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914World.com _ 914World Garage _ Rebuiding Inside-out

Posted by: bkrantz Oct 16 2019, 08:47 PM

I realize most rebuilds go from the inside to the outside, but I am struck by how straight and clean the outer panels, including paint, look on my 73 2.0. And all the nasty stuff is hidden underneath--which I know is also not unusual.

Any way, I bought the car knowing most of what it was: a 2.0 with all the sport and appearance group equipment, including 5 good Fuchs, and the original fuel injection. The original engine is confirmed by a COA. In contrast to the exterior the interior was mixed at best, with some funky carpet. And the front and rear trunks (and engine compartment, and interior) had been sprayed with black undercoating.

So after a month, I have the car stripped to a bare shell, except for suspension and steering. I measured everything I could, and the body is very square and on spec. I need to patch some local rust spots, and replace the rear floor. And then do some minor straightening: right headlight bucket, front edge of right front fender, rear panel, etc.


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Posted by: bkrantz Oct 16 2019, 08:49 PM

I forgot to mention that I will add some door braces before doing anything serious.

But I wanted to play with my new Fein tool. This thing is amazing for scraping off the floor tar mat: no effort at all to clear half the floor in about 20 minutes.




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Posted by: bkrantz Oct 16 2019, 08:53 PM

And I testing the Fein for cutting the floor sheet metal, using the round bimetal blade. This is a circle, but the blade does not rotate--it oscillates by about 5 degrees and cuts a straight, thin kerf very easily.




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Posted by: Mikey914 Oct 16 2019, 09:31 PM

Use the dry ice method if you need to remove more tar. Works well to make an alcohol dry ice slurry and chip it off in large chunks.

Posted by: bkrantz Oct 20 2019, 08:22 PM

Been a couple of days and I have nearly completed my "final" assessment (though surprises will await!). Now I get start more objective planning and start ordering parts.

The major areas and tasks now:
replace rear trunk floor
replace rear passenger floor and patch front corners
patch local spots on inner sills
repair hell hole, with rust areas on top of sill, inner fender wall, and firewall
repair the right front corner, where a previous repair got dinged again

I need to get the rear done before mounting the car on a rotisserie.




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Posted by: raynekat Oct 20 2019, 11:49 PM

Been there, done that (or at least Cary who did all the work on my car did)....you'll have some fun Bob.
And yes, must finish this up before it goes on the rotisserie.
Great job so far.

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Posted by: pploco Oct 21 2019, 08:31 AM

QUOTE(Mikey914 @ Oct 16 2019, 09:31 PM) *

Use the dry ice method if you need to remove more tar. Works well to make an alcohol dry ice slurry and chip it off in large chunks.


Or use one of these - the tar will come off in big chunks

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Posted by: bkrantz Oct 21 2019, 08:20 PM

QUOTE(raynekat @ Oct 20 2019, 11:49 PM) *

Been there, done that (or at least Cary who did all the work on my car did)....you'll have some fun Bob.
And yes, must finish this up before it goes on the rotisserie.
Great job so far.

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Thanks, Doug. Hoping mine looks like that in a few weeks.

Another question: do the body plugs have any purpose? Any reason to cut these into replacement panels besides originality?

Posted by: bbrock Oct 21 2019, 08:50 PM

The body plugs are important for separating the men from the boys. lol-2.gif Other than that, they are just cosmetic at this point. I think they allowed access for the spot welder during assembly. I did find them handy for clamping the floor during replacement, but I was doing a full floor pan. They are a fair amount of extra work to cut and replicate too. Save your old ones though. Somebody might want them. I had to buy a couple.

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Before ordering sheet metal, I would run boroscope inside those longs to have a look to be sure they look as sound on the inside as outside.

Posted by: bkrantz Oct 28 2019, 08:55 PM

I have been out of town a bit, but needed to make some physical progress.

First, I finished cutting loose the front right fender. It is not original (nor was the attachment), but is in good shape (except for a ding on the lower front seam). Now I can access the inner fender.




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Posted by: bkrantz Oct 28 2019, 09:01 PM

I was waiting for a delivery truck, so decided to make a rough cut out of the rear trunk floor. Still liking the Fein multi tool.




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Posted by: bkrantz Nov 4 2019, 09:08 PM

Cleaner cut for the rear trunk floor. Looks like the distance from the rear panel to the transaxle support cross member is short 1/4 inch, compared to the RD replacement panel.


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Posted by: bkrantz Nov 5 2019, 09:34 PM

Testing my spot weld drill bit.



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Posted by: bkrantz Nov 11 2019, 09:46 PM

The bumpers, and all trim, were painted black. I wanted see the condition of the chrome underneath, so cleared a patch with paint remover. Looks OK except for the sanding marks!



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Posted by: Garland Nov 11 2019, 10:37 PM

QUOTE(bkrantz @ Nov 4 2019, 10:08 PM) *

Cleaner cut for the rear trunk floor. Looks like the distance from the rear panel to the transaxle support cross member is short 1/4 inch, compared to the RD replacement panel.


Humm. I have the same one, but mine does not have that lip over the cross brace. It just runs out straight. Did you fold it over to make the flange for the spot welds? Did you drill and weld in a nut in the cross brace, or just go with out it?


I bent the lip, and made the flange. I did not add the nut. Just be sure to line it up tight, before you decide where to bend. And that the small center cap fits the width.

http://www.914world.com/bbs2/index.php?s=&showtopic=265772&view=findpost&p=2251890

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Posted by: bkrantz Nov 15 2019, 09:19 PM

Brought home a donor clip to use to replace my right front corner. Thanks, Steve!




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Posted by: bkrantz Nov 15 2019, 09:20 PM

Also a rear trunk lid, straighter than mine and without rust!




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Posted by: bkrantz Nov 16 2019, 10:08 PM

Starting surgery on the donor clip.




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Posted by: Superhawk996 Nov 17 2019, 12:22 PM

Watching this build. Keep going! cheer.gif

Posted by: bkrantz Nov 17 2019, 10:21 PM

Cut the donor clip down more. This is the largest section I might splice in, but still more thinking to do: what to save on the car (bent up but little rust) and what to splice in (straight but rusty in spots).




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Posted by: bkrantz Nov 18 2019, 09:34 PM

Started surgery on the receiver car. Removed the headlight box and the forward part of the inner fender. Lots of metal work to do on the floor corner.




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Posted by: bkrantz Nov 18 2019, 09:35 PM

Here are the parts removed. I will reuse the circular brace.


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Posted by: bbrock Nov 18 2019, 09:51 PM

Are you still using your Fein for the cutting? That looks great. Looking forward to seeing how you make out on straightening the boogers. popcorn[1].gif

Posted by: bkrantz Nov 19 2019, 09:19 PM

The Fein works best where I can cut from an exposed edge, and through a single layer. I also reach for a Rigid reciprocating saw, and a cut-off wheel on a grinder.

Posted by: bkrantz Nov 19 2019, 09:21 PM

First pass at reforming the floor corner.



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Posted by: bkrantz Nov 19 2019, 09:24 PM

And progress on the rear, removing the rear panel so I can repair the inner-outer fender seems and get the corners right for the replacement floor section.




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Posted by: bkrantz Nov 19 2019, 09:25 PM

Left corner detail. Pretty nasty work done when the original rear panel was replaced.




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Posted by: bkrantz Nov 20 2019, 05:45 PM

Quick adjustments of the inner fender corners, left:



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Posted by: bkrantz Nov 20 2019, 05:45 PM

and right:




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Posted by: bkrantz Nov 20 2019, 05:46 PM

Now the panel fits.


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Posted by: bkrantz Nov 20 2019, 05:48 PM

Back at the front, I am probably done working the floor corner, and got the front panel end mostly back in shape.


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Posted by: bkrantz Nov 20 2019, 05:51 PM

And started to dissect the donor clip. All I need now is the inner fender wall and headlight box. I will keep the vertical brace attached at least until I can check the fit.

Bad news is some local rust that will have to be patched before it can all go together.



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Posted by: bkrantz Nov 20 2019, 05:56 PM

Here's how the front corner started. I feel pretty good about what I was able to do.


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Posted by: FourBlades Nov 20 2019, 05:57 PM


Some great progress! smilie_pokal.gif

Nice work!

John

Posted by: jim_hoyland Nov 20 2019, 06:05 PM

Impressive ! smile.gif beer.gif

Posted by: bbrock Nov 20 2019, 09:41 PM

pray.gif Nice work!

Posted by: bkrantz Nov 21 2019, 09:51 PM

Thanks, everyone.

Donor part down to inner fender, headlight box, and vertical brace. I need to repair some local rust but will wait until I cut and fit the fender wall splice.


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Posted by: raynekat Nov 22 2019, 12:31 AM

Looking good there Bob.

Posted by: bkrantz Nov 22 2019, 09:21 PM

Thanks, Doug. I am in deeper than I wanted, but kinda enjoying it so far.

Posted by: Cairo94507 Nov 23 2019, 08:17 AM

Nice work and skills. beerchug.gif

Posted by: bkrantz Dec 5 2019, 09:15 PM

After a long trip to Tucson for turkey and visiting kids, I am back home and at work on the 914. Excited to start actually putting pieces together.

Got the front corner clip rough-fitted, and was surprised that my first attempt measures pretty close to exact (comparing left and right dimensions, and compared to my new straight frunk lid).




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Posted by: bkrantz Dec 5 2019, 09:18 PM

More work to do on the right end of the front panel, that was pretty banged up. I did some straightening by eye, and now have to precisely match the clip.




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Posted by: GTSandberg Dec 6 2019, 06:13 AM

Craftmanship and attention to details, Im in popcorn[1].gif

Posted by: bkrantz Dec 7 2019, 09:37 PM

Still working the fit. Made a cardboard template from the good side, and now need to work the bad side to match (and get the splice, the front panel, and the floor to align).



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Posted by: bkrantz Dec 7 2019, 09:38 PM

Work to do. Gap seen from below.



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Posted by: FourBlades Dec 8 2019, 11:26 AM


Looking good!

Do some diagonal measurements from the base of the windshield to the corner of the buckets. I had a car that was off by one inch on one side! Made fitting the headlights exciting until I realized and fixed it. Don't neglect the vertical checks as well.

