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Posted by: markhoward Apr 9 2021, 03:43 PM

Smoggy is the one that got me involved with the 914 flow but rather than following through with the build, I pivoted to another 914. Thought this would enable me to immediately participate in the madness without the shame of constantly showing up in an ass dragger. So things have come full circle and smoggy is on the top of the project list. The name comes from it being a 76 and living in California. I got her from my friend @http://www.914world.com/bbs2/index.php?showuser=7087 with intention of making a track car. Yes, I am stupid enough to buy a 76 knowing I would need to smog but there are crazier thoughts abound. Most notably is swapping in a six from a 78 911 complete with CIS, cats and whatever else is needed to satisfy the man. Just a thought but for now the focus is getting the tub sorted. The car seems structurally sound with some hell hole and lower long needs. Was going to do a 1/4 floor but am now going a full back half. Smoggy has been off the road since the early 90's and stored under a tarp in Oakdale until I took over. Luckily, Jeff's dad would change the tarp yearly and from what I can tell, it survived time well. What's really cool about this project is all the support the local 914 peeps have given me. Chris ( @http://www.914world.com/bbs2/index.php?showuser=19241 ) and Robert ( @http://www.914world.com/bbs2/index.php?showuser=3898 ) have been instrumental and now I am confident I can accomplish this build. Most recently, Chris styled me with his rotisserie! Never worked on a car in this manner before. Game changer.. Anyway, I hope to keep this thread updated with progress but don't be surprised if I am inconsistent. Here are some pics to get this going.


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Posted by: SirAndy Apr 9 2021, 04:08 PM

Posted by: tygaboy Apr 9 2021, 04:25 PM

Mark - It's gonna be so fun helping you wherever/however/whenever I can! And that's a "Good Karma" rotisserie. Just look what it did for my build!
Smoggy is gonna be one wicked cool car...

Posted by: markhoward Apr 9 2021, 04:32 PM

QUOTE(tygaboy @ Apr 9 2021, 03:25 PM)

Mark - It's gonna be so fun helping you wherever/however/whenever I can! And that's a "Good Karma" rotisserie. Just look what it did for my build!
Smoggy is gonna be one wicked cool car...

Posted by: markhoward Apr 9 2021, 04:48 PM

Had to do the rear bumper backdate to drill the rotisserie mounting holes. Great excuse to break out the @http://www.914world.com/bbs2/index.php?showuser=16669 bumper. Man that thing was mangled but came back nice! Oscar also hooked me up with the paint supplies to finish her off when the day comes.

Posted by: markhoward Apr 9 2021, 05:32 PM

Let's take a small hole and make it bigger. That took a bit to get used to but necessary to get to the crusty inner panel. Nice and clean up the long! Things are looking promising

Posted by: Cairo94507 Apr 9 2021, 05:44 PM

Nice Mark. Looking forward to seeing it come along.

Posted by: BuddyV Apr 9 2021, 08:21 PM

.... I have started a box of "smalls" parts for this project. (dash vinyl, speaker grills, etc).

Posted by: Krieger Apr 9 2021, 11:10 PM

Awesome! Looks like a quick and easy build

Posted by: Lucky9146 Apr 9 2021, 11:20 PM

Looking forward to watching your progress and especially how that smog thing goes with the swap. Best to you on the project.

Posted by: sixnotfour Apr 10 2021, 10:55 AM

Very Cool Rear Bulges....

Posted by: jeffdon Apr 10 2021, 10:56 AM

Just had my 2nd vax, so in a couple weeks I will feel comfortable seeing my folks. Dad will get a kick out of these pictures.

Posted by: Andyrew Apr 10 2021, 04:33 PM

Awesome!! Keep pushing through.

Posted by: markhoward Apr 10 2021, 09:21 PM

QUOTE(sixnotfour @ Apr 10 2021, 09:55 AM)

Posted by: tygaboy Apr 11 2021, 08:41 AM

QUOTE(markhoward @ Apr 10 2021, 08:21 PM)

QUOTE(sixnotfour @ Apr 10 2021, 09:55 AM)

Very Cool Rear Bulges....

