].gif


Chris man, Dave has been outstanding in helping me achieve my goals with this build.
He allows me to screw up and learn from my mishaps and then allows ME to correct them which I appreciate. Only way to learn.
And yes, I CANT WAIT TO GET THAT CONSOLE IN! Hahahahah.
I still owe you a coffee Chris. Need to get that done. :-)

Posted by: 914dave Sep 26 2017, 08:35 AM

QUOTE(Dion @ Sep 26 2017, 10:31 AM) *

QUOTE(tygaboy @ Sep 26 2017, 06:16 AM) *

QUOTE(914dave @ Sep 26 2017, 07:10 AM) *

QUOTE(porschetub @ Sep 25 2017, 11:04 PM) *

Yes correct you switch jobs to something else for a while and you come back to the other better focused....has always worked for me.
Cheers mate.


He's waiting on me to help with the inner drains rail patch. He's been patient. He's done a lot of the crap work. The going back together should go fast.


Dave - It's great that you and Dion are there for each other. Having another set of eyes and hands is (nearly!) always a good thing. I most appreciate the way Martin, my build co-conspirator, helps talk me off the ledge when I start to get overwhelmed by whatever the latest challenge happens to be. Having someone there who isn't so emotionally attached to the car really helps me maintain perspective.

So... Good on you both. Now get back to work. I want to see the replacement rear suspension console go in! popcorn[1].gif


Chris man, Dave has been outstanding in helping me achieve my goals with this build.
He allows me to screw up and learn from my mishaps and then allows ME to correct them which I appreciate. Only way to learn.
And yes, I CANT WAIT TO GET THAT CONSOLE IN! Hahahahah.
I still owe you a coffee Chris. Need to get that done. :-)


Chris
I'm only concerned that he's going to cover all his fine work with stickers. poke.gif he has an unresolved issue. Hahahaha!!!

Posted by: Dion Nov 6 2017, 06:11 PM

I prepped and painted the steering rack crossbar. Also cleaned up the rack & master cylinder area.
Just received back my reconditioned A-arms and bushings as well as new swaybar droplink from Elephant. Also picked up new CV/Axles and rear control arm bushings from Tangerine.
While probing a “tiny” area of perforation on the left front fender; a nice piece popped
right off. Pure bondo. Ok another area to get sorted and it will.
But first to get started on the rear console that Chris (Tygaboy) provided.
Always enjoyable removing spotwelds so that will be my life after work for the
next couple of nights.
Cheers all.


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Posted by: Dion Nov 6 2017, 06:12 PM

Front left fender bottom next to door opening. ar15.gif


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Posted by: tygaboy Nov 6 2017, 08:21 PM

Dion - Great to see you're making progress! It's been a while since you posted and I was getting a little worried. Glad to see it was all for naught.

ANd maybe we should have a little side bet on if you'll get your console in before I get the Tangerine raised pick ups installed! I'll take anything to help me get going on that.
And no complaining - I have to remove BOTH consoles! poke.gif

Keep on keepin' on! aktion035.gif

Posted by: Dion Nov 6 2017, 08:47 PM

QUOTE(tygaboy @ Nov 6 2017, 06:21 PM) *

Dion - Great to see you're making progress! It's been a while since you posted and I was getting a little worried. Glad to see it was all for naught.

ANd maybe we should have a little side bet on if you'll get your console in before I get the Tangerine raised pick ups installed! I'll take anything to help me get going on that.
And no complaining - I have to remove BOTH consoles! poke.gif

Keep on keepin' on! aktion035.gif


Chris I just checked your thread. OMG heheh
It’s staggering how much fabrication you’ve done.
It really is a Maserati/Porsche birdcage replica!
Heheheh
What Chris 914 will look like when complete see below


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Posted by: Dion Dec 10 2017, 06:00 PM

Ok so winter is setting in on Pennsylvania.
I don’t have my heat set up in garage yet therefore no
welding as of now.
So went ahead with some small projects I could do in the basement.
Placed the gauges in the gauge frame. I modified
a center console for a fuel gauge to have a home since the “6”
oil press/temp gauge is on the dash now. Obtained a really cool
warning lamp like the 917,935’s had. I still wanted a low fuel lamp.
So the yellow will glow when we are low! Should work out nice.


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Posted by: Dion Dec 10 2017, 06:00 PM

Pic2


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Posted by: raynekat Dec 10 2017, 06:21 PM

That warning light is cool, ultra rare, and likely worth many hundreds of dollars. Impossible to find these.

Posted by: mb911 Dec 10 2017, 08:11 PM

And a muffler coming this week to play with..

Posted by: Dion Dec 10 2017, 09:55 PM

QUOTE(mb911 @ Dec 10 2017, 06:11 PM) *

And a muffler coming this week to play with..


Thanks Ben! Look forward.

Posted by: Dion Jan 6 2018, 02:26 PM

It’s not as bad weather wise in PA as it is in New England but it’s cold enough to
keep me in the basement workshop.
I started taking the suspension console Chris (Tygaboy) supplied me with apart.
Porsche did a nice job spot welding this one together. Thanks Chris it is so much better
than what’s on the car now.
Dave came over last weekend and took some measurements for the buck and to make
a pattern for the kick up to the console.
First I removed the overlay reinforced steel pieces.


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Posted by: Dion Jan 6 2018, 02:27 PM

First piece removed


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Posted by: Dion Jan 6 2018, 02:27 PM

Steel overlays


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Posted by: Dion Jan 6 2018, 02:28 PM

Then the fun spotweld removal


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Posted by: Dion Jan 6 2018, 02:30 PM

Freed console


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Posted by: Dion Jan 6 2018, 02:30 PM

Interior look


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Posted by: Dion Jan 6 2018, 02:32 PM

Need to address small deterioration on this portion that was hidden under re-enforcement steel piece.


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Posted by: Dion Jan 6 2018, 02:33 PM

The collection... and yesterday’s view from my driveway!


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Posted by: Dion Jan 6 2018, 02:34 PM

Driveway


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Posted by: bbrock Jan 6 2018, 03:18 PM

Nice work! I know what a job getting those console pieces apart is. I'm in awe that you were able to get those metal reinforcement gussets off so cleanly. They still look useable. pray.gif Those are some nice pieces you got from Chris.

Posted by: Dion Jan 6 2018, 03:53 PM

Appreciate the compliment Brent.
Yeah that was time consuming. Chris certainly came up aces on such a
clean piece. Very well pleased. When the thermometer decides to
pop above freezing I can begin to dismantle the four cylinder mounts and
begin removing the old console once Dave and I get the jig in place and
can connect the “long/kick up” piece.

Posted by: tygaboy Jan 6 2018, 06:42 PM

Looking really good, Dion!
And I demand you not paint over my Sharpie writing. I took a lot of extra time to do that excellent parts identification documentation! lol-2.gif

Posted by: Dion Jan 21 2018, 06:06 PM

So just finished up removing 4 cylinder engine mount on the
drivers side. What a true mess this side of longitudinal this is.
Thankfully for Chris’ part of console and the parts from
Restoration Design all can be remedied.
Tiring and tedious job removing mount.
I wasn’t able to save it. I hope to save the right mount
in case someone would need it. It is in far better shape.


