 newbie 74 1.8 project, rustoration turning into a GT lookalike |
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| jmitro |
 May 18 2016, 12:50 PM
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#41
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Senior Member  Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None 
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Started repairing the rusted out right front Apillar support and pedestal. Basically three layers of metal to repair. First layer was completed, overlaid with POR15, and second layer shown here. Final external pedestal still in the works:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457841.1.jpg) Next I fabricated a new front bumper mount completely from scratch (both need to be done but I've only completed one so far). It's a huge amount of work due to the bracket being welded to the inner fender wells which were also rusted. So I had to cut out a large section of the inner structure as well as part of the external body sheetmetal. (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457841.2.jpg) Started adding the chassis stiffening braces from Mad Dog Motorsports: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457841.3.jpg) |
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| jmitro |
May 18 2016, 12:52 PM
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#42
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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started working on the rear trunk floorpan:
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| jmitro |
May 18 2016, 12:54 PM
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#43
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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| jmitro |
May 18 2016, 12:57 PM
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#44
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Cutting the entire section out while leaving the good metal intact turned out to be very tedious. But it got done.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458213.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458157.2.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458158.3.jpg) |
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| jmitro |
May 18 2016, 01:00 PM
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#45
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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surfaces cleaned down to bare metal in preparation for welding. The inner chanel got POR15 but I forgot to photograph it before welding in the new trunk floorpan
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458070.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458071.2.jpg) |
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| jmitro |
May 18 2016, 01:03 PM
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#46
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Here is where I stand now: about to weld in the trunk pan reinforcement after shooting it with weld-thru primer. The Car is getting fully media blasted this weekend, then continue the rust repair/replacement.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458377.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458377.2.jpg) Sway bar mount reinforcements: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458377.3.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464458377.4.jpg) |
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| mb911 |
May 18 2016, 01:41 PM
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#47
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914 Guru Group: Members Posts: 6,820 Joined: 2-January 09 From: Burlington wi Member No.: 9,892 Region Association: Upper MidWest
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QUOTE(jmitro @ Oct 9 2015, 09:02 PM)  QUOTE(bigkensteele @ Oct 9 2015, 11:33 PM) I have to ask - are you sure that you want to continue with this tub? From years of personal experience and reading threads on this board, you would most likely be much better off finding a better tub in SoCal or AZ and having it shipped to you. Perhaps you enjoy welding and grinding, but I fear that you have only discovered the tip of a very big iceberg. However you proceed, good luck! It looks like you have some talent, so this should be a fun thread! believe it or not, I looked for a car that needed work. I enjoy the cutting, grinding, welding, and making something new out of this old tired chassis. It will be a long process to fully restore this car, but I enjoy the restoration journey as much as the end result (IMG:style_emoticons/default/beerchug.gif) Oh yeah, I'm also training for the Houston Marathon in January. With a family and full time job. I'm living life to the fullest! (IMG:style_emoticons/default/biggrin.gif) I am with you .. I like welding, grinding, making new.. It's the soothing part of the project.. I have done so many cars over the years. The current 914 might be my last but it could take another year to complete welding and metal work and then still another year or 2 to finish from there but again soothing.. Looks good keep up the good work. |
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| DavidSweden |
May 18 2016, 02:13 PM
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#48
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Member Group: Members Posts: 479 Joined: 8-June 14 From: Sweden Member No.: 17,452 Region Association: Scandinavia |
I agree, working on the cars is a great distraction, stops one thinking about the futility of life....I found a lot of rust and my first thought was this is going to be fun
I guess I am sick, anyone else think this way? |
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| jmitro |
May 28 2016, 11:01 AM
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#49
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Finally got the chassis media blasted. I was fortunate enough to find a local company that does MOBILE blasting so I had it done in my driveway. Very convenient!! Here's the before photos:
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464454868.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464454868.2.jpg) And the after...... (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464454868.3.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464454868.4.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464454869.5.jpg) |
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| jmitro |
May 28 2016, 11:16 AM