Struggling on the what to do with those. Cut em out and replace with narrow body cuts from a GT conversion? Try to work with what's there and convert round contour on top to a more boxed design that follows the wheel arches, sort of like mini GT flares in the back? Cut all four corners out and go full steel GT wide body? Leave them intact and comfortably stuff the 911's 7's and matching 6's in front. Opinions welcome..

Posted by: BuddyV Apr 11 2021, 02:13 PM

Steel GT Flares

Posted by: Root_Werks Apr 13 2021, 12:28 PM

Those rear flares/bulges are cool. If you want to install GT flares, maybe try to save the bulges and sell them? They make a nice subtle street flare.

Posted by: wysri9 Apr 13 2021, 10:34 PM

I have an amazingly similar flare on my restomod.....
I didn’t want to over-tyre the car with my 2256 Type 4

Posted by: markhoward Apr 14 2021, 09:16 AM

QUOTE(wysri9 @ Apr 13 2021, 09:34 PM)

I have an amazingly similar flare on my restomod.....
I didn’t want to over-tyre the car with my 2256 Type 4

Posted by: tygaboy Apr 29 2021, 05:01 PM

Is there any better way to spend the day than helping a buddy work on his 914? I think not!

Here's Mark using the shrinker/stretcher to form a patch for the passenger side outer firewall where it meets the floor.


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Posted by: markhoward Apr 29 2021, 05:49 PM

Sometimes the best intentions get diffused by procrastination. I needed an intervention and before you know it, up the block I hear the baritone rumble of @http://www.914world.com/bbs2/index.php?showuser=19241 and his amazing 914.




Out Chris came bearing tools and an arsenal of skill. Smoggy must be stoked! After a short discussion, we started prepping the car to accept the new Restoration Design rear floor. There was some trimming involved which Chris took the helm on. That got me to acceptance that the fresh and not cheap panel need the knife. We then located the floor going through iterations of interpreting fit, checking, refitting, rechecking. Once satisfied, a line was scribed across the original pan where it will meet its Canadian mate and the death wheel was broken out. First Chris took his pass on one side and handed the tool to me. I started going on the other side and guess what, its not as easy to stay on the line as Chris made it seem. After some constructive feedback and several iterations, I got my side fitted.




A few tek screws later and wouldn't you know it, Smoggy is looking mighty fine!






Next up was making a lower patch panel for the driver's side inner firewall. Chris graciously lent his shrinker/stretcher. We made a template to create the curve. Some shrink, some stretch, repeat.. Notch out other areas and here is a very close fitting section of metal that will replace the scongy part. Final fitting to take place later.



All good things must come to an end so with progress in motion, its time to roll on. Thank you Chris for today!

Posted by: Dion Apr 29 2021, 06:10 PM

Awesome stuff!

Posted by: Root_Werks Apr 29 2021, 08:31 PM

Nothing like someone showing up to help motivate! Good progress!

Posted by: markhoward May 7 2021, 07:48 PM

Its another day with @http://www.914world.com/bbs2/index.php?showuser=19241 and smoggy. Today, we (meaning Chris) formed out the internal lower long panel that reinforces the area around the seat belt mount. This is a piece you will never see once closed up but that does not matter to the metal master. Hand formed and without the usual shop at his disposal, we got the panel fitting pretty nice. We also decided to replace the driver's side inner firewall instead of patching pinholes along the bottom. So that meant another RD order. Wait, you can't just order one thing given shipping so the only rational thing to do is to pull the trigger on a set of steel GT flares! Yes, it has been decided

Posted by: rmarx May 12 2021, 09:23 PM

Looking good Mark! Looking at your project makes me want to jump the gun and order my GT flares also.

Posted by: euro911 May 12 2021, 10:53 PM

Looks like the major surgery is going well

Posted by: AZBanks May 13 2021, 01:02 AM

I was missing my regular fix of tygaboy's metal mastery. Thanks for returning him to our regularly scheduled programming.