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Posted by: Dion Jan 21 2018, 06:07 PM

Pic


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Posted by: Dion Jan 21 2018, 06:07 PM

Right engine mount


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Posted by: tygaboy Jan 21 2018, 10:19 PM

Wow... You've made great progress! Did you make any sort of jig to help align things as you put it all back together? There are a couple key measurements and a few posts that cover all that. I assume you're all over that sort of thing...
Keep up the great work! aktion035.gif

Posted by: Dion Jan 21 2018, 11:19 PM

Hey Chris,
I haven’t freed up the existing left console yet.
The car is still with its door braces intact.
Dave has a jig/measurements plan before I tear that apart.
Thanks for the input and push to persevere!

Posted by: Dion Jan 23 2018, 12:33 PM

Moved on to Right engine mount. Challenging to
not destroy it upon removal. A cutting torch I reckon would make
quick work of it but I’d prolly set my car on fire!
I’ll post a pic of mount if any one would need of it pm me and I can take a few more pics of it for you.
The top of the mount was tied into engine shelf/long as well as 4 spot welds.
Totally unlike the left. You can see in the pics how the right side was repaired
back in the early nineties when I had a pro shop do the hell hole and reposition
my suspension so the right wheel would not have EXTREME exaggerated camber!
That’s when I learned of the hell hole troubles.
Looks like they did their best at the time. No rust.
But not factory like :-/ So I’ll get to welding up the right side deficiencies hopefully
this weekend.


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Posted by: Dion Jan 23 2018, 12:35 PM

Pre removal. Starting to separate


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Posted by: Dion Jan 23 2018, 12:35 PM

Removed


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Posted by: Dion Jan 23 2018, 12:37 PM

Right mount (back)


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Posted by: Dion Jan 23 2018, 12:38 PM

Some cleanup


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Posted by: Dion Jan 23 2018, 12:39 PM

The brake line clip was riveted on??


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Posted by: Dion Jan 23 2018, 12:40 PM

Picked this up the other day. Cool period appropriate oil catch tank!


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Posted by: defianty Jan 23 2018, 01:28 PM

Having recently removed my motor mounts I can vouch for what a pig of a job it is. Well done!

Posted by: Dion Jan 27 2018, 09:18 PM

Saturday’s project while listening and occasionally glancing at the 24hr at Daytona:
Addressed the hole in the floor that made me give my 914 the U-boat moniker.
It’s not pretty, no finish sanding or primer yet.
Just wanting to fill that split. It must have occurred due to an improperly
adjusted jack. That whole was filled with pure undercoating when I was removing it from the interior floor.



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Posted by: Dion Jan 27 2018, 09:19 PM

Interior/ exterior near jack donut.


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Posted by: Dion Jan 27 2018, 09:20 PM

Exterior repair


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Posted by: Dion Jan 27 2018, 09:29 PM

Some primer:


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Posted by: Dion Jan 29 2018, 05:24 PM

Closed the holes on the console piece that were under the extra steel plates.
Those plates are for strengthening the console.
I do enjoy the welding. Hopeful I will get more proficient the more I do. And there’s plenty to do!



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Posted by: Dion Jan 29 2018, 05:26 PM

Primer pic


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Posted by: mepstein Jan 29 2018, 06:01 PM

Looking good Dion!

Posted by: Dion Feb 10 2018, 05:17 PM

Attempted cleaning up the right engine mount area. Had a few holes to weld up
and a rather large one along the edge of the console. Some small holes were from the
spot welds holding the mount. Making progress.
Still need to reattach the brake line/hose bracket. Wanted to get some
primer on the bare metal. I’m getting flash rust showing up. It’s been raining and the
garage is a bit humid.



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Posted by: Dion Feb 10 2018, 05:18 PM

Top pic is primered.
Bottom pic just welded holes up.


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Posted by: Dion Feb 10 2018, 05:20 PM

Gap/hole on bottom of console edge/kick up.


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Posted by: Dion Feb 10 2018, 05:21 PM

Rough finish with primer.


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Posted by: Dion Feb 20 2018, 06:34 PM

Out of work early today to take advantage of good warm weather, tackled a small job.
I can finally tic that off the punch list.
Made a panel for the access panel in the firewall. Using a firewall provided by Garold
I cut a piece out oversized so it could lay on top of the contours of the existing firewall
in the car enabling me to use two sets of rubber weatherstripping.
One will surround the cut out and another will wrap around the larger cover.
So noise and any water (unlikely) will be stopped. As well as flames (ha, never know with carbs). I still need to weld the nuts to the engine side. Take care of that this weekend. Cheers all.

Posted by: Dion Feb 20 2018, 06:34 PM

double post, sorry


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Posted by: Dion Feb 20 2018, 06:35 PM

Pic


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Posted by: Dion Feb 20 2018, 06:36 PM

Front engine access panel


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Posted by: tygaboy Feb 20 2018, 06:44 PM

Very nice!
Just a minor suggestion: you may want to round the corners of the opening in the firewall. That'll eliminate the likelihood of a crack developing in that area.

Keep up the great work and progress and you'll be on the road before you know it. driving.gif

Posted by: Dion Feb 20 2018, 07:37 PM

Thanks Chris. Ok will round the edges. Thanks for the suggestion. Never thought of that happening.

Posted by: Dion Feb 26 2018, 03:40 PM

Took Chris advice and rounded the corners slightly of hatch opening.
Welded the nuts on the panel. Primered the cover, wanted to do more but the temps are
dropping quickly so no further primer today. Come on spring!


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Posted by: tygaboy Feb 26 2018, 04:45 PM

cheer.gif smilie_pokal.gif
Nice!

Posted by: mb911 Feb 26 2018, 05:16 PM

I need to do this as well.. Need to either find a panel like you did or weld a flange all around..

Posted by: JmuRiz Feb 26 2018, 07:50 PM

Ben, a panel might be a good idea for your /6 conversion parts smile.gif

Posted by: mb911 Feb 27 2018, 06:24 PM

QUOTE(JmuRiz @ Feb 26 2018, 05:50 PM) *

Ben, a panel might be a good idea for your /6 conversion parts smile.gif



Very true..

Posted by: Dion Mar 17 2018, 07:50 PM

So for a change of pace and not having a lot of free time for sanding/painting I did a
a small project for a bit of fun. I modified the horn bracket to accept a banjo horn like
a few of the real GT ran. I was lucky to stumble upon this one for a
reasonable price (to me). The prices on these horns can be ridiculous. Found it on a Sweden based car parts site. Tested and functions as it supposed to. It certainly sounds different from the stock horn.
I need to modify the “flat” area on the chrome bumper where the rubber spacer meets the body. I will make a slot on the bumper bracket for the trumpet end to slide through. Shouldn’t be too bad to do. Wel’ll see :-)


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Posted by: Dion Mar 25 2018, 06:30 PM

And here it waits...... Placed the Webers on.


If anyone needs some Zeniths from a 911T ,I’ll be posting them soon on
here as well as Pelican.


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Posted by: Dion Mar 25 2018, 06:32 PM

Began digging into the front left fender.


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Posted by: Dion Mar 25 2018, 06:35 PM

Cleaning out the bad metal.


