1973 2.0L Rustoration, Restoration turned OT garage build Options

[Superhawk996]

I purchased my first 914 back in 1987 (1973 1.7L) and had that car for nearly a decade and I personally put over 100,000 miles on it before it ultimately fell victim to a negligent driver that drove into the back end of it at about 40 mph while the vehicle was stopped at a red light. That rear end crash totaled the vehicle but what is amazing is how well it crumpled (early crush zones!) due to the kink in the frame where the halfshafts are. Everyone walked away unharmed.

I replaced it with a 1991 Miata. Great car in its own right but I've always missed my 914.

Purchased this "replacement" in May 2018 as a known poster child for a complete right side longitudinal rustoration.

This vehicle had been put into storage inside a pole barn around 2004 as far as I can tell.

Vehicle initially purchased in non-running condition:
Engine couldn't be started.
Transmission shift linkage was disconnected
Half shafts and CV's were in pieces, and the wheel stubs were not installed therefore the vehicle couldn't even be rolled without risking having the rear wheel separate from within the bearing.
Fiberglass laid into the floorpan . . . that can't be a good sign.

Vehicle looks great . . . until I got under it.

I spent the better part of the summer putting the items above back together and trying to confirm that it would:
1) Run under its own power
2) Drive though the neighborhood and shift though all gears.



Looks pretty nice eh?

Here is what is lurking underneath once the rockers came off.



and when I started cutting back the rust. Oh my . . . .

[Superhawk996]

Getting back to work after a few days off.

Slow going lately. Still removing parts and cutting metal to get access to the Hell Hole areas.

Had to remove the trunk to get the old trunk hinges out. Of course that meant screwing around with the torsion bars which is always a smashed finger waiting to happen if not done properly.

Also a reminder that I need to move the battery to the frunk! Previously was crudely mounted in the trunk and taking up too much area in that already limited space. Plus I prefer the weight to go up front like I had it in my 1st 914.



Previous paint job used bed liner type spay on material to hide a variety of repairs. I already know the rear trunk bottom edge has had the fiberglass treatment. Afraid to dig into that one this winter. Non structural and honestly, it is pretty inconspicuous at the moment. I don't see a way to repair this right now without ending up with even more paint work on my hands.



The trunk hinges had to be pulled:
1) to make way for new sheetmetal to repair the AC butchery. Hole saw pass thru is absurd. I can't believe the sheetmetal isn't rusted around the edges of the holes and leading to even more decay. Finally, a blessing! (IMG:style_emoticons/default/piratenanner.gif) That is the mystery of this car so far. . . . how is the underbody so gone but the upper is in decent shape?

2) Repair the trunk hinge brackets. Although not broken off they were welded in with snot welds and look like they will eventually break. Even if they don't break I don't want someone to think I welded them!.

3) Upon removal, I discovered that the proper hinge bolts are long gone. Replaced with a 10 mm threaded bolt that is enlarging the bracket hole each time the trunk is opened. So the bright side is that I found this out before they broke! New brackets will address #2.

I'm constantly amazed how poorly previous owners took care of maintenance and repair. I understand 914's not getting due respect but come on. . . . (IMG:style_emoticons/default/ar15.gif)

Makes be a bit worried about getting to that engine and transmission. (IMG:style_emoticons/default/dry.gif) I already know there are a couple of dicey exhaust studs and the compression is lacking (IMG:style_emoticons/default/sad.gif)

Got around to cutting the firewall to gain access to the Hell Hole to install the wheelhouse inner. More spot welds and cutting. (IMG:style_emoticons/default/sawzall-smiley.gif)



Spent the better part of two days getting this far. I think I was in for about 4 hours just to rough fit the inner frame rail. The way it fits up the the front of the trunk is tricky. Had to spend a lot of time reworking of the frame rail flanges to get it to fit right.

The one thing that bothers me is this frame section is corrugated. The original is two layers of steel. Inner is corrugated but the outer is smooth.

I think I'm probably going to have to fabricate a 0.030" (ish) outer layer to smooth out the appearance of this. Ideally, I'd like the rail to look OEM. May be too much work. Time to think that one over for a while. Open to suggestions if someone else has traveled this road. (IMG:style_emoticons/default/idea.gif)





Lots of rough mock up to figure how how stuff will fit and what the best assembly sequence will be.

Discovered that the Restoration Design outer clam shell will need to cut into two pieces for my install. There is no way to weld on the upper portion without cutting off that rear fender so it will have to get welded to the wheelhouse section before that whole section is welded in. Also it needs to sandwich to the wheelhouse and the longitudinal which can't be done after the door jamb is finish welded.

Not a big deal but better to find it out now before welding starts!