Posted by: tygaboy May 13 2021, 08:42 AM

Smoggy needs a patch for the outer layer of the long, right at the back where the floor panel attaches. I was able to bend up a suitable radius then use the bead roller to duplicate the recess where that floor panel sits.

The fun part was using one hand to gradually release the roller pressure while at the same time guiding the panel with the other hand to create the fade in the depth of that recess as it turns 90 degrees and moves outward to the edge of the panel. I wanted it like the factory shaped it. And hooray, it only took me two versions to get it.

Will anyone ever see it? Nope. But hey, it's for @http://www.914world.com/bbs2/index.php?showuser=20897 and Smoggy!


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Posted by: euro911 May 13 2021, 10:57 AM

Metal mastery

Posted by: markhoward May 13 2021, 05:36 PM

QUOTE(tygaboy @ May 13 2021, 07:42 AM)

Posted by: tygaboy May 18 2021, 05:09 PM

@http://www.914world.com/bbs2/index.php?showuser=20897 hard at work with his killer new Miller 211 mig welder

I have the previous generation of this same machine and can say this new version is REALLY nice. Highly recommended!

Also gotta say, Mark has jumped in with both feet and is doing a great job welding this tedious and critical area. He is careful and has, IMO, the right attitude about level of quality: Always strive for awesome - but don't let "perfect" get in the way of "really good".

The best news of the day was after completing ~75% of the welding on this final, outer patch piece on the long, we flipped the car over, removed all tension/pressure from the door braces and checked the windshield-to-targa bar corners distance. I always get a bit nervous when checking chassis measurements after welding on the longs...

25 1/8"! Right on the money!

Smoggy is coming along nicely.


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Posted by: MM1 May 18 2021, 10:46 PM

Great stuff - best of luck!

Posted by: markhoward May 19 2021, 10:47 AM

@http://www.914world.com/bbs2/index.php?showuser=19241 had a plan to take the 'little guy' to s-car-go on Tuesday for an alignment and corner balance and with me local to them, what better excuse is there to spend the day working on smoggy for free while running a tab over there! The task at hand has to fit Chris' killer hand made lower long patch complete with factory style bead rolled embossing. Nothing like having proper detailing on things that wont be seen on the finished product but hey, we know its there! First off was to start trimming the patch down to fit the car and form a nice flare around where there heater tube comes out. All of this totally freestyle using a sharpie, hand sheers, hammer, and a vice.




Last go around, Chris made a quick template out of cardboard and returned with that beautiful bead rolled piece. Basically created from memory and no car in sight to reference during the process. When time came to fit it, well..




the channel where the floor plan sits was slightly off and I mean slightly. Disappointment had set in on Chris. I could tell he had a hard time not heading back home for another cut. It was definitely hard for him to move forward but let me tell you, it was much harder for me given that this is my car and after all, he is getting paid handsomely by means of a sandwich and some water! Taking the high road on this one and am not letting on how I feel..
Back to the program.. lets burn in some metal




We got most of the welding done but ran out of time. Its so cool when you dress those welds and the old blends with the new. I will be attempting to finish her off without Chris' guidance. Wish me luck..




A great day in in the garage and what better way to top it off that to find a large box on your porch.



What could it be??

Posted by: rmarx May 19 2021, 10:56 AM

QUOTE(markhoward @ May 19 2021, 09:47 AM)

@http://www.914world.com/bbs2/index.php?showuser=19241 had a plan to take the 'little guy' to s-car-go on Tuesday for an alignment and corner balance and with me local to them, what better excuse is there to spend the day working on smoggy for free while running a tab over there! The task at hand has to fit Chris' killer hand made lower long patch complete with factory style bead rolled embossing. Nothing like having proper detailing on things that wont be seen on the finished product but hey, we know its there! First off was to start trimming the patch down to fit the car and form a nice flare around where there heater tube comes out. All of this totally freestyle using a sharpie, hand sheers, hammer, and a vice.