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Posted by: Dion Mar 25 2018, 06:38 PM

Next weekend I’ll make a patch and weld it up. Made sure I had clean metal to weld to
and no further perforations. Certainly going to be a challenging area to sort out.


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Posted by: bbrock Mar 25 2018, 07:14 PM

I'm going to be hitting that same spot on both sides of mine soon. I think I'll sit back and wait while you show me how it's done first. popcorn[1].gif

Posted by: mepstein Mar 25 2018, 07:42 PM

QUOTE(Dion @ Mar 25 2018, 08:30 PM) *

And here it waits...... Placed the Webers on.


If anyone needs some Zeniths from a 911T ,I’ll be posting them soon on
here as well as Pelican.

Pretty

Posted by: Dion Mar 25 2018, 07:59 PM

QUOTE(bbrock @ Mar 25 2018, 05:14 PM) *

I'm going to be hitting that same spot on both sides of mine soon. I think I'll sit back and wait while you show me how it's done first. popcorn[1].gif


av-943.gif You are too kind sir!

I will do my best. beerchug.gif

Posted by: bbrock Mar 25 2018, 08:05 PM

QUOTE(Dion @ Mar 25 2018, 07:59 PM) *

QUOTE(bbrock @ Mar 25 2018, 05:14 PM) *

I'm going to be hitting that same spot on both sides of mine soon. I think I'll sit back and wait while you show me how it's done first. popcorn[1].gif


av-943.gif You are too kind sir!

I will do my best. beerchug.gif


BTW, I have serious engine envy!

Posted by: Dion Mar 25 2018, 08:29 PM

It will be extremely nice to wrap this project up and drive it out your way Brent.
To cruise about Big Sky country would be awesome. I only had a taste of it
exiting Yellowstone near Roosevelt’s Arch.
Be more than happy to let ya have a go!

Posted by: bbrock Mar 25 2018, 09:33 PM

QUOTE(Dion @ Mar 25 2018, 08:29 PM) *

It will be extremely nice to wrap this project up and drive it out your way Brent.
To cruise about Big Sky country would be awesome. I only had a taste of it
exiting Yellowstone near Roosevelt’s Arch.
Be more than happy to let ya have a go!


Deal! Our house is only 1 hour from Roosevelt Arch and you are welcome to stay in our guest room. A cruise over the Beartooth Hwy is a must!

Posted by: tygaboy Mar 26 2018, 08:58 AM

Dion - Your engine wub.gif is BEAUTIFUL!

Posted by: mb911 Mar 26 2018, 01:23 PM

Dion,

Those are interesting cam covers what are they from?

Posted by: Dion Mar 26 2018, 01:34 PM

Ben it’s a 1967 aluminum case.

Posted by: mepstein Mar 26 2018, 01:38 PM

QUOTE(Dion @ Mar 26 2018, 03:34 PM) *

Ben it’s a 1967 aluminum case.

I must have missed that. Those cases are very pricey these days.

Posted by: Dion Mar 26 2018, 01:49 PM

Great, now I can be more nervous. Thanks Mark hehehe.

Posted by: mb911 Mar 26 2018, 01:51 PM

QUOTE(Dion @ Mar 26 2018, 11:49 AM) *

Great, now I can be more nervous. Thanks Mark hehehe.



If thats the case you just hit the lottery.. I would really consider cashing out on thay engine and buy another..

Posted by: Dion Mar 26 2018, 01:58 PM

Heheheh sweet. piratenanner.gif Didn’t know they’ve escalated. I’m trying to cash out with Mark right now on the Zeniths! Heheh. Fingers crossed Mark! popcorn[1].gif

Posted by: mb911 Mar 26 2018, 01:59 PM

Looks like 8-9k for a case..

???

Posted by: Dion Mar 26 2018, 02:09 PM

Wow. Well I appreciate that news. I spent 7k originally for the engine,carbs & an oil tank! Thanks Ben. Now the paranoia can set in! Heheheh beer.gif

Posted by: porschetub Mar 26 2018, 02:24 PM

QUOTE(Dion @ Mar 26 2018, 01:30 PM) *

And here it waits...... Placed the Webers on.


If anyone needs some Zeniths from a 911T ,I’ll be posting them soon on
here as well as Pelican.


Hi mate,love the engine tucked away in the corner crying 'bolt me in' hissyfit.gif I found having a built engine inspired to get on with the job,hope it works that way for you.
Wow that's a nice engine I notice an early cast iron dizzy too drooley.gif drooley.gif ,these work really well with carbs I have read.
Best of luck and keep knocking away @ that bloody rust smash.gif smash.gif sawzall-smiley.gif welder.gif welder.gif

Posted by: porschetub Mar 26 2018, 02:27 PM

QUOTE(mb911 @ Mar 27 2018, 08:59 AM) *

Looks like 8-9k for a case..

???


I did see one of these cases listed for 15k a while back .
I think Dion bought this a while back.....just guessing lol-2.gif lol-2.gif .

Posted by: Dion Mar 26 2018, 02:32 PM

Thanks Dean. Yes the clean motor does inspire, as
well as Dave’s completed beauty! I purchased the engine in 2015. I guess before all the 911 speculation took off.
Cheers mate!

Here’s 914Daves:


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Posted by: Dion Apr 1 2018, 07:43 PM

Happy Easter from the guy working on this project.
I worked on the front lower left fender today. What a treat this was.
Made some cardboard templates and then cut my shapes.
Bending the one piece was tricky as I don’t have the proper tools for this so
some pipe of different diameters and a vice helped me shape the curve.


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Posted by: Dion Apr 1 2018, 07:46 PM

Shapes


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Posted by: Dion Apr 1 2018, 07:49 PM

Placement


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Posted by: Dion Apr 1 2018, 07:52 PM

Curved outer piece mounted, welds ground & sanded.


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Posted by: Dion Apr 1 2018, 07:54 PM

Inside door jamb welded piece. None of my tools for grinding or sanding would fit in this area. So had to rely on primer and sealer to button up. Not the best but weather proofed.


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Posted by: Dion Apr 1 2018, 07:55 PM

seam seal & primer



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Posted by: mepstein Apr 1 2018, 08:07 PM

QUOTE(Dion @ Mar 26 2018, 04:32 PM) *

Thanks Dean. Yes the clean motor does inspire, as
well as Dave’s completed beauty! I purchased the engine in 2015. I guess before all the 911 speculation took off.
Cheers mate!

Here’s 914Daves:

No, aluminum cases have been pricey for awhile. You just bought well. I sold one for $12K last year and that was a core short block. It would be hard to find a good running engine for less than $20K these days.

Posted by: jmitro Apr 1 2018, 09:05 PM

nice work Dion. Keep at it.
Take it from my mistake and make sure your door gaps are still good before you get all that painted. I had to backtrack after having my whole car painted and cut out some extra metal in that spot as it squeezed my door gap down.

I should be installing your old 2056 by end of summer piratenanner.gif

Posted by: Dion Apr 1 2018, 09:59 PM

“I should be installing your old 2056 by end of summer” piratenanner.gif

That’s good news Joseph! Sorry to hear of the mishap with the doors. Especially after
the paint! Thanks for the reminder.