I have a feeling from your work that you know all that. biggrin.gif

John

Posted by: bkrantz Dec 8 2019, 09:35 PM

QUOTE(FourBlades @ Dec 8 2019, 10:26 AM) *

Looking good!

Do some diagonal measurements from the base of the windshield to the corner of the buckets. I had a car that was off by one inch on one side! Made fitting the headlights exciting until I realized and fixed it. Don't neglect the vertical checks as well.

I have a feeling from your work that you know all that. biggrin.gif

John


Thanks, John. The diagonal measurements (and lots more) check out. I also compared positions to the front hood (a very straight one).

Posted by: bkrantz Dec 8 2019, 09:37 PM

More metal work, and the fit is getting closer--off by no more than a 1/16 to 3/32 inch.




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Posted by: bkrantz Dec 8 2019, 09:42 PM

Last bit of mis-alignment is the outermost end of the front panel.



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Posted by: bkrantz Dec 9 2019, 09:16 PM

After a few more hours today, I am claiming victory and will get on to welding soon. All the gaps and measurements are within 1/16 inch, and all the angles within 1 degree.




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Posted by: bkrantz Dec 9 2019, 09:17 PM

Of course, I might tap on things a bit more, just to make things more pretty.




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Posted by: bkrantz Dec 10 2019, 09:45 PM

Now starting on the rear. Weeks ago, I cut out the badly rusted rear half of the trunk floor, and also the un-rusty rear panel. That was a replacement during a PO repair, not done well. Took some surgery to undo the triple-layer seams on each side.

Here is the left side, looking not bad, except the seam and lower edges.



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Posted by: bkrantz Dec 10 2019, 09:47 PM

And here is the lumpy right side. Previous repair work done quickly?



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Posted by: bkrantz Dec 11 2019, 08:38 PM

First effort, left side. Almost good.




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Posted by: bkrantz Dec 11 2019, 08:40 PM

And right side. Still needs work.




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Posted by: bbrock Dec 11 2019, 09:19 PM

You are a wizard. pray.gif

Posted by: bkrantz Dec 12 2019, 10:40 PM

Right side done enough for now.



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Posted by: bkrantz Dec 12 2019, 10:43 PM

Time to start on the rear panel.

And yes, almost all the work so far has been to repair collision damage that had been repaired before.



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Posted by: bkrantz Dec 17 2019, 09:05 PM

Getting back to work, and a real milestone today: actually adding metal (welded the holes and tears in various places before starting to install the front corner splice.


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Posted by: bkrantz Dec 17 2019, 09:08 PM

And the first parts of the bracing for the open body. Hoping to get the front and rear done, and the car on the rotisserie by Dec 31.



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Posted by: bkrantz Dec 22 2019, 09:27 PM

Completed the interior bracing with some diagonals. Not sure if necessary but my son was having fun with the new TIG welder.


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Posted by: bkrantz Dec 22 2019, 09:29 PM

And completed the patches on the right front inner fender splice.


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Posted by: bkrantz Dec 22 2019, 09:32 PM

Two steps forward, at least one back!

I knew about this "surprise", with a crappy lap joint in the outer rear fender. I tried to ignore it for as long as possible, but decided to at least see how bad. Only attached on the outer lap with some spot welds and brazing.




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Posted by: bkrantz Dec 22 2019, 09:35 PM

Decided to separate, in order to make it right. This also gives me better access to finish work on the inner fender. Pretty easy since the fender was only attached at the lap joint, some brazing around the tail light opening, and one spot of brazing on the top seam.


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Posted by: Superhawk996 Dec 23 2019, 02:50 AM

piratenanner.gif

Yea! Coming along nicely.

Saw your other post about prepping lap welds. Now you've definitely seen the down side of them. Take the time, fix it right with a butt weld.

welder.gif

Posted by: bkrantz Dec 23 2019, 09:27 PM

QUOTE(Superhawk996 @ Dec 23 2019, 01:50 AM) *

piratenanner.gif

Yea! Coming along nicely.

Saw your other post about prepping lap welds. Now you've definitely seen the down side of them. Take the time, fix it right with a butt weld.

welder.gif


This has to be a nomination for the worst lap joint. Crude cut left open inside the fender.

My question was more about spot-welded seams, where paint access will be difficult at best.

Posted by: bkrantz Dec 23 2019, 09:29 PM

Here's the front corner mostly welded in place. A few more tweaks and we can finish the butt seam.


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Posted by: bkrantz Dec 23 2019, 09:32 PM

Meanwhile, getting started on the rear. First trim and fit for the trunk floor.




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Posted by: bkrantz Dec 23 2019, 09:34 PM

And starting the fit for the rear panel. This will need some work.



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Posted by: bkrantz Dec 23 2019, 09:35 PM

Right side is looking better, with access after removing the outer fender.


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Posted by: djway Dec 23 2019, 10:49 PM

AWESOME
There has got to be some Satisfaction there smile.gif

Posted by: sixnotfour Dec 23 2019, 11:09 PM

agree.gif
smash.gif welder.gif beerchug.gif

Posted by: bkrantz Dec 24 2019, 09:56 PM

QUOTE(djway @ Dec 23 2019, 09:49 PM) *

AWESOME
There has got to be some Satisfaction there smile.gif


Yeah, I do enjoy this. Certainly not doing this for profit!

Posted by: bkrantz Dec 24 2019, 09:58 PM

Got the outer fender cut and fit. A few more tweaks and it should be ready for welding, along with the floor and the rear panel.




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Posted by: bkrantz Dec 24 2019, 10:00 PM

And...here's the last dodgy previous repair, where somebody spliced a replacement front panel with a lap joint, just inside of the left head light. Time to fix this.




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Posted by: bkrantz Dec 25 2019, 09:16 PM

Only a half-day for xmas, since I want to get as much done as possible during my son's visit.

Working on the dodgy front lap joint, starting with a cut through the overlapping metal.



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Posted by: bkrantz Dec 25 2019, 09:21 PM

And a further adjustment and test fit for all the rear pieces--almost ready to start welding. Fits are within about 1/16 inch and alignment looks good with my replacement trunk lid.


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Posted by: Superhawk996 Dec 26 2019, 09:19 AM

smilie_pokal.gif

Looking better.

My car has been clipped in the front and I'm not thrilled with the way it was done. Unfortunately it won't get done until I decide to paint the car. Too much other work going on right now! At one point they must have been teaching lap welds as the quick and dirty way to fix stuff because I see it done a lot.

The problem is that no one ever saw these cars as worthy of a proper fix and most prior 914 owners back in the day were just too cheap to have it done properly since 914's were NARP.

Times have changed. Keep up the great work.

Posted by: bkrantz Dec 26 2019, 09:07 PM

QUOTE(Superhawk996 @ Dec 26 2019, 08:19 AM) *

smilie_pokal.gif

Looking better.

My car has been clipped in the front and I'm not thrilled with the way it was done. Unfortunately it won't get done until I decide to paint the car. Too much other work going on right now! At one point they must have been teaching lap welds as the quick and dirty way to fix stuff because I see it done a lot.

The problem is that no one ever saw these cars as worthy of a proper fix and most prior 914 owners back in the day were just too cheap to have it done properly since 914's were NARP.

Times have changed. Keep up the great work.


Thanks. So far, none of the previous repairs meet even my lowest standard. And the lap joint in the rear fender was truly awful, with a jagged, irregular cut along the underlying edge (and nothing to even pretend sealing that inner joint).

Definitely learning as we go, and enjoying having my son do most of the welding.



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Posted by: bkrantz Dec 26 2019, 09:09 PM

Got the rear panel and outer fender welds mostly done.



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Posted by: bkrantz Dec 26 2019, 09:11 PM

Left side needed a 3/4 inch wide filler for the gap in the raised ridge below the tail light. Looks a bit crude, but will be better after grinding.


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Posted by: bkrantz Dec 26 2019, 09:12 PM

Same on the right side, but the gap was only 3/16 inch.



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Posted by: bkrantz Dec 26 2019, 09:14 PM

And what was the lap joint in the front panel, now ready for a tidy butt joint weld.


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Posted by: FourBlades Dec 27 2019, 09:47 AM


Nice work! first.gif

Great to fix things the correct way.

You are making rapid progress.

These cars are worth much more now then they were when new, kind of ironic.

John

Posted by: bkrantz Dec 27 2019, 09:48 PM

QUOTE(FourBlades @ Dec 27 2019, 08:47 AM) *

Nice work! first.gif

Great to fix things the correct way.

You are making rapid progress.

These cars are worth much more now then they were when new, kind of ironic.

John


Thanks. It is fun indulging my sense of "doing it right", even if my skills are not pro level. And while I do not expect to make money, at least the hole will not be too deep.

Posted by: bkrantz Dec 27 2019, 09:52 PM

Getting the front seam stitched up, along with the horizontal brace (it needs a patch to fill the gap in the center).


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Posted by: bkrantz Dec 27 2019, 09:57 PM

Here are the accessory pieces I made for the rear: heavy gauge L-brackets for the bumper mounting holes below the floor, light gauge reinforcements for the holes above the floor, and reinforcing patches for the floor above the rear sway bar brackets.



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Posted by: Kansas 914 Dec 28 2019, 06:29 AM

Bob - you are doing everything right.

It was nice to see the progress in person Friday.

Keep up the great work and let me know if you need another set of hands after your son leaves.

Posted by: FourBlades Dec 28 2019, 08:28 AM


What are the reinforcement pieces for?

John

Posted by: bkrantz Dec 28 2019, 09:45 PM

John, the 1/8 inch thick L-braces are for the bumper mount holes under the trunk floor. They replace original factory braces that were pressed in a design too hard for me to duplicate. I created my own 18 gauge rectangular reinforcement for the upper holes. These have no big hole in the center yet. And the trapezoidal pieces double up the floor above the sway bar brackets that mount on the underside of the trunk floor.

Posted by: bkrantz Dec 28 2019, 09:48 PM

Got the trunk floor welded in, with plug welds all around, and some creative thick beads in the rear corners (these will get ground down).



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Posted by: bkrantz Dec 28 2019, 09:50 PM

Lower bumper mount hole reinforcement, using 1/8 inch flat bar to replace the factory L-brace.



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Posted by: bkrantz Dec 28 2019, 09:51 PM

And my own additional brace for the upper bumper mount hole, to double the metal and add strength.