Last go around, Chris made a quick template out of cardboard and returned with that beautiful bead rolled piece. Basically created from memory and no car in sight to reference during the process. When time came to fit it, well..

the channel where the floor plan sits was slightly off and I mean slightly. Disappointment had set in on Chris. I could tell he had a hard time not heading back home for another cut. It was definitely hard for him to move forward but let me tell you, it was much harder for me given that this is my car and after all, he is getting paid handsomely by means of a sandwich and some water! Taking the high road on this one and am not letting on how I feel..
Back to the program.. lets burn in some metal

We got most of the welding done but ran out of time. Its so cool when you dress those welds and the old blends with the new. I will be attempting to finish her off without Chris' guidance. Wish me luck..

A great day in in the garage and what better way to top it off that to find a large box on your porch.

What could it be??

Posted by: markhoward May 19 2021, 04:15 PM

Finished welding the outer patch without @http://www.914world.com/bbs2/index.php?showuser=19241 watching over me. Think its alright. Did not want to dress the vertical stiches with the grinder in fear of taking off too much parent metal. May hit it later with Chris around to guide me

Posted by: tygaboy May 19 2021, 06:46 PM

Wow, that looks great! Really nice work, Mark.
And see? I told you. Not too big a deal, once you've had a bit of practice.

Hit that with some acetone and get a squirt of primer on it: weld-through where the floor and firewall pieces will get spot welded, regular everywhere else.

Again, nice, nice work. You should be proud of that repair.

Posted by: Krieger May 20 2021, 08:33 AM

Looking really good guys!

Posted by: Shivers May 20 2021, 08:45 AM

Great job

Posted by: Andyrew May 20 2021, 11:38 AM

Fantastic job guys!!! Keep the progress moving forward!!!!

Posted by: markhoward Aug 10 2021, 06:13 PM

It seems like I let other things get in the way of smoggy but we are back. Since the last update, the outer lower firewall has been removed. Next up is replacing sconged out metal on the top of the longs and doing some minor patching in the vicinity. Chris ( @http://www.914world.com/bbs2/index.php?showuser=19241 ) whipped up these nifty patches which should be installed in the coming days. Vacation and two other projects got in the way (toyota pickup engine rebuild and 68 camaro front clip assembly). The pickup is back on the road and I stuck the Camaro in storage to help keep focus on smoggy. Feel free to hassle me if I slack


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Posted by: Cairo94507 Aug 11 2021, 07:32 AM

Great job and keep it coming. Before you know it all that metal work will be in the rear view.

Posted by: Dion Aug 11 2021, 08:15 AM

That’s some great metal work going on there! Well done.

Posted by: tygaboy Aug 11 2021, 08:24 AM

Mark - great job on the prep for the hell hole! Nice looking metal in the under-layer.
Time for more

Posted by: markhoward Oct 29 2021, 06:20 PM

Looks like life got in the way again but we are back on smoggy. A month or so ago, this cap was put in to address a small section of tin foil like metal at the top of the long. Just to be clear, @http://www.914world.com/bbs2/index.php?showuser=19241 is not loosing his touch. This is my welding.




Chris and I have a plan to lay in some more metal tomorrow so what better way to get in the mood than to start today. This is first section I have done unsupervised and I have to say, I'm starting to get the hang of it. The welds are a bit proud but have nice penetration on the back side. Hope to report more progress through the weekend.

Posted by: tygaboy Oct 29 2021, 10:38 PM

=

Looks great, Mark. Nice work!

Posted by: markhoward Oct 31 2021, 12:26 PM

Good progress on Saturday. Aside from some metal dressing, the hell hole is done. Thanks @http://www.914world.com/bbs2/index.php?showuser=19241 for all the excellent session! We also started in on fitting the new lower firewall. Cut it in half to enable passing over the heater tubes and discovered the hole was too small. Tried to swage it wider with a tailpipe expander but was not able to get it enlarged enough. The plan is to take to my local muffler shop and have them do it in their machine. For the time being, I am starting in on some light patching on top of the left long. Then its back on the firewall. Feels great to be putting fresh metal back in instead of cutting out crap.