Send some pics would love to see it.

Posted by: Dion Apr 14 2018, 12:22 PM

Ok gentlemen need advice. So my flares were welded on, not in the ideal way.
They used an overlap weld instead of butt welds. Removing and starting over is not on the table. Although that’s the ultimate answer. I’d like to prevent further rust. I have some surface rust below the thinly applied undercoating. I wire wheeled off the undercoating. I was thinking of using an acid etch and spraying it in all the seams then
use a rust “encapsulate” type spray and then prime/paint then undercoat.
Any other “ chemical suggestions for getting in those overlapping seams?
Thanks guys.



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Posted by: Dion Apr 14 2018, 12:23 PM

Seams


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Posted by: Dion Apr 14 2018, 12:25 PM

Also need to re do the seam seal on the rear of front fender where it meets chassis.
And a little welding.


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Posted by: Dion Apr 14 2018, 12:27 PM

Damage that needs welding up. Lower portion in front of long. Base of front fender.


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Posted by: Dion Apr 14 2018, 07:32 PM

So had a suggestion to use the Eastwood Internal Frame coating.
I had that on hand. This stuff creeps into crevices so it made sense.
After washing it down with the “ Fast Etch” and cleanup with pre paint prep,
I hit it with the “frame coating” then coated with rubberized undercoating.
Didn’t get to the welding today. Drying time of the chemicals ate into weld time.
That’s for another weekend. Thanks for looking in!


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Posted by: Dion Apr 14 2018, 07:33 PM

Etch turning rust to black with the phosphates.


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Posted by: Dion Apr 14 2018, 07:35 PM

Frame coating and seam sealer


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Posted by: Dion Apr 14 2018, 07:35 PM

Undercoating


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Posted by: Dion Apr 14 2018, 07:36 PM

Undercoating on overlap welded areas


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Posted by: porschetub Apr 15 2018, 12:58 AM

QUOTE(Dion @ Apr 2 2018, 01:43 PM) *

Happy Easter from the guy working on this project.
I worked on the front lower left fender today. What a treat this was.
Made some cardboard templates and then cut my shapes.
Bending the one piece was tricky as I don’t have the proper tools for this so
some pipe of different diameters and a vice helped me shape the curve.


Ha ha just like me older and hopefully wiser,good skills on the safety gear,I admit to being a bit slack @ times and payed the price,last we while I have 2 cut fingers with 1mm cutting wheels decided to wear mig/tig gloves from that point....makes sense.
If your flairs were overlap welded that's not too much of an issue as long as the steel was "keyed up" with a course abrasive and the filler hasn't cracked you should be fine,never been a fan of fillers but if prepped properly generally they are fine.
I understand this was done a while back if still holding up well on the exterior leave it,there's a lot you can do on the inside that's not seen afterall.
Good luck mate bye1.gif .

Posted by: mb911 Apr 15 2018, 09:42 AM

What kind of metal etch are you using? I have some areas I would like to apply this to on my car and I have never used an etch applied by hand that converts rust. Please share.

Posted by: Dion Apr 15 2018, 12:23 PM

QUOTE(mb911 @ Apr 15 2018, 07:42 AM) *

What kind of metal etch are you using? I have some areas I would like to apply this to on my car and I have never used an etch applied by hand that converts rust. Please share.


Hey Ben, it was Eastwood “Fast Etch”
Shop personnel explained to me it etches and will
coat the rust with a phosphate. I used it in spray form, I let soak in for around 45 minutes. It then needs to be cleaned off. I used pre paint prep to clean it up. Then I used the frame interior coating.
Cheers, Dion

Posted by: bbrock Apr 15 2018, 04:16 PM

As near as I can tell, Fast Etch is comparable to Ospho or any other phosphoric acid etcher/converter/protectant. I'm using KleanStrip brand form Home Depot now that Jasco discontinued theirs. Same as Ospho but cheaper.

Looking good Dion! thumb3d.gif

Posted by: mb911 Apr 15 2018, 04:24 PM

QUOTE(bbrock @ Apr 15 2018, 02:16 PM) *

As near as I can tell, Fast Etch is comparable to Ospho or any other phosphoric acid etcher/converter/protectant. I'm using KleanStrip brand form Home Depot now that Jasco discontinued theirs. Same as Ospho but cheaper.

Looking good Dion! thumb3d.gif



So can you prime right over this stuff or ?

Posted by: Dion Apr 15 2018, 05:06 PM

For the Fast Etch brand once it’s cleaned off with acetone or pre paint prep
cleaner it can be primered over.

Posted by: Dion Apr 15 2018, 05:36 PM

QUOTE(Dion @ Apr 1 2018, 05:55 PM) *

seam seal & primer


Left front fender buttoned up.


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Posted by: bbrock Apr 15 2018, 05:42 PM

QUOTE(mb911 @ Apr 15 2018, 04:24 PM) *

QUOTE(bbrock @ Apr 15 2018, 02:16 PM) *

As near as I can tell, Fast Etch is comparable to Ospho or any other phosphoric acid etcher/converter/protectant. I'm using KleanStrip brand form Home Depot now that Jasco discontinued theirs. Same as Ospho but cheaper.

Looking good Dion! thumb3d.gif



So can you prime right over this stuff or ?


Yep. I neutralize with water and after it is dry, use a red scotch brite pad to knock off any loose phosphate, then clean and dewax as usual. PPG even has a note in their epoxy primer tech sheet that use of this type of rust converter improves adhesion. Of course, they want to sell you their brand and outrageous prices.

Posted by: mb911 Apr 15 2018, 06:08 PM

Having never done it this way on my paint jobs prior should this be applied to all bare metal then scotch brite and spray primer?

Posted by: mb911 Apr 16 2018, 09:10 AM

QUOTE(bbrock @ Apr 15 2018, 02:16 PM) *

As near as I can tell, Fast Etch is comparable to Ospho or any other phosphoric acid etcher/converter/protectant. I'm using KleanStrip brand form Home Depot now that Jasco discontinued theirs. Same as Ospho but cheaper.

Looking good Dion! thumb3d.gif


Looks like that stuff is about 15 dollars.. Gonna give that a try. Dion thanks for bringing this up ..now gonna make my car better in the end

Posted by: Dion Apr 16 2018, 09:58 AM

No worries Ben, and thanks again for the muffler bracket & the straps info!

Plenty more bodywork to be done.

I told Dave I’m gonna have to get the whole car resprayed.
In for a pound in for a penny! The paint job is over 14 years now, it always
had it’s blemishes. Chance to rectify all that.
Maybe have it done by Octeenerfest.....
Dave .... poke.gif Hehehehe

Posted by: 914dave Apr 16 2018, 11:59 AM

popcorn[1].gif

Posted by: Dion Apr 25 2018, 06:30 PM

Just wanted to give a shout out to Eric and the gang at PMB.
Received my restored S calipers and regulator today as well as the brake line kit.
Thanks a bunch guys. They look awesome,& I’m sure they’ll provide plenty of STOP! smilie_pokal.gif crest.gif


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Posted by: Dion Apr 26 2018, 07:10 PM

This afternoon repaired the remaining rust issue on the right front fender wheelhouse/longitudinal area. Cut off the offending piece. Made
a new one in as close a profile as I could. Using the workbench vise and a hammer to make the bend. Tacked it in. I’m pleased as to how it came out.
Listening to Ben, Chris, Brent & Dave, I think I’m finally gettIn the hang of this
welding business!