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Posted by: bkrantz Dec 28 2019, 09:54 PM

And a simple bent strip to bridge the gap between the left and right horizontal braces in the front trunk.



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Posted by: bkrantz Dec 28 2019, 09:57 PM

Now the fun part: fabricating brackets from 2 inch square tubing to attache the car to the rotisserie lift using the bumper mount holes. This is the back.



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Posted by: bkrantz Dec 28 2019, 09:58 PM

And the front, where greater curvature requires longer stand-off.



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Posted by: bkrantz Dec 28 2019, 09:59 PM

Here's the rear, with the horizontal mount from the lift bolted on.


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Posted by: bkrantz Dec 28 2019, 10:02 PM

Finally! The car is on the rotisserie lift. This was the big milestone I hoped for, with my son visiting for 2 weeks. His willingness to help, and welding skills, made it possible.


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Posted by: ndfrigi Dec 28 2019, 10:10 PM

wow @http://www.914world.com/bbs2/index.php?showuser=23343 you and your son are doing a lot of accomplishment each day! keep up the pace and for sure next summer the car will be on the road. thanks for sharing all the details!

Posted by: bkrantz Dec 29 2019, 10:03 PM

Final steps. First, we detached the suspension--took the front out as one assembly, including the steering rack. Then some final adjustment of the lift, and the car spins nicely onto its side.




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Posted by: bkrantz Dec 29 2019, 10:05 PM

Just the right position now for the next task: rehab the rusted floor.


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Posted by: bkrantz Dec 30 2019, 09:17 PM

Another view of the car on the lift. I bought this rotisserie from Northern Tool. The design has two key features. Hydraulic rams at either end allow easy lifting and dropping by about 18 inches. This made it easy to attach the brackets with the car on jack stands, and then elevate it enough to clear the side while rotating to sideways. The second feature allows for tuning the position of the car relative to the pivots, thus getting the center of gravity close to the rotation axis.



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Posted by: Kansas 914 Dec 31 2019, 08:02 AM

It appears you achieved your goal while your son was in town. At this point the work becomes fun!

Did you uncover any surprises when you removed the suspension?


Posted by: sixnotfour Dec 31 2019, 09:02 AM

wow your goin for it...your garage is @http://www.914world.com/bbs2/index.php?showuser=116 worthy... beerchug.gif

Posted by: Kansas 914 Dec 31 2019, 09:14 AM

QUOTE(sixnotfour @ Dec 31 2019, 08:02 AM) *

wow your goin for it...your garage is @http://www.914world.com/bbs2/index.php?showuser=116 worthy... beerchug.gif


Jeff - he needs a few more bikes! wink.gif

Posted by: bkrantz Dec 31 2019, 09:23 PM

QUOTE(Kansas 914 @ Dec 31 2019, 07:02 AM) *

It appears you achieved your goal while your son was in town. At this point the work becomes fun!

Did you uncover any surprises when you removed the suspension?


None obvious. We did drop the front as a complete assembly, and I still have to take it apart.

Posted by: raynekat Jan 1 2020, 05:45 PM

What? No updates on the 1st? w00t.gif welder.gif
Haha
Happy New Years Bob.
Your progress is looking great from way over here.

Posted by: Superhawk996 Jan 1 2020, 06:30 PM

Sweet Rotisserie. I've always like the type like this with the hydraulic ram.

I measured my garage and determined that I'll have to remove the garage door opener and the upper guide tracks if I hope to use a rotisserie. sad.gif

Looking like you've got this beat and are will on your way to easy street to work on the undersides.

Posted by: bkrantz Jan 1 2020, 09:44 PM

QUOTE(raynekat @ Jan 1 2020, 04:45 PM) *

What? No updates on the 1st? w00t.gif welder.gif
Haha
Happy New Years Bob.
Your progress is looking great from way over here.


Thanks, Doug--back at you guys, too.

Shirlee wanted to get outside and enjoy another snowy day, so we hiked the ridge behind our house--about 1000 ft up.


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Posted by: bkrantz Jan 1 2020, 09:45 PM

And after that I got about an hour of garage time. Enough to separate the struts and steering rack from the front suspension, and pull the torsion bars.



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Posted by: bkrantz Jan 1 2020, 09:47 PM

Torsion bars look like blue strip coding.



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Posted by: Kansas 914 Jan 2 2020, 07:02 AM

QUOTE(bkrantz @ Jan 1 2020, 08:47 PM) *

Torsion bars look like blue strip coding.

I'm sure you know this but don't mix up right and left torsion bars when re-installing. There should be a R & L stamped on the end.

Keep up the good work!

Posted by: bkrantz Jan 2 2020, 08:59 PM

QUOTE(Kansas 914 @ Jan 2 2020, 06:02 AM) *

QUOTE(bkrantz @ Jan 1 2020, 08:47 PM) *

Torsion bars look like blue strip coding.

I'm sure you know this but don't mix up right and left torsion bars when re-installing. There should be a R & L stamped on the end.

Keep up the good work!


Thanks for the reminder. I did see the L and R stamps.

Posted by: bkrantz Jan 2 2020, 09:02 PM

And on the the floor, starting with some rough cuts between all the welded seams. Next step is drilling out LOTS of spot welds.


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Posted by: bkrantz Jan 2 2020, 09:04 PM

Inside the center tunnel is the obligatory mouse nest.


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Posted by: raynekat Jan 2 2020, 09:33 PM

QUOTE(bkrantz @ Jan 2 2020, 07:04 PM) *

Inside the center tunnel is the obligatory mouse nest.


Now that is pretty glorious....and Shirlee, I don't jest. wink.gif

Posted by: bkrantz Jan 3 2020, 09:07 PM

QUOTE(raynekat @ Jan 2 2020, 08:33 PM) *

QUOTE(bkrantz @ Jan 2 2020, 07:04 PM) *

Inside the center tunnel is the obligatory mouse nest.


Now that is pretty glorious....and Shirlee, I don't jest. wink.gif



And that's just the part I could not vacuum out through the holes in the top of the tunnel.

Posted by: bkrantz Jan 3 2020, 09:09 PM

Now for the surgical removal of the rest of the rear floor, starting on the left side. BTW access on the rotisserie, and also raising the lowering the car height, is glorious.

First drill out the welds and remove the jacking donut.


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Posted by: bkrantz Jan 3 2020, 09:11 PM

Then drill out the welds and remove the triangular gusset.




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Posted by: bkrantz Jan 3 2020, 09:12 PM

Then a happy hour or so of drilling out spot welds along the sill, tunnel, and firewalls.


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Posted by: bkrantz Jan 3 2020, 09:13 PM

Then some sections can come free, exposing the interior firewall space--and a bit of surface rust (but not looking bad).


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Posted by: bkrantz Jan 4 2020, 09:17 PM

Only had about an hour in the garage today, so just finished up the rest of the left side. I will get the remaining interior remnants once I spin the car to horizontal.



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Posted by: bkrantz Jan 4 2020, 09:19 PM

I discovered the trailing edge of the tunnel has welding, in addition to the spot welds.


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Posted by: bkrantz Jan 4 2020, 09:21 PM

Getting ready to work on the right side, which was down near floor level. With the lift feature of the rotisserie, I was able to raise the car about 18 inches, and make the working height much better. Nice feature.


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Posted by: sixnotfour Jan 5 2020, 06:26 PM

beerchug.gif

Posted by: bkrantz Jan 5 2020, 09:08 PM

Got the other side done today. Now I need to grind off the spot weld remnants and clean up rusty metal--and look for any spots that need replacement.


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Posted by: bkrantz Jan 5 2020, 09:09 PM

Here's the rear floor, in pieces after removal.



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Posted by: bkrantz Jan 5 2020, 09:11 PM

Interior cross brace is also fully gone. Ground off a few surface welds (not spot welds) at the center tunnel.



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Posted by: bkrantz Jan 5 2020, 09:14 PM

Before fitting the new floor I have a few things to fix, including a dent in the bottom of the right long. Probably a dumb attempt to jack the car up from the middle. The photo makes it look like only the flange is pushed in, but the flat surfaces are also bent.



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Posted by: altitude411 Jan 5 2020, 09:22 PM

Fantastic work and photos. Thanks for posting. beerchug.gif popcorn[1].gif

Posted by: Kansas 914 Jan 6 2020, 06:26 AM

QUOTE(altitude411 @ Jan 5 2020, 08:22 PM) *

Fantastic work and photos. Thanks for posting. beerchug.gif popcorn[1].gif

Agreed!

You are really doing a terrific job documenting your work to the benefit of anyone that will face this task in the future.

Posted by: bkrantz Jan 6 2020, 09:28 PM

QUOTE(Kansas 914 @ Jan 6 2020, 05:26 AM) *

QUOTE(altitude411 @ Jan 5 2020, 08:22 PM) *

Fantastic work and photos. Thanks for posting. beerchug.gif popcorn[1].gif

Agreed!

You are really doing a terrific job documenting your work to the benefit of anyone that will face this task in the future.


Thanks, Mike. Documentation makes it more fun for me.

Posted by: bkrantz Jan 6 2020, 09:32 PM

Now for the front corners. I had already explored the left side, so just some clean up (drill out the seam spot welds and clean up the sill surface). Sill looks solid.


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Posted by: bkrantz Jan 6 2020, 09:34 PM

Right corner floor looks about the same, just a slightly bigger area cut out. But the inner sill has a rust hole!


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Posted by: bkrantz Jan 6 2020, 09:36 PM

Fortunately, the rust-through on the sill is small, and the rust was eroding from outside in. This should be easy to patch before jabbing a new floor corner.


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Posted by: bkrantz Jan 6 2020, 09:39 PM

Another sill problem: the inside of the left sill has the classic web of cracks, near the folded recess for grabbing the parking brake lever.


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Posted by: bkrantz Jan 6 2020, 09:41 PM

For better access I drilled out the rest of the spot welds to detach the left edge of the remaining floor. With the floor propped out, I ground a recess along each crack for better weld penetration.



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Posted by: bkrantz Jan 6 2020, 09:43 PM

Just for fun before quitting today, I mounted the replacement floor section. Fits nicely, but will need trimming on all sides.



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Posted by: bkrantz Jan 6 2020, 09:44 PM

And looks good on the inside.



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Posted by: bkrantz Jan 7 2020, 09:17 PM

Just some trivial work today, straightening one of the rear floor triangle braces.