Posted by: tygaboy Oct 31 2021, 03:47 PM

SMOGGY! Getting there, Mark, getting there.

Posted by: markhoward Nov 1 2021, 10:55 AM

What, 3 days in a row on Smoggy? Yesterday, I removed questionable metal on top of the left long. Was debating on restricting patch to the flat area, leaving intact the original vertical flange. It looked pretty questionable and after thinking about how the right side had lots of corrosion funk sandwiched between where the outer skin and inner structure meet on outer fenderwell side, I decided go for it and include the flange.



Found similar crud but luckily, no pinholes at the top of the long.



Cleaned it out pretty well and will be treating with some rust converter. Hope to get this section complete in the next week.

Posted by: tygaboy Nov 1 2021, 11:20 AM

Look at that shiny metal... You're going to have these repairs wrapped up in no time!

Posted by: markhoward Nov 4 2021, 06:00 PM

Got the left vertical patch in today. Sunday, we will sealing off the left long and moving on to the firewall install.

Posted by: tygaboy Nov 4 2021, 06:14 PM

Super Duper Awesome... Mark. your welding skills are improving really quickly!

Posted by: markhoward Nov 7 2021, 08:15 PM

Another solid day on Smoggy in the company of @http://www.914world.com/bbs2/index.php?showuser=19241 . Today, we officially completed the hell hole repair by sealing off the left side long. After that, we moved on to fitting the firewall and planning what is next. Here are a few pics of today's progress including a few glamour shots with the firewall and floor clamped in place. The firewall needs a bit more modification to make fit. Both sides came short on the outermost part that mounts vertically above the long. We are about a 1/4" short on the passenger side and 3/8-1/2" short on the driver's. Chris took home the driver's side so he could make a new corner section to gain the needed length. On the passenger side, we are going to bend the flange flat to gain the material needed to close the gap. Next installment should include some permanent additions to the tub.










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Posted by: BuddyV Nov 7 2021, 08:32 PM

Amazing progress, Mark!

Can't wait to see this car running!

Posted by: Krieger Nov 7 2021, 11:43 PM

Fantastic! That looks really good!

Posted by: TRS63 Nov 8 2021, 03:20 AM

Great progress, thanks for sharing ! Inspirational as I have now to tackle this area!

Bests

Antoine

Posted by: Cairo94507 Nov 8 2021, 07:24 AM

That is coming right along.

Posted by: tygaboy Nov 8 2021, 09:18 AM

Mark's commitment to his cars is something to behold. In the case of the work he's doing now, he pauses after every tack to assess its quality, evaluate his technique and improve the next tack. I'm getting a lesson in patience and stick-to-it-ism from him. And let me say, things are turning out really nicely. Smoggy is going to be one badassmofo!

But more importantly, can I just add:

There are few things better in life than spending time with a good and trusted friend. Yesterday was a great day.

Posted by: Cairo94507 Nov 8 2021, 11:02 AM

Amen Chris.

Posted by: markhoward Nov 8 2021, 12:05 PM

Thanks for the kind words Chris! This community is like no other!!

Posted by: roundtwo Nov 9 2021, 03:34 PM

WOW, truly inspirational Mark and Chris. I knew you were talented but not THIS talented. My recently discovered rust issues are looking more surmountable after seeing what can be achieved.

The transformation magical!

Posted by: markhoward Jan 4 2022, 11:16 AM

Posting this pic of a nose section I picked up from another member so that I can link it to the vin database. Got it for the passenger side cross panel corner and possibly the headlight bucket. If anyone can use other sections or has feedback on sections that should be retained for future use, let me know.

Posted by: ClayPerrine Jan 4 2022, 11:47 AM

I watch threads like this in Awe. I can't do that type of metal work, so I am always impressed with what I see.