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Posted by: Dion Apr 26 2018, 07:11 PM

New shape offered up


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Posted by: Dion Apr 26 2018, 07:12 PM

Tacked


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Posted by: Dion Apr 26 2018, 07:13 PM

Clean up


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Posted by: Dion Apr 26 2018, 07:14 PM

Fin!


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Posted by: bbrock Apr 26 2018, 07:50 PM

Looks great!

Posted by: Dion Apr 29 2018, 07:29 PM

Nothing exciting today except for the cheap high. Man even while wearing the 3M
NIOSH respirator those fumes creep in!
I sanded the engine side of the firewall yesterday and today I coated it with
Epoxy primer.


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Posted by: Dion Apr 29 2018, 07:46 PM

Question fellas. I’m working on the right side sill next. I have six holes. Centered 6” apart.
Can someone verify if that is correct for the factory sill plates.
Mine are packed away. Not at hand to check. I have a little welding to repair one as it
really isn’t s circular hole anymore and I want to redrill properly afterwards.
Thanks.


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Posted by: Dion Apr 30 2018, 06:31 PM

Ok, Dave says just weld them all close and redrill when
the rust issue is fixed and I can then use the sill as a template.
It’s great when common sense prevails. Thanks bro!
I was ready to make it more complicated.

Posted by: Dion May 8 2018, 10:17 AM

Worked on passenger side sill area.
Welded up the too numerous holes for rocker panels and sill plate.
Also removed some surface rust. A general cleanup.
Next up will be working on the left rear quarter panel/fender.


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Posted by: Dion May 8 2018, 10:18 AM

Welded & cleaned


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Posted by: Dion May 8 2018, 10:20 AM

Primered & seam sealed.


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Posted by: Dion May 8 2018, 10:22 AM

Done


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Posted by: 914dave May 8 2018, 12:36 PM

That’s some fine looking work. Looks like you don’t even need help. You got this. Let me know when you want to borrow the finish gun. Hahaha

Posted by: Dion May 8 2018, 01:07 PM

QUOTE(914dave @ May 8 2018, 10:36 AM) *

That’s some fine looking work. Looks like you don’t even help! shades.gif


WOW! slap.gif Nice save with the edit. Splitter! :-)

Posted by: Dion Jul 9 2018, 06:23 PM

Ok, trying not to piss off Brent anymore biggrin.gif while working on 944s...the weather in PA finally broke. I can breathe again. Damn humidity!
So did some masking around windows and dash to protect them.
Started sanding and cleaning the cabin floor and trunk floor so I could epoxy prime them.



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Posted by: Dion Jul 9 2018, 06:24 PM

Cabin


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Posted by: Dion Jul 9 2018, 06:25 PM

Trunk


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Posted by: Dion Jul 9 2018, 06:26 PM

Application of the epoxy primer.


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Posted by: Dion Jul 9 2018, 06:27 PM

Trunk primed


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Posted by: Dion Jul 9 2018, 06:29 PM

& finally interior firewall primed.


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Posted by: tygaboy Jul 10 2018, 07:36 AM



Hey Dion - good to see you back at it!
It's got to be a great feeling to see paint instead of bare metal, eh? Keep it coming, you're making great progress!

(And selfishly): So that's what a complete fire wall looks like...! biggrin.gif

Posted by: bbrock Jul 10 2018, 08:33 AM

Sweet! Looking good. About time you stopped fiddling with that water pumper and got back to your project poke.gif biggrin.gif

Posted by: Dion Jul 10 2018, 02:32 PM

Yes, thumb3d.gif getting the bare metal protected is a good feeling.
We had such hi temps and humidity I wasn’t sure if the primer would adhere proper.
So finally was able to do this. headbang.gif bought different colours of primer
but it will all be the same later. Now on to more difficult tasks: left rear fender &
The all important Left long/kick up and console.
sawzall-smiley.gif welder.gif beerchug.gif
Thanks guys


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Posted by: ThreeV8s Jul 10 2018, 08:48 PM

I just read through this entire thread and have no idea how I missed all this. I did not realize you were doing anything to this extent. You are way too modest about your skillset...truly impressive work! Looking forward to stopping by at some point soon and seeing it in the metal.

Posted by: Dion Jul 11 2018, 07:04 AM

Thanks for those kind compliments Brian.

Posted by: Dion Aug 2 2018, 07:20 PM

Started prep work on drivers rear quarter panel.
Removed the undercoating with heat gun, left the flare alone since that is
paint and not tar. Found yet another hole lurking. Apparently minding its own
business till the flap disc found him out. Oh how I miss my complete car.....
Oh well we are here to make it whole again. There is a nice chunk missing by the tail lamp I’ll be utilizing a good piece from Garold. I’ll prep
that next week hopefully. So some before and after pics:


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Posted by: Dion Aug 2 2018, 07:23 PM

Unbelievable the amount of seam sealer that was around the snorkel. Dug that out.
I have a new snorkel and slam panel for that area.
Removed the ..urethane? Foam from the panel as well.


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Posted by: Dion Aug 2 2018, 07:24 PM

Ugly metal:


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Posted by: Dion Aug 2 2018, 07:26 PM

Foam


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Posted by: Dion Aug 2 2018, 07:26 PM

Sail panel damage


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Posted by: Dion Aug 2 2018, 07:27 PM

Panel


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Posted by: Dion Aug 2 2018, 07:29 PM

If any one has a compromised panel but not in the area I need to repair
would gladly like to have it so I could make a patch.
Let me know what ya have...thanks for checking in.


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Posted by: bbrock Aug 2 2018, 10:03 PM

QUOTE(Dion @ Aug 2 2018, 07:29 PM) *

If any one has a compromised panel but not in the area I need to repair
would gladly like to have it so I could make a patch.
Let me know what ya have...thanks for checking in.


Let me check the scrap pile in the morning. I had a pair of extra sail panels that were too far gone to use to replace mine, but I don't remember where they were damaged. We might get lucky.

Posted by: Dion Aug 3 2018, 03:29 AM

Thanks Brent beerchug.gif

Posted by: bbrock Aug 3 2018, 09:03 AM

Pulled it out of the scrap pile. It's a bit crusty under vent tube but looks like it might clean up and cover the area you need to patch. If you think it has promise, I can hit it with the media blaster this evening and send more pics. If you decide you want it, pm me with your address and how much you want cut off and it's yours.

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Posted by: Dion Aug 3 2018, 09:14 AM

Brent that should do the trick. Will save me trying to duplicate that contour. Thanks buddy!

Posted by: 914dave Aug 3 2018, 09:25 AM

Oh look , a real snorkel! We can use that

Posted by: Dion Aug 3 2018, 09:48 AM

I broke down and bought a snorkel from RD.
Ya guilted me. I’m diggin the racing stripes on the yellow/ green colour!
Yeah baby, groovy!

