*Project 2.4* • Dion’s endeavor • Six conversion, Rustoration & transformation Options

[Dion]

Well did more exploratory surgery and it's ugly. Beauty on
the left side was in fact only skin deep. Consulted with my
bro Dave ( 914Dave ). So time to cut out the outer long complete.
To the kickup and replace the metal accordingly. Inside the cabin
area can be fixed with a few patches. Floor is in good shape remarkably.
I should just enter the buildoff at this point (IMG:style_emoticons/default/biggrin.gif)
Stay tuned...

[Dion]

Ugly

[Dion]

(IMG:style_emoticons/default/blink.gif)

[Dion]

(IMG:style_emoticons/default/dry.gif)

[Dion]

Opened up whole of left longitudinal today. I'll be ordering some metal
for the U-boat. I'll be replacing the sill,door jamb, rocker outer cover,
the rear jack donut and inner rear lower firewall.
Dave lent me his spot weld remover bits so that's where I'll begin.
Then I'll address a "hatch" for the six to adjust the timing. Lots of work ahead.
Many of you guys have been here before. Wish me luck.
This will be going at the same time as reassembling Dave's GT. So little time!

[altitude411]

Your going to need a few more license plates and possibly another roll of duct tape... (IMG:style_emoticons/default/popcorn[1].gif)

*subscribed*

[Dion]

Your going to need a few more license plates and possibly another roll of duct tape... (IMG:style_emoticons/default/popcorn[1].gif)

*subscribed*

Hahahah. Yeah pretty much!
What has the collective done with regards to the door jamb
sticker? Is it salvageable? Do you even bother.
Being it's an "Antique" here in PA, the car doesn't get inspected.
Just wondering what you have done.
Thanks

[Dion]

So the build challenge is on. Happy to say I've obtained a nice heater tube from
Rich (rdauerhauer). So that's a relief as the original was a little cut into.
My supply of spotweld cutters is here, so hope to post more pics soon of progress.
Goal for this time frame till January is to remove rear quarter panel and lower firewall
driver side. As well as weld up the many numerous holes in the firewall that were used for running wires. Parts have been ordered from Restoration Design as well as 914rubber. Carry on.

[mepstein]

Your going to need a few more license plates and possibly another roll of duct tape... (IMG:style_emoticons/default/popcorn[1].gif)

*subscribed*

Hahahah. Yeah pretty much!
What has the collective done with regards to the door jamb
sticker? Is it salvageable? Do you even bother.
Being it's an "Antique" here in PA, the car doesn't get inspected.
Just wondering what you have done.
Thanks

Take a picture of it for your records and then order a new one from Andy ( I forget his screen name on this site but someone will chime in)

I guess the lift purchase is paying off.

[Dion]

Mark, I don't think I'd go this deep into "hell" if it wasn't for this lift. Heheheh
I'll keep checking on the sticker. For some reason "car-bone" comes to mind regarding
odd,one off stickers and such. Thanks.

[Larmo63]

SoCalAndy makes the stickers.....

[altitude411]

Socalandy. His awesome six build is in the restoration forum

[Dion]

Thanks for the info on the stickers. I'll give him a shout. Yes I have his build bookmarked. It's excellent.

[mbseto]

I would say you have your work cut out for you. But really, your work is cutting everything out. :-)

[Dion]

Still cutting away. Parts from Restoration Design on the way. Time to break out
the kerosene heater soon. Hitting 38*F tonite.
Drilling out spotwelds is certainly a test of wills. Progress is
slow but it's progress.

[JmuRiz]

After knowing and talking with ScottyB enough, he says that even the nice looking ones have rust...looks like you got lucky and hit the motherload (IMG:style_emoticons/default/icon8.gif)
I guess it's good restoration design is a sponsor. Best of luck on the fixn', your progress thus far shows you are going to be able to handle it just fine.

[theleschyouknow]

keep up the good work

somebody I think in the 2016 build off had an alternate method of drilling out the spot welds using regular bits
sorry can't remember who it was or the details like bit sizes but basically it involved drilling just thru the first layer with a larger bit and 'exposing' the weld then drilling a thru hole large enough to remove most if not all of the weld then, if necessary, he reported it was easy to pry/pop the panels apart
kinda sounds like 2 steps to do 1 to me but he seemed to like the results

looks like you have your hands full but also that it is in good hands, have fun!

(IMG:style_emoticons/default/beerchug.gif)
cjl

[Dion]

Thanks guys. Appreciate the confidence.

[JoeDees]

keep up the good work

somebody I think in the 2016 build off had an alternate method of drilling out the spot welds using regular bits
sorry can't remember who it was or the details like bit sizes but basically it involved drilling just thru the first layer with a larger bit and 'exposing' the weld then drilling a thru hole large enough to remove most if not all of the weld then, if necessary, he reported it was easy to pry/pop the panels apart
kinda sounds like 2 steps to do 1 to me but he seemed to like the results

looks like you have your hands full but also that it is in good hands, have fun!

(IMG:style_emoticons/default/beerchug.gif)
cjl

Doesn't sound exactly like my technique, but I use a cut off (so it only sticks out about 1/4" from the chuck to prevent breaking bits) 1/8" bit to start a pilot hole (aids a big bit's bite), then use something like a 3/8" bit to only go through that top layer before carefully using a seam buster tool to separate. The technique allowed for welding separate panels back together.

Then again, you could be talking about somebody different...

[theleschyouknow]

keep up the good work

somebody I think in the 2016 build off had an alternate method of drilling out the spot welds using regular bits
sorry can't remember who it was or the details like bit sizes but basically it involved drilling just thru the first layer with a larger bit and 'exposing' the weld then drilling a thru hole large enough to remove most if not all of the weld then, if necessary, he reported it was easy to pry/pop the panels apart
kinda sounds like 2 steps to do 1 to me but he seemed to like the results

looks like you have your hands full but also that it is in good hands, have fun!

(IMG:style_emoticons/default/beerchug.gif)
cjl

Doesn't sound exactly like my technique, but I use a cut off (so it only sticks out about 1/4" from the chuck to prevent breaking bits) 1/8" bit to start a pilot hole (aids a big bit's bite), then use something like a 3/8" bit to only go through that top layer before carefully using a seam buster tool to separate. The technique allowed for welding separate panels back together.

Then again, you could be talking about somebody different...

yep that was you nice work!
I got it kinda backward in my explanation
re reading my post it I think it might sound critical but no offense was meant in fact I was impressed with your ingenuity and hoping to pass it on
keep up the good work!


(IMG:style_emoticons/default/beerchug.gif)
cjl