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Posted by: bkrantz Jan 7 2020, 09:19 PM

Got distracted by the need to make progress in converting my garage lights from fluorescent to LED, with brighter and whiter light.


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Posted by: bkrantz Jan 7 2020, 09:22 PM

The problem is that not only are the LED "bulbs" direct wire, so cannot use the ballast, but the stock sockets are double-pole and must be replaced. I have to strip each fixture down to a bare shell, and then install new sockets.


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Posted by: Kansas 914 Jan 8 2020, 07:35 AM

LED replacements are well worth the time and money.

As I get older I can never have enough light in the garage. I am glad I did mine and might install a few more.

Posted by: bkrantz Jan 8 2020, 09:35 PM

Finished the two fixtures above my work area. Replaced all the sockets and did the direct wiring.



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Posted by: bkrantz Jan 8 2020, 09:35 PM

Let there be light!


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Posted by: bkrantz Jan 8 2020, 09:37 PM

Had just a bit of time to play, so I tackled the muffler shield. It was still attached to the remnant of the old trunk floor.


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Posted by: bkrantz Jan 8 2020, 09:40 PM

Drilled out some spot welds, and ground off beads on welded mounts, and then a little hammer work to remove some dents and straighten the edge.


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Posted by: GTSandberg Jan 10 2020, 03:02 AM

Super thread, superb craftmanship and thorough documentation. Keep it coming!

Posted by: sixnotfour Jan 10 2020, 03:36 AM

backdate the attachment method for the heat shield....screws,, see the 70s...

Posted by: bkrantz Jan 11 2020, 11:08 PM

QUOTE(GTSandberg @ Jan 10 2020, 02:02 AM) *

Super thread, superb craftmanship and thorough documentation. Keep it coming!


Thanks, and will do, after a break to visit my kids.

Posted by: bkrantz Jan 11 2020, 11:09 PM

QUOTE(sixnotfour @ Jan 10 2020, 02:36 AM) *

backdate the attachment method for the heat shield....screws,, see the 70s...


What are the advantages?

Posted by: raynekat Jan 11 2020, 11:21 PM

I was thinking....maybe you could put hydrofoils on this car with a prop coming out of the back. Then you wouldn't need to buy that future bike?

I attached the muffler heat shield with screws on my car. It's been ceramic ally coated and is removable....as if I'll ever need to do that. Looks nice tho.
Good work there Bob.

Posted by: bkrantz Jan 12 2020, 08:54 PM

QUOTE(raynekat @ Jan 11 2020, 10:21 PM) *

I was thinking....maybe you could put hydrofoils on this car with a prop coming out of the back. Then you wouldn't need to buy that future bike?

I attached the muffler heat shield with screws on my car. It's been ceramic ally coated and is removable....as if I'll ever need to do that. Looks nice tho.
Good work there Bob.


Thanks, Doug. Never too many bikes.

Posted by: aggiezig Jan 13 2020, 12:17 AM

Great build so far! Enjoyed reading your progress. Man, all that metalwork makes me thankful that I only had to do floors and trunks on my car. Keep up the good work beerchug.gif

Posted by: bkrantz Jan 13 2020, 11:18 PM

QUOTE(aggiezig @ Jan 12 2020, 11:17 PM) *

Great build so far! Enjoyed reading your progress. Man, all that metalwork makes me thankful that I only had to do floors and trunks on my car. Keep up the good work beerchug.gif


Thanks. I am actually enjoying this more than I expected. That could change when I get to more finish work.

Posted by: bkrantz Jan 20 2020, 09:21 PM

Back from "vacation" from my retired life, where I do some teaching, research, and consulting from my house in Colorado. Spent a week with my son in Arizona, and pretty much did the same thing.

Anyway, getting back to work on the 914, but first had to play with some new tools, including the Fein dust catcher attachment for the grinder. Works pretty well, and started on the welds around the floor seams.


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Posted by: bkrantz Jan 20 2020, 09:23 PM

Dang, the photo posting still does not want to honor my right side up. I have tried opening and saving photos in different ways--and 914World still posts things sideways.

Posted by: raynekat Jan 20 2020, 11:18 PM

Bob....this is what I do with all my photos....and it seems to work.

After you load them on your computer and before posting them, pull them up in some kind of viewer.
On my iMac, it's just the built-in photo viewer.
Then rotate them 90 deg, 90 again, 90 again, and another 90 to get them back to where they started from.
So rotate them through a total of 360 deg (another way to say the above).
Then save them.

Now you should be able to post the pics on 914World (or other sites) right side up.

I don't know why this goofy little photo dance seems to work, but it always has for me.
Gud luk! Ha

Posted by: bkrantz Jan 21 2020, 09:35 PM

Thanks, Doug. That may have worked! I reposted the photo to my previous post, and it looks right.

Posted by: bkrantz Jan 21 2020, 09:37 PM

No garage work today. I only had a spare hour, and did this instead.


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Posted by: Kansas 914 Jan 22 2020, 06:06 AM

QUOTE(bkrantz @ Jan 21 2020, 08:37 PM) *

No garage work today. I only had a spare hour, and did this instead.

I had a similar exercise as well. wink.gif

It was some wet heavy stuff.

Posted by: sixnotfour Jan 22 2020, 07:10 AM

QUOTE
It was some wet heavy stuff.

In UT. I call that WA. snow... barf.gif

dust collector// idea.gif popcorn[1].gif

Posted by: Kansas 914 Jan 22 2020, 09:33 AM

QUOTE(sixnotfour @ Jan 22 2020, 06:10 AM) *

QUOTE
It was some wet heavy stuff.

In UT. I call that WA. snow... barf.gif

dust collector// idea.gif popcorn[1].gif

biggrin.gif

Jeff - I will remember that line. wink.gif

Posted by: bkrantz Jan 22 2020, 10:02 PM

Back to work. First prepping all the joints, grinding out remains of spot welds and cleaning up metal.



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Posted by: bkrantz Jan 22 2020, 10:04 PM

Then fitting the new floor section. First trim the excess around the edges, and then cut the remaining floor piece to fit. Decided to keep as much of the RD panel as possible since some of the rust extended forward of the cross brace.


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Posted by: bkrantz Jan 22 2020, 10:06 PM

Other side.


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Posted by: Ferg Jan 22 2020, 10:35 PM

Just found this thread, Nice work!

Posted by: Mark Henry Jan 22 2020, 10:40 PM

QUOTE(bkrantz @ Jan 21 2020, 10:37 PM) *

No garage work today. I only had a spare hour, and did this instead.

Unique looking house. smile.gif

Posted by: raynekat Jan 22 2020, 11:21 PM

QUOTE(Mark Henry @ Jan 22 2020, 08:40 PM) *

QUOTE(bkrantz @ Jan 21 2020, 10:37 PM) *

No garage work today. I only had a spare hour, and did this instead.

Unique looking house. smile.gif


It is....but he likes that.
His last house was an igloo. confused24.gif rolleyes.gif laugh.gif

Posted by: Kansas 914 Jan 23 2020, 07:28 AM

QUOTE(Ferg @ Jan 22 2020, 09:35 PM) *

Just found this thread, Nice work!

Ferg,

Bob is doing a great job. It will be nice to have another 914 at Cars & Coffee in Durango!

Bob used to campaign a 914 in Texas a few years ago.

Posted by: Ferg Jan 23 2020, 08:11 PM

QUOTE(Kansas 914 @ Jan 23 2020, 06:28 AM) *

QUOTE(Ferg @ Jan 22 2020, 09:35 PM) *

Just found this thread, Nice work!

Ferg,

Bob is doing a great job. It will be nice to have another 914 at Cars & Coffee in Durango!

Bob used to campaign a 914 in Texas a few years ago.



Sounds like the Durango crew just keeps getting better driving.gif

Posted by: bkrantz Jan 23 2020, 09:27 PM

QUOTE(Mark Henry @ Jan 22 2020, 09:40 PM) *

QUOTE(bkrantz @ Jan 21 2020, 10:37 PM) *

No garage work today. I only had a spare hour, and did this instead.

Unique looking house. smile.gif


Thanks. We found a local architect who designed the house to fit the site--and our preferences. Of course, I should have made the garage bigger.

Posted by: bkrantz Jan 23 2020, 09:27 PM

QUOTE(raynekat @ Jan 22 2020, 10:21 PM) *

QUOTE(Mark Henry @ Jan 22 2020, 08:40 PM) *

QUOTE(bkrantz @ Jan 21 2020, 10:37 PM) *

No garage work today. I only had a spare hour, and did this instead.

Unique looking house. smile.gif


It is....but he likes that.
His last house was an igloo. confused24.gif rolleyes.gif laugh.gif


Only half the year.

Posted by: bkrantz Jan 23 2020, 09:31 PM

QUOTE(Ferg @ Jan 23 2020, 07:11 PM) *

QUOTE(Kansas 914 @ Jan 23 2020, 06:28 AM) *

QUOTE(Ferg @ Jan 22 2020, 09:35 PM) *

Just found this thread, Nice work!

Ferg,

Bob is doing a great job. It will be nice to have another 914 at Cars & Coffee in Durango!

Bob used to campaign a 914 in Texas a few years ago.



Sounds like the Durango crew just keeps getting better driving.gif


I have really enjoyed getting to know the local car crowd, and feel welcomed. If we could only get Colorado DOT to stop laying down gravel instead of sand on winter roads.

Posted by: bkrantz Jan 24 2020, 10:07 PM

A few things to do before I can start welding in the floor. Item #1: welding the web of cracks in the left inner long, at the parking brake handle recess. A little sloppy (my excuse: upside down, which I could have corrected by rotating the rotisserie, but...).


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Posted by: bkrantz Jan 24 2020, 10:08 PM

And then grinding (and then some more welding and grinding).


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Posted by: bkrantz Jan 24 2020, 10:17 PM

And before I forget, I welded the rear sway bar mounts to the new trunk floor.


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Posted by: bkrantz Jan 26 2020, 09:29 PM

Item #2: Straightening the bottoms of both sills, with dents probably from jacking incidents. Here is the right sill.


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Posted by: bkrantz Jan 26 2020, 09:30 PM

And the left sill.


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Posted by: bkrantz Jan 26 2020, 09:31 PM

I made some studs that can be welded onto the sill seam, and screw into an adapter for my slide hammer.