Posted by: bbrock Aug 3 2018, 10:19 AM

QUOTE(Dion @ Aug 3 2018, 09:48 AM) *

I broke down and bought a snorkel from RD.
Ya guilted me. I’m diggin the racing stripes on the yellow/ green colour!
Yeah baby, groovy!


Ah! headbang.gif I wish I'd have known. My recollection is that part isn't cheap and you can have this one for free.

Posted by: Dion Aug 3 2018, 11:01 AM

All part of the adventure! lol-2.gif

Posted by: tygaboy Aug 3 2018, 01:14 PM

QUOTE(Dion @ Aug 3 2018, 10:01 AM) *

All part of the adventure! lol-2.gif


agree.gif
I was about to say "Forget the snorkel. You're in deep enough that you need full on SCUBA gear!" lol-2.gif
Look great, Dion. You're really getting there!

Posted by: Jeff Hail Aug 3 2018, 02:36 PM

QUOTE(Dion @ Jan 22 2017, 08:30 PM) *

Repacked



Nice work.

When you get your car on the road if you find you have any vibrations even subtle ones in the front wheels or run out in the hubs, wheels that mystifies all diagnostics start here.

Those are high spots where the race bottoms out which occurs when removing the old races with a drift, punch etc I usually take an old race slice it with a cut off wheel, a rubber drum on a drill motor, some 600 grit lapping compound and spin the "race lapping tool" for about 20 seconds until the high spots are gone. (hubs are soft aluminum)

Yours aren't bad but could show up as a gremlin later. I've seen hubs much worse that I have repaired were murdered by the BFH.

On the Pelican site I have seen a 50+ times guy replaces bearings and races then shows back up three month later with an issue and a new vibration thread then later needlessly replacing hubs.

The high spots are small but when you extend that small rise to tread distance or wheel bead it turns into preventable amount of run out. The tapered rollers will last longer also.


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Posted by: Dion Aug 3 2018, 02:46 PM

Jeff , thanks for the heads up! Would never had known. I really appreciate that. Great info. Always learning something.
Cheers, mate.

PS: love your thread, tons of info.

Posted by: Dion Aug 19 2018, 11:04 AM

No body work updates ...but just wanted to share a story in which I wanted to honor my friend Jim McLeod (type47). Before the time of his passing he and I were both doing
2.4L six conversions. So we had a friendly wager going on as to whom was
gonna get on the road first. Well Jim we both are!
I was fortunate to obtain Jim’s 2.4L yellow fan/engine shroud at the recent picnic honoring him. So it’s now home on my engine. I hope his spirit will enjoy
some road trips with me and my 914 friends. It may be silly to some
but has meaning to me.



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Posted by: Dion Aug 19 2018, 11:05 AM

Yellow


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Posted by: mb911 Aug 19 2018, 03:13 PM

I personally think that's awesome.. I am all kinds of about these type of thing's. Everytime I see someone that has served in the military I shake their hand, everytime I look at something my dad has given me I think about back to my childhood and remember the time he gave it to me. Your tribute to Jim is just fantastic..

Posted by: bbrock Aug 19 2018, 04:07 PM

QUOTE(mb911 @ Aug 19 2018, 03:13 PM) *

I personally think that's awesome.. I am all kinds of about these type of thing's. Everytime I see someone that has served in the military I shake their hand, everytime I look at something my dad has given me I think about back to my childhood and remember the time he gave it to me. Your tribute to Jim is just fantastic..


Couldn't have said it better. Very cool and now you will never be lonely in your car.

Posted by: Dion Aug 19 2018, 04:15 PM

Thanks fellas. Appreciate your sentiments.

Posted by: Dion Aug 20 2018, 07:07 PM

Duplicate

Posted by: Dion Aug 20 2018, 07:08 PM

Back to this welder.gif
Rear left tail lamp area. Swiss cheese.
Nothing too exciting just documenting.


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Posted by: Dion Aug 20 2018, 07:08 PM

Duplicate post

Posted by: Dion Aug 20 2018, 07:09 PM

Donor piece


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Posted by: Dion Aug 20 2018, 07:14 PM

Upper outer portion repair


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Posted by: Dion Aug 20 2018, 07:15 PM

Next: rear just above rubber cap region. Offending piece cut out.


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Posted by: Dion Aug 20 2018, 07:16 PM

Patch piece test fit.


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Posted by: Dion Aug 20 2018, 07:17 PM

For those wondering about all those other holes on the perimeter those are the spot weld holes
which will be addressed when mounting panel to car structure. Will be working on sail panel tomorrow and get some primer on the bare metal.


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Posted by: Dion Aug 24 2018, 05:23 PM

Worked on the sail panel a bit. Brent thanks mate!
The piece you sent worked out fine. When the finish body work is done all should look
proper. Glad it has metal back where it should be.
Here’s some photos of progress. Next on the “ to do “ list, will be the Left console/ longitudinal. sawzall-smiley.gif


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Posted by: Dion Aug 24 2018, 05:24 PM

Patch piece being sized up


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Posted by: Dion Aug 24 2018, 05:26 PM

Cut & weld


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Posted by: Dion Aug 24 2018, 05:27 PM

Some primer


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Posted by: bbrock Aug 24 2018, 07:10 PM

QUOTE(Dion @ Aug 24 2018, 05:23 PM) *

Worked on the sail panel a bit. Brent thanks mate!
The piece you sent worked out fine. When the finish body work is done all should look
proper. Glad it has metal back where it should be.
Here’s some photos of progress. Next on the “ to do “ list, will be the Left console/ longitudinal. sawzall-smiley.gif


Hey look at that! I'm glad that old rusty turd still had a use for someone. Nice work. beerchug.gif

Posted by: Dion Aug 24 2018, 07:16 PM

Thanks boss, I’m trying. beerchug.gif

Posted by: Dion Sep 8 2018, 04:35 PM

Went back to work on the sail panel patch again.
Wasn’t really happy that some flash rust had shown through the primer.
Sanded that area again and prepped. Then used some self etching primer there
since it has the “zinc” content in it.



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Posted by: Dion Sep 8 2018, 04:45 PM

Flipped the fender over and used the same treatment I did for the other flares.
Where as my flares had been “lap welded” as opposed to “butt weld” , I wanted to add
an extra means chemically to warn off problems.
I used Eastwood’s internal chassis coating to have it creep into the small crevices of the welded areas. Of course cleaned it thoroughly first. Then I used “rubber undercoating” on the flare itself. The condition of paint on the inner flare was quite sound. After prepping and cleaning the rest of the interior of the fender I then sprayed with epoxy primer. This should keep till the rest of the chassis is done. Then finish bodywork can begin.... that’s a bit aways yet!


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Posted by: Dion Sep 23 2018, 07:37 PM

I know this car was a COTM & I appreciate that very much.
However the paint job was 14 years old and was just applied on the topsides.
No door jambs or underhood areas. So since we’re in for a pound in for a penny,
I’m addressing areas that need attention. I’m not calling this a restoration but a freshening. This is my build, my hot-rod. Not concours by any means. So if ya see flaws
oh well I’m doing my best. So this weekend I tackled the headlite hardware and
the buckets. Sanded the headlite hardware, primered and gave em the zinc phosphate look with a spray bomb from Eastwood.


