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> Rob Watson's ear, R&R right rear suspension ear
watsonrx13
post Aug 29 2004, 02:54 PM
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Today I began the process of replacing the right rear suspension ear. I purchased my pieces from Restoration-Design. The pieces included the right engine shelf, suspension ear, battery tray and battery support.

I began by removing the center section of the engine tray. This shows the spot-welds drilled out. I used a 1/4" drill bit. Any spotw-welds that weren't completely drilled out I used a air hammer to complete the separation.

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watsonrx13
post Aug 29 2004, 02:55 PM
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Then I removed the front section of the engine tray. I used a disk grinder to grind down the metal edge of the tray because I couldn't get a drill in the correct position. I also cleaned up and straightend the triangle piece at the bottom.

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watsonrx13
post Aug 29 2004, 02:56 PM
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I removed the rear section of the engine tray next. After the engine tray was completely removed, I began with the suspension ear. I worked on the top section first. Since the ear had been previously repaired, it was difficult to determine where the spot-welds were on the bottom, therefore, I decided to remove the ear in piecemeal. This shows how I used the 3M purple wheel to identify the spot-welds. There were spots welds on the top, sides and in the middle.

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watsonrx13
post Aug 29 2004, 02:56 PM
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Once I drilled out the spot-welds on the top section, I used a cutting wheel to cut the ear in half. This shows the top section removed. Notice the extra plate welded on the bottom of the ear.

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watsonrx13
post Aug 29 2004, 02:56 PM
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This shows the top section removed. Notice the heavy rust area, which was the reason the DAPO repaired this ear his way instead of the right way.

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watsonrx13
post Aug 29 2004, 02:57 PM
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Here's another shot of the patched ear.

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Brad Roberts
post Aug 29 2004, 02:57 PM
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Yep. Should be 10 factory spot welds at the top of that piece.


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watsonrx13
post Aug 29 2004, 02:57 PM
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Finally, these are the tools that I used. Unfortunately in other posts, very few of them have include a list or photo of the tools used. If you get the right tools, it makes the job much easier.

This is all for this weekend, stay tuned for more progress.

BTW, I'm hoping to be able to complete this by the end of next month. But, I'll be out of town next weekend, so it will be 2 weeks from now.


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Brad Roberts
post Aug 29 2004, 02:59 PM
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Those two scab plates will take longer than the removal AND install of the ear (if you are trying for a factory look)

What measurement did you get from the firewall dimple to the center of the ear ?? In Metric.



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watsonrx13
post Aug 29 2004, 03:01 PM
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21 3/8" --
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Brad Roberts
post Aug 29 2004, 03:13 PM
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Somebody convert that for me...LOL I have gone all metric. The factory Porsche race car manuels are all in metric.... so I practice..


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watsonrx13
post Aug 29 2004, 03:16 PM
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Metric, we don't need no stinkn' METRIC.

This is a 'Merica (IMG:style_emoticons/default/flag.gif) home the free, land of the brave and keeper of the foot/inch...
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SpecialK
post Aug 29 2004, 03:19 PM
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21.375 Inches equals 542.925 Millimeters
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Gary
post Aug 29 2004, 03:19 PM
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I think you were kidding... but I get 543mm, give or take a standard paperclip thickness, which I was taught in school measures 1mm. Come to think of it, I've never put a pair of calipers on a paperclip. (IMG:style_emoticons/default/biggrin.gif) (IMG:style_emoticons/default/biggrin.gif)
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watsonrx13
post Aug 29 2004, 03:24 PM
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So, I guess I'm close enough to the 545mm for government work?

(IMG:style_emoticons/default/smilie_pokal.gif) Who da man now.... (IMG:style_emoticons/default/cool_shades.gif)
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Brad Roberts
post Aug 29 2004, 03:27 PM
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I installed mine at 545mm. I wasnt joking about the MM thing.. I measure just about everything in metric when it comes to cars.


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watsonrx13
post Aug 29 2004, 03:34 PM
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Hey B, if I can get this ear replaced, it is the only thing structural wrong with this car. My intent is to finish the engine compartment, clean and upgrade the suspension and after Joe Ricard finishes my engine, put it back in the car. I still have to work on the interior and front and rear trunks, but I'll do them during short down times. This car has been on blocks since Jan 2003.
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Brad Roberts
post Aug 29 2004, 03:38 PM
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Go man Go. You have the BEST support group right here. There wont be anything on the car that we cant help you with.

Joe is building your engine ?? I didnt know Joe built engines..


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watsonrx13
post Aug 29 2004, 03:42 PM
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Personal favor. (IMG:style_emoticons/default/aktion035.gif)

I got his 'burnt' car and we became friends. My wife and I travel to Biloxi, MS (red-neck riviera) for gambling every other month. So I always drop by Joe's place. Once he got his new teener from Washington, he volunteered to rebuild my engine, what a guy.

He's doing a standard rebuild, I can't afford a Raby engine.

Just another teener club member helping another. (IMG:style_emoticons/default/smilie_pokal.gif)
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Brad Roberts
post Aug 29 2004, 04:07 PM
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Glad to hear it. (IMG:style_emoticons/default/clap56.gif)


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