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Posted by: bkrantz Jan 26 2020, 09:32 PM

One on each sill, welded onto the seam at the center of each dent.


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Posted by: bkrantz Jan 26 2020, 09:33 PM

Slide hammer in action. Each side took a good number of hard hits to get close to straight.


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Posted by: bkrantz Jan 26 2020, 09:34 PM

Left side, after cutting off the stud and grinding away the weld.


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Posted by: bkrantz Jan 26 2020, 09:35 PM

And the right side.


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Posted by: bkrantz Jan 26 2020, 09:37 PM

Item #3: patching the hole in the front inner right sill, where rust ate through (fortunately from outside in). Here's the hole after cutting.


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Posted by: bkrantz Jan 26 2020, 09:39 PM

I made a patch from a section of 914 front fender.


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Posted by: bkrantz Jan 26 2020, 09:40 PM

Patch in place. Magnets are helpful.


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Posted by: bkrantz Jan 26 2020, 09:41 PM

Welded in place.


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Posted by: bkrantz Jan 26 2020, 09:42 PM

And after grinding. I was less aggressive, and left some of the weld since the sheet metal here is relatively thin.


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Posted by: Kansas 914 Jan 27 2020, 07:30 AM

welder.gif

The great work continues!

Posted by: FourBlades Jan 27 2020, 11:25 AM


Nice job, making great progress! beerchug.gif

John

Posted by: bkrantz Jan 27 2020, 09:40 PM

Thanks, guys. Keeping the progress going...

Item #4: the. front floor corners. Here's the patch for the left side, again made from genuine 914 sheet metal.



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Posted by: bkrantz Jan 27 2020, 09:41 PM

Test fit.




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Posted by: bkrantz Jan 28 2020, 09:20 PM

Jumping ahead to #5: treating and painting the rust inside the lower firewall.


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Posted by: bkrantz Jan 30 2020, 09:31 PM

Back to Item#4: the floor front corners. I decided to reshape my patches to better duplicate the original floor channels.

Here's the left side, ready to weld.


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Posted by: bkrantz Jan 30 2020, 09:32 PM

And the right side, still needs a few tweaks.



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Posted by: bkrantz Jan 31 2020, 09:27 PM

Left side welded in, and a quick grinding. A few spots to re-weld and then grind it pretty.



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Posted by: bkrantz Feb 1 2020, 10:42 PM

Finishing up #4. Here's the left side done.



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Posted by: bkrantz Feb 1 2020, 10:43 PM

And from the inside.


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Posted by: bkrantz Feb 1 2020, 10:45 PM

Right side welded in.


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Posted by: bkrantz Feb 1 2020, 10:46 PM

And ground down to almost pretty.


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Posted by: bkrantz Feb 1 2020, 10:48 PM

Since the front floor corners are where the front jack point donuts, mount, I decided to reinforce things on the inside.


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Posted by: bkrantz Feb 1 2020, 10:49 PM

Left side welded in.


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Posted by: bkrantz Feb 1 2020, 10:49 PM

And the right side.


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Posted by: bkrantz Feb 1 2020, 10:51 PM

While welding in the neighborhood, I filled in some holes in the floor from where a PO pop-riveted some sheet metal in a cheesy attempt to cover the holes in the floor.


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Posted by: bkrantz Feb 1 2020, 10:52 PM

With all the preliminaries down, its time to fit and weld in the rear floor panel. To make that easier, and avoid any asymmetric sag with the car sideways, I rotated the car to upside-down.


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Posted by: Kansas 914 Feb 2 2020, 07:47 AM

While I have been hibernating you have been busy.

Posted by: bkrantz Feb 2 2020, 09:22 PM

Got the floor panel fitted today. My plan to is do a few spot welds along the sides, tack a few spots on the butt seam with the front floor, and a few short beads along the rear edge. Then I can flip it sideways again to get all the flanges on the inside.


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Posted by: bkrantz Feb 3 2020, 08:25 PM

Before welding on the new floor section, I painted the areas that will be inaccessible (inside the center tunnel and the firewall). That's Rustoleum self-etching primer.


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Posted by: bkrantz Feb 3 2020, 08:28 PM

While waiting for paint to dry, I started work on the rust at the base of the A-pillars. This is the right side. Note the small hole above the sill edge (and remember the car is currently upside down). That was probably from when somebody pulled the pillar straight from a previous collision--and did not bother to fix it.


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Posted by: bkrantz Feb 3 2020, 08:32 PM

Here is the rusted section cut out, after removing part of the sill edge.


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Posted by: bkrantz Feb 3 2020, 08:34 PM

And a cardboard template for the patch. (The left side is about the same, maybe a bit smaller.)


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Posted by: bkrantz Feb 4 2020, 09:38 PM

No garage time today, but got some more body parts from AA and RD.


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Posted by: sixnotfour Feb 5 2020, 02:18 AM

beer.gif


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Posted by: bkrantz Feb 5 2020, 10:08 PM

Great. Now I have to check the rotisserie lock.

Posted by: raynekat Feb 6 2020, 05:56 PM

Yep.....just a whee bit left of the tin worm in there.
Doing a great job there Dr. Bob!

Posted by: bkrantz Feb 6 2020, 10:02 PM

Thanks, Doug. I may need to pick your brain soon. I hear little voices telling me about how I should "improve" the car and deviate from a stock restoration.

Posted by: bkrantz Feb 6 2020, 10:03 PM

Back to 914 work today. First up: finish the A-pillar patches. Here is the right side patch in place.


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Posted by: bkrantz Feb 6 2020, 10:04 PM

And welded in, ready for grinding.


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Posted by: bkrantz Feb 6 2020, 10:05 PM

Left side patch, a bit more challenging since the base of the A-pillar is curved inward for clearance for the fuel vapor hoses.


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Posted by: bkrantz Feb 6 2020, 10:06 PM

Tack-welded.


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Posted by: bkrantz Feb 6 2020, 10:09 PM

Finally on to attaching the new floor section. Here it is after tack-welding the butt seam (with metal work during welding to improve alignment), about 1/3 of the plug welds along the sills, and a few tack welds along the rear seam.


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Posted by: bkrantz Feb 7 2020, 09:37 PM

Allright! I flipped the car to right side up, and started work on the new floor cross member. Here is the piece as it cam from RD, with the ends notched for flange tabs but not bent.


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Posted by: bkrantz Feb 7 2020, 09:38 PM

After measuring and bending, here is one end after bending some.


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Posted by: bkrantz Feb 7 2020, 09:39 PM

After more fitting and bending, here is the cross member installed ready for welding.



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Posted by: Trophy Feb 8 2020, 12:13 PM

Nice work you are doing, what sort of tools are you using for the job, Welder's, spot weld cutters etc?

Posted by: bkrantz Feb 8 2020, 08:58 PM

Thanks. I have mostly electrical tools: 4.5 inch grinders (new Hein and old Bosch) with cutting, grinding, and flap-sanding discs, Makita die grinder with 2 inch cut-off discs and carbide grinding bits, Rigid reciprocating saw, plus cordless drills, drill press, etc. For welding, I have a Hobart MIG and Easton TIG. 95% of the welding on car sheet metal is MIG. For metal forming I just have some hammers, including body work hammers, dollys, and miscellaneous bits of metal bars or angles. I have been cutting spot welds with the Blair 3/8 inch cutter (and lots of bits to stay sharp) as well as standard drill bits.

Posted by: bkrantz Feb 8 2020, 09:05 PM

Just some incremental work today, mostly rescuing the brackets on the floor cross brace that hold the teeth for the seat tilt mechanism. Here is the left side, still attached to the section I cut out of the rusty floor.


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Posted by: bkrantz Feb 8 2020, 09:06 PM

Here's the bracket and surrounding sheet metal cut out.


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Posted by: bkrantz Feb 8 2020, 09:08 PM

And finally both brackets, after removal of old sheet metal and welds, and initial cleanup.


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Posted by: bkrantz Feb 9 2020, 10:11 PM

Some progress on welding inside the floor panel, including the cross member. Until I ran out of MIG wire (next time, buy 2 spools).


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Posted by: bkrantz Feb 9 2020, 10:15 PM

Also progress on the A-pillar bases. Ground down the welds on the left side.



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Posted by: bkrantz Feb 9 2020, 10:15 PM

And the missing piece of the sill ledge, in place for welding.


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Posted by: bkrantz Feb 9 2020, 10:16 PM

Right side ground down.


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Posted by: bkrantz Feb 9 2020, 10:17 PM

And right sill edge piece.


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Posted by: horizontally-opposed Feb 9 2020, 10:22 PM

QUOTE(bkrantz @ Feb 9 2020, 08:17 PM) *

And right sill edge piece.


^ Nice work—in an inspiring thread...wow!

Posted by: bkrantz Feb 10 2020, 10:11 PM

QUOTE(horizontally-opposed @ Feb 9 2020, 09:22 PM) *

QUOTE(bkrantz @ Feb 9 2020, 08:17 PM) *

And right sill edge piece.


^ Nice work—in an inspiring thread...wow!


Thanks. Nothing fancy or as quality as some really talented people can do. I just figure I can learn by doing and get something functionally better.

Posted by: bkrantz Feb 10 2020, 10:12 PM

Right sill edge welded.


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Posted by: bkrantz Feb 10 2020, 10:14 PM

Right side floor interior welding done. Still a challenge to get the plug welds functional and pretty. I go for functional first.


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Posted by: bkrantz Feb 12 2020, 10:54 PM

And the left side done. Getting a little better at plug welding.


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Posted by: bkrantz Feb 12 2020, 10:56 PM

Left side sill ledge piece. Had a couple of burn-throughs so these beads are a bit fat.


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Posted by: bkrantz Feb 12 2020, 10:58 PM

An overall shot of the car--feeling like I have made some progress, and maybe over the hump. (At least this hump)


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Posted by: bkrantz Feb 14 2020, 09:34 PM

So after 3 days of measuring and fitting and aligning, I was confident enough to weld in the seat bracket mounts. I did the hinges and floor mounts first, then lined up the front bracket that holds the tilt adjustment teeth.

Here's the left side:


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Posted by: bkrantz Feb 14 2020, 09:35 PM

And with the seat mount in place. It tilts!


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Posted by: bkrantz Feb 14 2020, 09:36 PM

And the right side:



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Posted by: bkrantz Feb 14 2020, 09:37 PM

This side tilts, too!