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Posted by: Dion Sep 23 2018, 07:38 PM

Sanded


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Posted by: Dion Sep 23 2018, 07:39 PM

Sanded


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Posted by: Dion Sep 23 2018, 07:39 PM

Paint


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Posted by: Dion Sep 23 2018, 07:44 PM

Sunday’s chore was the bucket area and the front portion of the rain channel around the hood. Also did a re-spray of the floor of the frunk. It was a bit scuffed up.


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Posted by: Dion Sep 23 2018, 07:45 PM

Primer & Paint on channel


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Posted by: Dion Sep 23 2018, 07:49 PM

The buckets & frunk


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Posted by: Dion Sep 23 2018, 07:50 PM

P


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Posted by: Dion Sep 23 2018, 07:52 PM

Frunk


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Posted by: Dion Sep 23 2018, 07:52 PM

Fresh paint


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Posted by: Dion Sep 23 2018, 07:53 PM

Supervisor


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Posted by: mb911 Sep 23 2018, 08:23 PM

QUOTE(Dion @ Sep 23 2018, 05:39 PM) *

Paint



Dion,

I sand blasted mine as well and I swear that 914rubber.com had a kit to do this and replace the hardware.. Am I imagining that? Mine have been bare metal while I wait to find that kit. Any insight?

Posted by: Dion Sep 23 2018, 08:27 PM

Honestly Ben I don’t recall that. I wouldn’t doubt it though.
@http://www.914world.com/bbs2/index.php?showuser=9892

Posted by: Dion Sep 23 2018, 08:36 PM

@http://www.914world.com/bbs2/index.php?showuser=9892 just checked Mikey’s site. He has the lite adjuster blocks, nylon bushings and the arm/lever. That’s what I found.

Posted by: bbrock Sep 23 2018, 08:49 PM

QUOTE(mb911 @ Sep 23 2018, 08:23 PM) *

QUOTE(Dion @ Sep 23 2018, 05:39 PM) *

Paint



Dion,

I sand blasted mine as well and I swear that 914rubber.com had a kit to do this and replace the hardware.. Am I imagining that? Mine have been bare metal while I wait to find that kit. Any insight?


This one? https://shop.914rubber.com/Headlight-Bundle-914HLA.htm?categoryId=-1

Posted by: bbrock Sep 23 2018, 08:51 PM

Lookin' great Dion! No doubt it couldn't be done without that good looking supervisor.

Posted by: Dion Sep 23 2018, 09:08 PM

Thanks Brent! Yes the pup is a task master. I didn’t see that headlite kit. Good find. Might have to spring for that, hmmm....Xmas will soon be here.... beerchug.gif

Posted by: Dion Oct 2 2018, 06:15 PM

This is what happens when you see too many Rennsport reunion pictures,
and there is a drill nearby..... just a bit of fun. biggrin.gif


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Posted by: Dion Oct 14 2018, 02:36 PM

Took the fuel tank out, being that I’ll being running a different pump for the carbs and rerouting fuel lines.
Cleaned up the area under the tank.


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Posted by: Dion Oct 14 2018, 02:36 PM

Spruced up


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Posted by: Dion Oct 14 2018, 02:38 PM

Also since I’m tired of breaking my knuckles when dealing with and checking the fuel lines and fittings I enlarged the access opening.


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Posted by: Dion Oct 14 2018, 02:41 PM

Fitted with edging so ya don’t get cut up & lines don’t get sliced.


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Posted by: Dion Oct 14 2018, 02:42 PM

Placed the headlamps hardware back in. Rust free!


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Posted by: Dion Oct 14 2018, 02:45 PM

Since I’m not running a rear valance and don’t ever intend to...
I removed the tabs off the rear closing panel and welded up the gaps.
I wanted a smoother look.


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Posted by: Dion Oct 14 2018, 02:48 PM

I used the metal from the piece i cut from the front firewall
to make strips to fill the gaps of the former tab locales.


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Posted by: Dion Oct 14 2018, 02:51 PM

Sanded and primered. I’m pretty happy with it.
There is a slight dip on one area I took too much metal away.
The bumper should trick the eye that it’s all level :-)


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Posted by: bbrock Oct 14 2018, 08:29 PM

Looking good! I had to zoom in on the full sized image to see the dip you were talking about. Only you will ever notice. bye1.gif

Posted by: mepstein Oct 14 2018, 08:41 PM

I wanted a ride when you were done but I don't think I can be seen in a car with such an obvious flaw. Everyone will point. av-943.gif







WTG. Former COTM made even better. smilie_pokal.gif

Posted by: saigon71 Oct 15 2018, 05:33 AM

Freaking awesome work Dion!

I can't believe that this much rust was hiding in your stellar car.


Posted by: Dion Oct 15 2018, 01:34 PM

As someone else said earlier, even the “nice” ones may have treacherous rust hiding.
Obviously our east coast cars are more susceptible.
My car did spend its early life along the Chesapeake Bay area. So salt air and
it being a daily driver for five years in PA by me took its toll.
I’m having fun with this project. It’s given me a chance to make it sound, and to
really customize it. Thanks for the support guys I wouldn’t have tackled this without
your help. Particularly 914Dave. Thanks for the compliments as well,
It’s a nice motivator. The big structural stuff is up next as well as tacking in the six mount. beerchug.gif


Posted by: Dion Nov 9 2018, 07:05 PM

Update time. Had a cool distraction. Dave’s buddy from another PCA region grabbed some tickets for us to see Hurley Haywood at the Simeone Museum in Philadelphia.
What can I say about Hurley...just one damn cool dude.
Bought his book and got it signed, also signed my 914 baseball cap. smilie_pokal.gif
Dr Simeone is the fella with the mic introducing Hurley.
Funny part was, we met Hurley out in the parking lot before the dinner and the event started , he was checking out Dave’s 914. He approved! Thought it was very cool.


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Posted by: Dion Nov 9 2018, 07:12 PM

Ok here’s where I’m at on the project.
Rust inhibitor (Green colour) and undercoating applied to the right rear fender/flare.


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Posted by: Dion Nov 9 2018, 07:13 PM

Flare


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Posted by: Dion Nov 9 2018, 07:13 PM

Right flare


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Posted by: Dion Nov 9 2018, 07:26 PM

The 6 mount gave this amateur trouble. Welding thick metal to thin challenged me.
I’m using the RJ mount. It is a nice piece of kit.
I got a little bit overzealous in the application of the mig. Paranoid about not having a
6 cylinder drop anchor! Ben (mb911) was gracious and patient with my questions.
My buddy Rich in England (tig welds, makes his own mufflers, Turbothomas) also criticized my lack of skills but I’m here to share and learn. Hopefully you’ll learn as well, what not to do.
So here’s the pics: Prepped the area.
And checking placement.


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Posted by: Dion Nov 9 2018, 07:27 PM

Weld thru Primer:


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Posted by: Dion Nov 9 2018, 07:31 PM

First attempt at melding metal. First pic: Rubbish! 2nd: hmmm getting there.


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Posted by: Dion Nov 9 2018, 07:32 PM

Weld


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Posted by: Dion Nov 9 2018, 07:34 PM

Then I had my welding discussion regarding “fusion”, heat & speed.
So we tried again...