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#51
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Hell hole will need replacement on both sides, then on to the longitudinals.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455817.1.jpg) Mad Dogs Motorsports hell hole repair kit is on the way: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455817.2.jpg) Left side is nearly as bad (blast media is the white powdery substance - hadn't cleaned it as of this photo) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455817.3.jpg) So now begins patchwork of rusty areas, and installation of Mad Dogs Motorsports chassis reinforcements. This is the front side of the left firewall. This area will need quite a bit of work. (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455817.4.jpg) Rusty area in the front bulkhead was cut out and replacement sheetmetal scavenged from the fenders to form a patch. (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455818.5.jpg) Weld thru primer on the backside of all chassis reinforcement plates: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455818.6.jpg) Three of the five plates completed on the right side (still need to weld the plate perimeters): (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464455818.7.jpg) |
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| jmitro |
May 28 2016, 11:45 AM
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#52
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Strangely, I found a crack in the driver's side inner longitudinal. I suspect it developed as a result of the structure weakening from all the rust damage.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457553.1.jpg) Front trunk rubber channels aren't too bad and easily repaired: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457554.2.jpg) Headlight buckets in pretty good shape: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457554.3.jpg) Inside the left rear fender flare, looking upwards. Trying to put most of the weld bead inside to avoid grinding too much on the outside of the fenders: (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1464457554.4.jpg) |
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| Claus Graf |
May 28 2016, 12:09 PM
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#53
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Member Group: Members Posts: 51 Joined: 25-November 14 From: Houston, TX Member No.: 18,154 Region Association: None |
Great Job! Keep forging through!
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| jmitro |
Jul 9 2016, 05:11 PM
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#55
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Free formed the pedestal for the Apillar, as the original was rotten.
(IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1468105882.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1468105882.2.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1468105882.3.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1468105882.4.jpg) On another note, I also bead-blasted the rear control arms, removed the bearings, and welded on the reinforcement plates from Mad Dogs Motorsports. Next is a few coats of epoxy primer. (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1468105882.5.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1468105882.6.jpg) |
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| mb911 |
Jul 10 2016, 06:08 AM
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#56
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914 Guru Group: Members Posts: 6,820 Joined: 2-January 09 From: Burlington wi Member No.: 9,892 Region Association: Upper MidWest
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Looking good we are in similar stages.
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| jmitro |
Jul 27 2016, 10:13 PM
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#57
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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I know to most of you this may be boring but I'm making really nice progress, and in any event this documents the rebuild for future vehicle buyers to see.
I'm fairly proud of the jack point rebuild. If you recall, the car had some angle iron (which itself was pretty rusty) welded to the underside of the long to substitute for the original jack point. (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1469680231.1.jpg) I carefully teased out each layer of metal (see photo above), excised the rotten jack point, and hand-fabricated a new base layer (with dimple die) then welded on the new jack points. (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1469679236.1.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1469679237.2.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1469679237.3.jpg) (IMG:http://www.914world.com/bbs2/uploads_offsite/i75.photobucket.com-18986-1469679237.4.jpg) |
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| Cuda911 |
Jul 27 2016, 10:22 PM
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#58
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Senior Member Group: Members Posts: 1,489 Joined: 20-May 14 From: Oceanside (N. San Diego County), CA Member No.: 17,376 Region Association: Southern California |
Very much enjoying your posts. I am very jealous of your skills. Also, it is wonderful to see yet another 914 saved from the great scrap heap in the sky. Great work!!!
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| jmitro |
Jul 27 2016, 10:35 PM
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#59
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Senior Member Group: Members Posts: 713 Joined: 23-July 15 From: Oklahoma Member No.: 18,986 Region Association: None
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Thanks Mike! Replacing the rust is not as sexy as building a monster engine, but to me it's very gratifying and it will give me a strong chassis for whatever future powerplant I have.
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| mark04usa |
Jul 27 2016, 10:55 PM
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#60
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'70 1.7 Tangerine Group: Members Posts: 351 Joined: 14-September 09 From: Austin TX Member No.: 10,805 Region Association: Southwest Region
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Great project saving another one! Press on.... (IMG:style_emoticons/default/beerchug.gif)
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