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Posted by: bkrantz Feb 14 2020, 09:38 PM

Only one more thing to weld on the floor interior. Any guesses?


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Posted by: bbrock Feb 14 2020, 10:08 PM

QUOTE(bkrantz @ Feb 14 2020, 08:38 PM) *

Only one more thing to weld on the floor interior. Any guesses?


Carpet buttons.

Posted by: Kansas 914 Feb 15 2020, 07:37 AM

QUOTE(bkrantz @ Feb 14 2020, 08:38 PM) *

Only one more thing to weld on the floor interior. Any guesses?


E-brake mount?

Posted by: bkrantz Feb 15 2020, 09:04 PM

QUOTE(Kansas 914 @ Feb 15 2020, 06:37 AM) *

QUOTE(bkrantz @ Feb 14 2020, 08:38 PM) *

Only one more thing to weld on the floor interior. Any guesses?


E-brake mount?


Here it is.


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Posted by: bkrantz Feb 15 2020, 09:04 PM

QUOTE(bbrock @ Feb 14 2020, 09:08 PM) *

QUOTE(bkrantz @ Feb 14 2020, 08:38 PM) *

Only one more thing to weld on the floor interior. Any guesses?


Carpet buttons.


Not planning to put these in--but you have a good eye!

Posted by: bkrantz Feb 15 2020, 09:07 PM

While the car is upright, I started welding in the rear cross member brace that goes on top of the trunk floor.


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Posted by: raynekat Feb 16 2020, 06:04 PM

Lots of great work going on there Bob. Keep it rolling. beer.gif

Posted by: FourBlades Feb 16 2020, 06:39 PM


Great job!

Getting close now.

John

Posted by: bkrantz Feb 16 2020, 08:50 PM

Thanks, guys. Starting to eye the firewall and hell hole.

Posted by: bkrantz Feb 16 2020, 08:51 PM

Bottom of the floor is nearly done! I flipped the car upside down to weld on the seat reinforcing strips and finish the welding along the butt seam between the front and rear sections.


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Posted by: bkrantz Feb 16 2020, 08:53 PM

Also welded on the front jacking donuts. Feeling good about the reinforcements I put on the inside surface of the floor above these.

Once I weld the rear floor edge seam, I can attache the rear gussets and donuts and the floor will be done!


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Posted by: bkrantz Feb 17 2020, 09:28 PM

Got to the rear seam, at the base of the firewall in the engine compartment. Plug welded all the way across plus seam welding the edge of the center tunnel, just like original.


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Posted by: bkrantz Feb 17 2020, 09:29 PM

Last job on the floor: the rear corner gussets and jacking donuts. Here is on as it came from RD.


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Posted by: bkrantz Feb 17 2020, 09:30 PM

And after trimming to fit and punching holes.


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Posted by: bkrantz Feb 17 2020, 09:31 PM

Here's the right side welded in.


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Posted by: bkrantz Feb 17 2020, 09:32 PM

And the left side. The floor is done!


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Posted by: bkrantz Feb 17 2020, 09:33 PM

Here's a preview of what is next: firewall, inner fender wall, and top of sill.


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Posted by: bkrantz Feb 19 2020, 09:47 PM

OK, now for what everyone has been waiting for (at least me): the hell hole, or what George wants us to call the slightly rusty battery area.

Here is the first cut taking out the rusty section of the firewall, mostly above the seam with the engine shelf.


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Posted by: bkrantz Feb 19 2020, 09:49 PM

Some of the rust extended below the shelf/upper-lower panel seam, down to the top of the sill.


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Posted by: bkrantz Feb 19 2020, 09:52 PM

Next, cutting out the top of the sill, and trying to separate the inner and outer layers of sheet metal. For now I stopped cutting where the outer layer shows only moderate to light pitting.


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Posted by: bkrantz Feb 19 2020, 09:53 PM

The good news: inside the sill I found only very minor surface rust, even on the bottom.


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Posted by: bkrantz Feb 19 2020, 09:56 PM

Now for the big hole, after cutting the inner fender wall from just above the battery tray level down to the sill.


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Posted by: bkrantz Feb 19 2020, 09:57 PM

Another view.


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Posted by: bkrantz Feb 19 2020, 09:58 PM

And from inside the rear fender.


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Posted by: bkrantz Feb 19 2020, 10:00 PM

A look at the engine mount.


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Posted by: bkrantz Feb 19 2020, 10:01 PM

Investigating between the back side of the mount and the sill face, seems like something is missing.


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Posted by: bkrantz Feb 21 2020, 09:13 PM

After deliberation and input from others on 914World (thanks!) I decided to leave the engine mount in place, at least for now. I dosed the joint between the mount and the sill with Corroseal.



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Posted by: bkrantz Feb 21 2020, 09:15 PM

Now to start filling in the holes I cut. Here's the patch for the inner fender wall, cut from the larger reproduction panel I got from AA.


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Posted by: bbrock Feb 22 2020, 10:18 AM

I think you made the right call on that engine mount. As usual. I'm in awe of the speed and quality of your work.

Posted by: Kansas 914 Feb 22 2020, 11:00 AM

QUOTE(bbrock @ Feb 22 2020, 09:18 AM) *

I think you made the right call on that engine mount. As usual. I'm in awe of the speed and quality of your work.

agree.gif

I have seen this project in person a few times. The quality and speed of work is there but more importantly to note is Bob is a one man show. Very inspiring!

Posted by: FourBlades Feb 22 2020, 01:09 PM


Nice, neat welding job! welder.gif

You are making record time.

John

Posted by: bkrantz Feb 22 2020, 09:13 PM

Thanks, guys. I am lucky to have the time to play restoration almost every day.

Posted by: raynekat Feb 23 2020, 12:34 AM

QUOTE(bkrantz @ Feb 22 2020, 07:13 PM) *

Thanks, guys. I am lucky to have the time to play restoration almost every day.


Yeah...your'e a slacker big time. Haha

Betch you miss Alaska?

Posted by: bkrantz Feb 23 2020, 08:26 PM

QUOTE(raynekat @ Feb 22 2020, 11:34 PM) *

QUOTE(bkrantz @ Feb 22 2020, 07:13 PM) *

Thanks, guys. I am lucky to have the time to play restoration almost every day.


Yeah...your'e a slacker big time. Haha

Betch you miss Alaska?


Sometimes, but not so much in the extra long dark winter. Colorado mountains are at least as good, and the driving around here is way better.

Posted by: bkrantz Feb 23 2020, 08:27 PM

Before welding the inner patch in place, I wanted to take advantage of the hole to access the inside of the outer fender panel. This had a PO repair with LOTS of bondo.


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Posted by: bkrantz Feb 23 2020, 08:28 PM

The fill was at least 1/8 across the entire panel.


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Posted by: bkrantz Feb 23 2020, 08:30 PM

To minimize the mess I mounted the Fein dust shield on the angle grinder. Not 100% but much better than without it.


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Posted by: bkrantz Feb 23 2020, 08:31 PM

Got the panel cleaned up, and did some initial smoothing. More work to come.


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Posted by: bkrantz Feb 23 2020, 08:35 PM

I also started on the top of the sill. This normally has two layers of sheet metal, but I decided to add a third inner layer patch. This extends about 2 inches forward and rear of the hole.


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Posted by: bkrantz Feb 23 2020, 08:36 PM

Here it is welded in place. I will need to grind this down to fit the "middle" panel patch.


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Posted by: bkrantz Feb 23 2020, 08:37 PM

And at the same time I tack welded the inner fender wall patch, and got the edges aligned.


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Posted by: bkrantz Feb 24 2020, 09:42 PM

Did some grinding and then tried to finish the butt seam welding around the patch. Got it done, but very frustrating with lots of burn-throughs. The final result is ugly, with lots of thick spot welds and big boogers. That will lead to more quality time with my grinder.


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Posted by: bkrantz Feb 26 2020, 09:29 PM

After a couple of hours of quality time with my angle grinder and die grinder, things are looking better. A few spots and holes to re-weld.


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Posted by: bkrantz Feb 26 2020, 09:31 PM

Getting ready for the next patch, the outer layer on the top of the sill.


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Posted by: bkrantz Feb 27 2020, 09:03 PM

I feel like I am in a groundhog day loop with the inner fender wall patch. After grinding yesterday, I checked the weld with a light inside the fender. This revealed a Buch of pin holes and thin spots, and a few segments where the weld did not penetrate.

So weld (#2) all suspect areas.



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Posted by: bkrantz Feb 27 2020, 09:04 PM

And grind (#2).



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Posted by: bkrantz Feb 27 2020, 09:05 PM

Check with the light inside again, more holes!

Weld (#3).



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Posted by: bkrantz Feb 27 2020, 09:06 PM

Tomorrow, if I hear Sonny and Cher on the garage radio, I may go back to bed.

Posted by: bbrock Feb 27 2020, 09:19 PM

QUOTE(bkrantz @ Feb 27 2020, 08:06 PM) *

Tomorrow, if I hear Sonny and Cher on the garage radio, I may go back to bed.

Boy do I know that pinhole routine. Thank goodness I never woke up to I've Got You Babe. av-943.gif

Posted by: bkrantz Feb 28 2020, 09:25 PM

Well, I was hearing "I got you babe" again today for sure.

After grinding (3rd time) I had more holes and bad weld bits, especially in one spot.

So I finally did the right thing (I hope) and cut out the worst section. The size and shape shows where I was chasing a growing hole, especially into the original sheet metal.


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Posted by: bkrantz Feb 28 2020, 09:28 PM

I formed a new mini-patch and welded it in place--much better.


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Posted by: bkrantz Feb 28 2020, 09:30 PM

At the same time, I welded a few more holes around the original patch (4th time), and then ground them down (4th time). A quick look showed only a couple of pin hole around the new mini-patch. I might be able to beat the groundhog!


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Posted by: bkrantz Feb 28 2020, 09:32 PM

BTW, here in the back(!) side of the small area I cut out. Pretty nasty (and not the work quality I am aiming for).


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Posted by: bkrantz Feb 29 2020, 10:12 PM

I beat the groundhog!

I did hear a faint echo of Sonny and Cher, but after welding and grinding just 3 or 4 spots, the inner fender wall patch is done. Not pretty, but should finish fine after some cosmetic work later on.