Honestly, I think that if we gave these guys a VIN plate and tag set, they could build a 914 tub under it in all new metal.


Clay

Posted by: tygaboy Mar 12 2022, 07:53 PM

Today's weather report said it was going to be SMOGGY! And boy, was it!

Mark and I made some serious progress getting the new inner and outer fire wall sheet metal installed.

It was a great opportunity to break out the spot welder. Here are a couple videos you fellow tool whores may enjoy:


https://www.youtube.com/watch?v=8R1QnCuBJLU



https://www.youtube.com/watch?v=MfnAnjTU7KM

Posted by: tygaboy Mar 12 2022, 07:56 PM

And a few other pics of the general progress. Note that in Smoggy's case, the main fire wall panel was too narrow at the very ends. Extensions were fabbed, the ends of the Restoration Design panel were sliced off so the extensions could be fit. Here they are being final trimmed ahead of welding.


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Posted by: tygaboy Mar 12 2022, 07:57 PM

A couple shots of the final look of those spot welds! I have to say, it's sooooo much nicer than drilling and plug welding.


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Posted by: tygaboy Mar 12 2022, 07:59 PM

As mentioned earlier, you have to cut the main fire wall panel into two pieces in order to get it over the heater tubes. Here's the seam weld that makes them one again. And you get another view of those wonderful spot welds. Pretty factory looking, IMO.


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Posted by: tygaboy Mar 12 2022, 08:01 PM

The money shot!

OK, OK, so there's still some welding to do but, come on, don't it look GREAT?

Big "ATTABOY" to Mark. He's doing a REALLY good job on his car. Plus, he's just a great guy to hang out with! What a wonderful day...


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Posted by: Cairo94507 Mar 12 2022, 09:39 PM

Definitely a work of art. Congratulations and keep up the great work.

Posted by: markhoward Mar 12 2022, 11:50 PM

Smoggy got some serious love! Major milestone achieved today and @http://www.914world.com/bbs2/index.php?showuser=19241 pretty much said it all. Chris, I can’t thank you enough for all the guidance and craftsmanship along the way. Your generosity is appreciated and runs rampant through our community.

Posted by: roundtwo Mar 13 2022, 02:16 AM

Incredible work. You accomplished so much really quickly and it looks so good!!!

Posted by: markhoward Mar 13 2022, 08:30 PM

Seems that the weather is still SMOGGY! Today, I pretty much finished all the welding to call the inner and outer firewall installed. I still have to complete the seam where the left and right halves meet. After seeing Chris in action yesterday, I felt it was best to practice stitch welds before attempting myself. Next up is brazing in the parking brake, heater cable tubes and all the rest at the back of the firewall. I plan on doing this at the same time as brazing in a new clutch tube on Foggy. After that, the floor can go on.

Posted by: Krieger Mar 13 2022, 10:22 PM

Wow, that looks awesome Mark! You have to feel pretty dang good!

Posted by: tygaboy Mar 13 2022, 10:33 PM

Posted by: markhoward May 10 2022, 09:29 AM

Just a quick Smoggy update as she rests in the shadows of Foggy. No progress has been made other than bouncing around thoughts of what to do long term now that I have two project 914’s and barely time for one. I am going to keep chipping away at least to the point where she is a roller sporting all that fresh metal. Have not figured things out past that and the rational part of me is saying to find someone wanting to take over. Food for thought..

Posted by: ssuperflyoldguy Jul 21 2022, 04:02 PM

We should all learn giving is just as good as getting from Tyga - while I'm on my out of 914's (but I do have half of one left - long story) for the moment to concentrate on Classic Mini's & helping out the new kids a la Chris, the Mini community has one named Andy

Thx for all the support Chris!

Posted by: Root_Werks Jul 21 2022, 04:35 PM

Wow, look at all the progress!

Posted by: markhoward Jul 21 2022, 04:46 PM

QUOTE(ssuperflyoldguy @ Jul 21 2022, 03:02 PM)

Posted by: Shivers Jul 22 2022, 06:14 AM

Great work guys