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Posted by: Dion Nov 9 2018, 07:38 PM

After grinding some metal away and “adding” some, I got to the point where Ben said I should be safe. chair.gif
So sanded all, primered and seam sealed.


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Posted by: Dion Nov 9 2018, 07:39 PM

Seam sealed, paint & clear coat.


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Posted by: Dion Nov 9 2018, 07:41 PM

Painted Marathon Blue and clear coated.


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Posted by: Dion Nov 9 2018, 07:42 PM

Top view


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Posted by: Dion Nov 9 2018, 07:43 PM

I’m hoping this is the gods smiling down upon this project,
( artsy pic) biggrin.gif. Storm just ended and a very cool sky with double rainbows occured


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Posted by: Dion Nov 9 2018, 07:45 PM

Another artsy pic:


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Posted by: Dion Nov 9 2018, 07:55 PM

Pics of the 6 mount welder.gif “fusion” location. I’ll need to primer and paint before this side gets buttoned up.


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Posted by: bbrock Nov 9 2018, 08:56 PM

I'd have this one framed! Nice fab work too thumb3d.gif

QUOTE(Dion @ Nov 9 2018, 06:43 PM) *

I’m hoping this is the gods smiling down upon this project,
( artsy pic) biggrin.gif. Storm just ended and a very cool sky with double rainbows occured
IPB Image






Posted by: mb911 Nov 10 2018, 03:02 PM

Dion looks much better..

Posted by: Dion Nov 25 2018, 08:34 PM

A small update before the Christmas holiday hits.
See how much garage time is available.
Dave stopped by this past Saturday to evaluate the left chassis issue.
So now we have a game plan. It will be nice to make progress on this critical
area and the suspension console.
Found out when Dave was cutting, that part of the existing long was not
a factory piece of metal! This was previously repaired even before I had someone address the jackpoint years ago,(another butcher job). I’d know since I’m still a hack at this.
The very outer edge of long just before the kick up
was a 1” X 14” strip welded in and attached to the floor.
Dave was suspicious, so asked me to strip the underside of floor pan in this
area. Somewhat clean metal with some pinholes. Thank the gods. Maybe that rainbow was a lucky sign. biggrin.gif I’m sure it could have been worse.

Placed another order with Restoration Design for the left
overlay frame stiffener with the kick up portion.
Ok that’s all for now beerchug.gif


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Posted by: Dion Nov 25 2018, 08:36 PM

Cut out


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Posted by: Dion Nov 25 2018, 08:36 PM

Clean floor pan with some pinholes. Will address.


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Posted by: Dion Nov 25 2018, 08:37 PM

This undercoating s**t sticks to everything!



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Posted by: Dion Nov 25 2018, 08:42 PM

In contrast.... a clean Right side of chassis.



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Posted by: Dion Dec 4 2018, 06:44 PM

I’ve addressed some holes left behind on the left engine shelf that occurred when I removed the motor mount. This left side is SO totally screwed up
I honestly can’t believe the carnage I’ve been driving around with the past 31 years.
Very hard to get a good pic of this area and keeping perspective of where the holes were.



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Posted by: Dion Dec 4 2018, 06:45 PM

Need to weld up the left engine shelf holes left behind when I removed the rear fresh air fan.


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Posted by: Dion Dec 4 2018, 06:51 PM

Went back to the drivers side floor where the seat mounts. Thought I had this
buttoned up. No I didn’t.
Dave saw a few spaces under the mount. He has a good one to
use later. So I went ahead and removed the crap one.
I also cut out an area of perforations in the floor adjacent to mount.
Like I said, I thought i addressed this.....
Underside pic trying to find pinholes.


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Posted by: Dion Dec 4 2018, 06:55 PM

Sorry looking seat mount...fellas check these buggers, when Dave tackled his car
He said his seat was only attached by the inboard mount. Mine was pretty similar.


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Posted by: Dion Dec 4 2018, 06:56 PM

Removal of seat hinge:


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Posted by: Dion Dec 4 2018, 06:57 PM

Clean up of surrounding metal.


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Posted by: Dion Dec 4 2018, 06:59 PM

Found the bastards ar15.gif


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Posted by: Dion Dec 4 2018, 07:00 PM

Cut a nice clean patch and welder.gif


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Posted by: Dion Dec 4 2018, 07:03 PM

Cleaned up, I’ll put the seat hinge/mount back after the lower firewall and longitudinal are in fixed positions.


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Posted by: Dion Dec 4 2018, 07:03 PM

Overall floor pic. I’ll get some primer on this tomorrow.


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Posted by: Dion Dec 4 2018, 07:07 PM

Couldn’t resist a test a test fit of Restoration Designs
Outer long chassis plate. Fits beautifully. Can’t wait till it’s actually welded to the
chassis! beerchug.gif Thanks for lookin in.


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Posted by: ThreeV8s Dec 4 2018, 08:15 PM

Great to see the progress! I think it's safe to say that there a lot of us here who find this thread extremely interesting, motivating, and educational.

Posted by: Dion Dec 7 2018, 08:11 PM

Still wasn’t satisfied with that patch, went back at it.
Cleaned it up again finding more pinholes. I’m more pleased
this round. It’s solid again. I’m finding a balance between the welding and cleaning up with the grinder. I have been taking away too much parent metal, thinning it and creating my pinholes. It’s all up to experience I guess. As I’m sure all you experienced metal workers can attest. And we have a lot of skilled peeps on this forum I’m in awe of. I’ll hit the bottom with primer, paint and undercoating as usual.
Ok here’s the pics:


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Posted by: Dion Dec 7 2018, 08:14 PM

Final


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Posted by: bbrock Dec 7 2018, 08:20 PM

Lookin' good! beerchug.gif I think the grinding is as tricky as the welding. I tended to have the opposite problem of leaving too much meat on the bone.

Posted by: Dion Dec 15 2018, 08:04 PM

Your going back in the garage again?!?!


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Posted by: Dion Dec 15 2018, 08:07 PM

Well yes. Tackled the engine shelf debacle.
Couple of holes welded,hit it with primer till the rest of this left side
is finished.


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Posted by: Dion Dec 15 2018, 08:10 PM

Left engine shelf


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Posted by: Dion Dec 15 2018, 08:11 PM

Primer


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Posted by: Dion Dec 15 2018, 08:12 PM

Primer and paint of left floor patch near seat mount


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Posted by: Dion Dec 15 2018, 08:14 PM

Exterior of floor area in question. Primer & Paint. I’ll undercoat it when all is wrapped up
on the chassis repairs.


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Posted by: Dion Dec 15 2018, 08:17 PM

Getting some fresh air.... while paints dry.
View of neighbors and some Christmas lites.


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Posted by: Dion Dec 15 2018, 08:21 PM

Some surface rust lurking under the engine shelf.
I honestly don’t think it was hit with paint under here or very minimalistic amounts.
Looks just primer on engine rubber seal channel area.
Just sprayed some rust converter for now on the underside
of shelf. All this will be sanded again when the suspension console goes in.



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Posted by: Dion Dec 15 2018, 08:22 PM

Rust converter spray coating


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Posted by: Dion Dec 15 2018, 08:23 PM

Definitely needs a freshening...


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