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Posted by: bkrantz Feb 29 2020, 10:13 PM

Now time to move on. Here is the middle layer patch for the top of the sill, final fit.


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Posted by: bkrantz Feb 29 2020, 10:15 PM

And welded in place.


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Posted by: bkrantz Feb 29 2020, 10:16 PM

And here is the top layer patch, nearly fitted.


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Posted by: bkrantz Mar 1 2020, 09:36 PM

Started welding on the last layer, beginning with the flange against the inner fender wall. Nice to have the car on the rotisserie, so I could weld with the flange and fender wall horizontal.



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Posted by: bkrantz Mar 1 2020, 09:40 PM

I ground down the welds along the flange and they looked good, so went on the weld the main part of the patch. Mostly straight-forward, except along the seam against the remaining original pitted metal. That led to some more ugly welds.


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Posted by: bkrantz Mar 1 2020, 09:42 PM

I still have to grind this down and check the weld success, but I am happy to be close to done on closing up the hell hole, only 6 months after I cut a hole in the top to explore for internal rust.


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Posted by: tygaboy Mar 1 2020, 10:56 PM

A bit of sawzall-smiley.gif smash.gif welder.gif

And now some piratenanner.gif aktion035.gif smilie_pokal.gif

Super job! Isn't it a great feeling when it's "job done"? Keep up the great work and detailed documentation.

Posted by: bkrantz Mar 2 2020, 09:55 PM

Thanks. Milestones are good for my mental health, as are my documentations and posts.

Anyway, here is the finished (for now) product. A bit lumpy, but it should be functional and look OK, especially after prep and paint.


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Posted by: bkrantz Mar 2 2020, 09:56 PM

On to the firewall. Here's a cardboard template fit for the lower patch.


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Posted by: bkrantz Mar 4 2020, 08:44 PM

Small patch cut and formed, with holes in the flanges for plug welds.


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Posted by: bkrantz Mar 4 2020, 08:45 PM

Final fit.


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Posted by: bkrantz Mar 4 2020, 08:46 PM

After welding and grinding. Now time for the bigger hole...


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Posted by: bkrantz Mar 4 2020, 08:47 PM

And from the engine side.


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Posted by: bkrantz Mar 5 2020, 10:02 PM

Spent about an hour today working on forming the upper firewall patch, including the diagonal raised ribs. Still needs more work in the complex corner on the right side.


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Posted by: FourBlades Mar 6 2020, 08:13 AM


Looking good!

You are making good progress.

John

Posted by: 9146C Mar 6 2020, 09:20 AM

Very impressed with your fabrication work!

Posted by: tygaboy Mar 6 2020, 09:26 AM

Fabricationlous! smash.gif Nice looking patch piece. You're making great progress. smilie_pokal.gif

Posted by: bkrantz Mar 6 2020, 06:03 PM

Thank, guys. Just a bit of time to play body shop today. The corner fold looks better, and I am ready to trim this patch.


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Posted by: bkrantz Mar 7 2020, 09:44 PM

Spent a couple of hours fitting the new patch. After the initial cut, I had it in and out about a dozen times--definitely trying to attain the Zen level of patience. Here it is near the end of fitting trials.


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Posted by: bkrantz Mar 7 2020, 09:45 PM

And after tack-welding. Time for more patience.



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Posted by: bkrantz Mar 8 2020, 07:09 PM

Welding done, and initial grinding. Might be a few spots to touch up.


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Posted by: bkrantz Mar 10 2020, 08:43 PM

On to the last thing in the hell hole area: the right engine shelf. Here is the piece from RD.


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Posted by: bkrantz Mar 10 2020, 08:45 PM

First fit check after my initial trim. I need only the front half of the shelf, and a bit more of the rubber seal channel.


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Posted by: bkrantz Mar 10 2020, 08:46 PM

And after about a dozen cycles of check, trim, bend, repeat. About 90% fitted.


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Posted by: raynekat Mar 10 2020, 10:49 PM

Looks good Bob.

Posted by: bkrantz Mar 11 2020, 07:48 PM

Thanks, Doug. Still lots to do on the body shell (finish the shelf, remount the front fender, straighten the rear fender and rear panel, miscellaneous brackets and braces) and then both doors and the replacement trunk lid need a bit of work.

But we do this for fun, right?

Posted by: bkrantz Mar 12 2020, 08:25 PM

Had a couple of hours of garage time and worked to finish the fit. I could not get both ends just right, so I tried tack welding one end and working the fit as I welded towards the other end. Seemed to work OK.


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Posted by: Lilchopshop Mar 13 2020, 08:14 AM

Bob, I'm really enjoying your thread! Thank you for the excellent documentation! Its great to see that top-level workmanship can still be achieved without a fully-outfitted fabrication shop. This will be a great reference for me as I go through my project.

beerchug.gif

Posted by: tygaboy Mar 13 2020, 08:42 AM

I'm going to start calling you Bob "Dunwright".

Thanks for saving your car and installing so very much love into it. Great stuff. smilie_pokal.gif

Posted by: bkrantz Mar 13 2020, 08:36 PM

Thanks, guys. Encouragement always helps.

Posted by: bkrantz Mar 13 2020, 08:41 PM

Got the engine shelf welding done. I am pretty happy with results except where I fumbled the grinder inside the groove for the rubber engine shelf seal. I will probably splice in a piece to fix this.


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Posted by: bkrantz Mar 13 2020, 08:43 PM

On to the rest of the issues in the engine compartment. First is the right trunk hinge bracket. Grinding out the old, torn bracket resulted in a couple of small holes (and some brass from the brazing done by the PO).



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Posted by: bkrantz Mar 13 2020, 08:44 PM

After welding the grind the holes.


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Posted by: bkrantz Mar 13 2020, 08:46 PM

And after measuring, and re-measuring, I tack-welded the new bracket in place. I will triple-check the position tomorrow and finish the welds.


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Posted by: bkrantz Mar 13 2020, 08:48 PM

Meanwhile, I started the next task. Both the left and right engine lid hinge brackets were torn out. The PO "fixed" these by bolting through the firewall. Left side.


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Posted by: bkrantz Mar 13 2020, 08:48 PM

Right side.



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Posted by: bkrantz Mar 13 2020, 08:50 PM

I cut out just enough to get straight edges, and did a bit of metal work to even things up. Left side.


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Posted by: bkrantz Mar 13 2020, 08:50 PM

And right side. I will cut some patches tomorrow.


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Posted by: bkrantz Mar 14 2020, 08:07 PM

When I measured the right trunk hinge bracket today, I found it to be about 1/8 inch low. So I cut off the tack welds, repositioned, measured about 5 more times, and welded it in for good (I hope). My MIG welder is acting funny, so I may grind these semi-ugly welds and redo it once I figure out what is wrong.


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Posted by: bkrantz Mar 14 2020, 08:09 PM

Back to the engine lid hinges, here's the patch for the left side.


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Posted by: bkrantz Mar 14 2020, 08:11 PM

And the right side.


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Posted by: bkrantz Mar 14 2020, 08:11 PM

Left side bracket in position.


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Posted by: bkrantz Mar 14 2020, 08:12 PM

And welded.


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Posted by: bkrantz Mar 14 2020, 08:13 PM

And right side.


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Posted by: raynekat Mar 14 2020, 08:56 PM

Yeah, those engine lid brackets need to be in the correct position. If too low, your engine lid will be too low and have a big gap on the leading edge. If too hight you could use some washers to space the lid down to the correct height.

Moral...better to be too high than too low.

Posted by: bkrantz Mar 15 2020, 08:19 PM

I will find out before too much longer. Before any final body and paint work I plan to mount all the lids and doors to check alignment.

Posted by: bkrantz Mar 15 2020, 08:20 PM

Last task in the engine compartment area is dealing with the festival of holes in the firewall, left by POs.


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Posted by: bkrantz Mar 15 2020, 08:21 PM

Here's my favorite. How and why did somebody do this?



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Posted by: bkrantz Mar 15 2020, 08:24 PM

After straightening the sheet metal at some holes, I got the grinder with the paint stripping disk busy.


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Posted by: bkrantz Mar 15 2020, 08:27 PM

Looking ahead to the next job: repairing the sides of the cowl panel where it meets the tops of the front fenders. The front trunk lid opened too far, probably many times, and made contact with the cowl weatherstrip channel. This deformed the channel and tore the corner joint.

Here is the right side, where I have previously removed the fender.



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Posted by: bkrantz Mar 15 2020, 08:28 PM

And the left side.



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Posted by: bkrantz Mar 15 2020, 08:29 PM

But the left side had a surprise! First, some bondo in the channel, hiding distortion of the channel side.


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Posted by: bkrantz Mar 15 2020, 08:32 PM

And then LOTS of bondo on the cowl top surface, hiding a big divot in the sheet metal. I can imagine the trunk lid flying up and whacking the cowl hard enough to bend it. But I can't imagine why somebody did not straighten it better, before slathering on 1/4 of bondo.



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Posted by: bkrantz Mar 16 2020, 09:03 PM

Festival of holes, part 2, is done. I patched and welded all the holes in the passenger side firewall...



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Posted by: bkrantz Mar 16 2020, 09:04 PM

...driver side firewall...



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Posted by: bkrantz Mar 16 2020, 09:05 PM

...and dash under-panel. Plus the front right inner fender wall.


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Posted by: raynekat Mar 16 2020, 10:34 PM

QUOTE(bkrantz @ Mar 15 2020, 07:19 PM) *

I will find out before too much longer. Before any final body and paint work I plan to mount all the lids and doors to check alignment.


Put windows in the doors and seals too.
I had a big issue of the doors seeming to fit, but when I installed the door glass and seals, nothing fit above the doors.
Meaning the opening for the side glass in the doors wasn't wide enough.

It necessitated me to push the entire windshield assembly, posts and all, forward.
Not the best of situations.
I accomplished it though and the side windows fit much better.

Posted by: raynekat Mar 16 2020, 10:35 PM

Bob....seems like you're going to have a field day grinding down all your welds?
Or are you doing it as you go?

Posted by: bkrantz Mar 17 2020, 08:28 PM

I try to spend time grinding as I go, but I have fallen behind. I definitely have some grinding party days ahead.

Posted by: bkrantz Mar 17 2020, 08:30 PM

Speaking of grinding, at least bondo grinding, I decided to check out the right side of the cowl. Sure enough, about 1/8 inch of bondo. And then another surprise (but not completely).



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Posted by: bkrantz Mar 17 2020, 08:33 PM

I guess PO decided not to have a radio antenna.



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Posted by: bkrantz Mar 17 2020, 08:35 PM

Got the Dremel tool out and cut the brazing. The hole is whole again.



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Posted by: bkrantz Mar 17 2020, 08:37 PM

And in keeping with PO repair quality, check the piece they brazed on the underside. Nice shape!


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Posted by: bkrantz Mar 17 2020, 08:42 PM

One more job for the grinder: the left front fender. And if you are keeping score, this means the only panel not (yet) subject to repair or replacement is the left rear fender.

Anyway, I knew the front part of the fender had been repaired, with puller holes showing on the inside and some filler. Turns out quite a bit of filler.

The metal can be made lots better.


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Posted by: bbrock Mar 17 2020, 09:29 PM

Am I seeing right that the antenna hole is in the cowl? I've never seen one mounted there. Usually on driver's side fender or sometimes passenger side.

Posted by: bkrantz Mar 18 2020, 08:31 PM

Thats my guess for the purpose of the hole. Now you reminded me to do more research for the standard location for 1973.

In any case, the metal is not really strong enough there.

Posted by: bkrantz Mar 18 2020, 08:37 PM

Just a little time today to play 914, so I worked more on the right side of the cowl. I got the alignment pretty good, but the channel might need replacing.


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Posted by: bkrantz Mar 19 2020, 08:17 PM

Finished the festival of holes, with step 3: grinding. Here is the right side of the firewall.


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Posted by: bkrantz Mar 19 2020, 08:17 PM

And the left side.


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Posted by: bkrantz Mar 19 2020, 08:18 PM

And the dash under-panel.



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Posted by: bkrantz Mar 19 2020, 08:20 PM

I also refilled the antenna hole in the right cowl. Besides not being a stock location, the metal is not strong or stiff enough. Here is a patch cut to fit from genuine 914 sheet metal.


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Posted by: bkrantz Mar 19 2020, 08:21 PM

Welded in place.


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Posted by: bkrantz Mar 19 2020, 08:22 PM

And after a quick grinding.


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Posted by: FourBlades Mar 20 2020, 07:40 AM


Nice work as always! smile.gif

You are really good at welding thin sheet metal.

Do you use copper backers or just have a really skillful trigger finger?

Do find the spark to be distorted when using strong magnets nearby?

John

Posted by: bkrantz Mar 20 2020, 09:02 PM

Thanks. I have a copper spoon and use it whenever I can. I have also learned (the hard way) to weld one dot at a time.

I have not noticed any affect from the magnets.

Posted by: bkrantz Mar 21 2020, 08:08 PM

I got to try my latest tool acquisition: a shrinking disk. This is a polished stainless steel disk with a raised edge. On the grinder, it spins against sheet metal and the friction creates local heat. A quick spray of water cools and shrinks the hot spot.



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Posted by: bkrantz Mar 21 2020, 08:10 PM

I did this for about 20 minutes on the left side of the cowl, where previous deformation and repair had stretched the metal and created a 4 inch spot that oil-canned up and down. The shrinking worked great and made the cowl section flatter and more rigid.


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Posted by: bkrantz Mar 21 2020, 08:11 PM

After the shrinking work, I decided to cut out a smaller area than planned.



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Posted by: bkrantz Mar 21 2020, 08:12 PM

And I had time to fit a cardboard template for the patch. Too bad metal does not work as fast.


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Posted by: bkrantz Mar 22 2020, 08:11 PM

Translating cardboard into recycled 914 sheet metal. Here is the piece cut out and marked.


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Posted by: bkrantz Mar 22 2020, 08:13 PM

And after an hour of metal work, I had this. I evened managed to get some curvature in the piece.


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Posted by: bkrantz Mar 22 2020, 08:15 PM

And fitted into place.



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Posted by: bkrantz Mar 22 2020, 08:18 PM

While in the mood, I started on the last big job--reinstalling the right front fender. Here's the mounting flange on the A-pillar after cutting out a segment that was mangled.


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Posted by: bkrantz Mar 22 2020, 08:21 PM

And a small patch ready for welding.


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Posted by: bkrantz Mar 23 2020, 08:49 PM

MIG time today. First, the patch in the left side of the cowl.


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Posted by: bkrantz Mar 23 2020, 08:50 PM

Then a bit of grinding.


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Posted by: bkrantz Mar 23 2020, 08:51 PM

And then another session with the shrinking disk, to get the profile near right.


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Posted by: bkrantz Mar 23 2020, 08:52 PM

Then the right side, welding up the semi-rotten metal in the trough.


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Posted by: bkrantz Mar 23 2020, 08:53 PM

And ground down.


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Posted by: bkrantz Mar 23 2020, 08:54 PM

Finally, the section of the fender mounting flange.


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Posted by: bkrantz Mar 23 2020, 08:56 PM

Looking ahead, the next job is the last big task on the body shell: remounting the right front fender that I cut off months ago to start this restoration.


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Posted by: bkrantz Mar 23 2020, 08:57 PM

The fender needs a little work first, along the leading edge where it meets the side of the front panel, by the end of the bumper.


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Posted by: bkrantz Mar 24 2020, 07:43 PM

Got to work on the fender today. Here it is in a quick jig to stabilize it while I removed the crumple along the leading edge bumper recess. And my big movement tools (section of 2x4 and 4 lb hammer).


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Posted by: bkrantz Mar 24 2020, 07:45 PM

With the recess 90% straight, the next step is stripping paint to expose the bare metal. Guess what--bondo!


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Posted by: bkrantz Mar 24 2020, 07:46 PM

And with metal exposed, I can see what I need to fix: mostly along the leading 3 or 4 inches.


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Posted by: bkrantz Mar 25 2020, 08:10 PM

Before any more metal work, I wanted to see how the fender fits overall. Here is it roughly in place.


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Posted by: bkrantz Mar 25 2020, 08:10 PM

Another view.


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Posted by: bkrantz Mar 25 2020, 08:14 PM

Besides dealing with the seam along the top, inside the weatherstrip channel, and the fit along the rear, the biggest challenge is the front, where the fender meets the front panel. Both were deformed, so I can't use one to guide the other.

Time for lots more measurements and comparing distances and angles from right side to left side. And also check against the frunk lid and bumper.


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Posted by: bkrantz Mar 25 2020, 08:16 PM

Looking inside the fender, where it meets the mounting flange on the A-pillar.


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Posted by: bkrantz Mar 25 2020, 08:18 PM

And from the back side of the A-pillar.


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Posted by: bkrantz Mar 25 2020, 08:20 PM

Yep, some quality time ahead.


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Posted by: 911GT2 Mar 26 2020, 06:28 AM

QUOTE(bkrantz @ Mar 23 2020, 06:49 PM) *

MIG time today. First, the patch in the left side of the cowl.

I think it would help to set the wire feed just a bit down. welder.gif
Less time grinding the welds down.

Posted by: bkrantz Mar 26 2020, 07:28 PM

QUOTE(911GT2 @ Mar 26 2020, 06:28 AM) *

QUOTE(bkrantz @ Mar 23 2020, 06:49 PM) *

MIG time today. First, the patch in the left side of the cowl.

I think it would help to set the wire feed just a bit down. welder.gif
Less time grinding the welds down.



Thanks for the suggestion. Each day it seems like the MIG responds differently.

Posted by: bkrantz Mar 26 2020, 07:33 PM

After more tweaks and bends, and cutting the top seam to fit, I clamped the fender in place. I then started measuring and comparing from right side to left side.



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Posted by: bkrantz Mar 26 2020, 07:35 PM

I also propped the frunk lid in place, a good reference since this piece (not from this car) is almost certainly straight.


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Posted by: bkrantz Mar 26 2020, 07:37 PM

Fit by the cowl (the fender is just a bit low and too far out).


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Posted by: bkrantz Mar 26 2020, 07:39 PM

The front corner. The front panel still needs to shift inward, confirmed by measured lengths and angles.


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Posted by: bkrantz Mar 26 2020, 07:41 PM

Along the headlight box, nearly there.


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Posted by: bkrantz Mar 26 2020, 07:42 PM

A-pillar inside.


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Posted by: bkrantz Mar 26 2020, 07:46 PM

A-pillar outside.


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Posted by: bkrantz Mar 27 2020, 08:32 PM

Still trying to assess and adjust the fender fit. I would like to bolt on the door, but really can't without setting the body down from the rotisserie, and removing the braces (which would require cutting). So I made a cardboard template directly from the door, and got it as close as I could accounting for the curvature. I think it is accurate except for the upper part of the leading edge.


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Posted by: bkrantz Mar 27 2020, 08:34 PM

Gaps are about 3/16 inch front...


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Posted by: bkrantz Mar 27 2020, 08:34 PM

And rear. I don't think the fender should shift any more rearward (and probably not forward).


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Posted by: bkrantz Mar 28 2020, 06:45 PM

No 914 work today. I did some office work in the morning, and then started on a big outdoor project: removing and thinning the scrub oak that are too close to the house. This should help reduce danger from brush fires.

Here's the boss checking the first 10 minutes of work.


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Posted by: bkrantz Mar 29 2020, 07:44 PM

After more brush clearing, I got back to the 914, still in measuring mode. I marked more reference points, and compared distances and angles from right to left.


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Posted by: bkrantz Mar 29 2020, 07:44 PM

And more.


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Posted by: bkrantz Mar 29 2020, 07:46 PM

I also installed the eyebrows, as another way to check alignment and compare. Here's the right side from above.


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Posted by: bkrantz Mar 29 2020, 07:47 PM

Left side from above.


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Posted by: bkrantz Mar 29 2020, 07:47 PM

Right side from in front.


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Posted by: bkrantz Mar 29 2020, 07:48 PM

Left side from in front.


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Posted by: bkrantz Mar 29 2020, 07:51 PM

To me, the alignment looks pretty good--about as good on the right as on the left, and the dimensions are within 1/16 from side to side in most cases.

The only mismatch is the recess in the fender lap edge, where it clears the mounting area in the headlight box for the pivot.


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Posted by: bkrantz Mar 29 2020, 07:52 PM

Compared to the left side, where the recess sits more centered above the mounting point.


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