Intro from Montana: '73 2.0L rustoration thread Options

[bbrock]

My name is Brent and I’m new to 914 World but certainly not to 914s. My 1973 2.0L has being lying dormant and neglected for over thirty years now and is long overdue for a resurrection. The path to where I am now has been a long one so forgive me for the long introduction, but some of you might be able to relate.

History

I wasn’t much of a car guy as a kid growing up in NE Kansas. I liked cars, but I didn’t LOVE them. But when I saw my first 914, it spoke to me in a way that no other car had before… or since. My first ride in a teener didn’t come until my senior year in high school when a co-worker took me for a spin in a 914 he had borrowed from his dad’s used import car dealership. The car did not disappoint and I was hooked! I knew I had to have one.

The year was 1981. I was 19 and beginning my second year of college at Kansas State when I took out a small loan to buy my first car. I found a barely road-worthy 1970 1.7L in Missouri for $2,300 and was beaming with pride when I rolled up to the college dorm with my new, but rather shoddy looking, prize. But being as I was 19, and that organ that would eventually become a brain was not yet developed, I managed to shove the nose of my new Porsche under the tail end of a pickup truck at an intersection the very next day. Devastated; I had the car towed to a little one-man body shop at the edge of town. The front left corner was toast. I had enough money left from my loan to buy a partial front clip from AA. I got a call from the body shop the day the clip arrived and was told there was a problem. I went to inspect and saw that AA had sent a wrecked clip. The fender was smashed and the cost to hammer out the panels was 3X the cost of the part. I got in a heated argument over the phone with AA when I was told that sort of condition should be expected with used parts. What a bunch of BS! Surface rust and a few dings is one thing, but this part has been smacked hard enough the turn signal opening was half the width it should have been. Pointing out that their own advertising promised used parts would be collision free got me nowhere. In the end, I had to pay return freight and a restocking fee to get rid of the shitty part. That was the first and ONLY time I’ve done business with AA and I’m still pissed 36 years later. Luckily, a 914 had arrived at a junk yard 60 miles away and I picked up the parts, minus the lid, for a fraction of what AA had charged and hauled it myself.

But my woes of fixing my 914 were far from over. The body shop guy told me he found a trunk lid and that if I prepaid for parts and labor, he could put my car back together, shot with primer, for $400. Like an idiot, I believed him. I took out another small loan and wrote him a check. Every time I stopped by to check out the progress, there was a different excuse. The lid was at another shop getting MIG welded to repair minor rust… things like that. Then the guy just disappeared. I spent a few weeks stopping by almost daily to find an empty shop. Finally, one day a crusty looking old guy was there. “Are you looking for Joe?”, he asked. “Join the club.” Joe had been bilking lots of people out of money and had skipped out of the country. The guy telling me this had recently entered partnership with Joe and had lost thousands of dollars. We would both shortly receive a bankruptcy letter listing us as creditors and leaving us with little recourse to recoup our losses. It was my first hard lesson in trust. The silver lining was that the new guy had another shop and took pity on me and completed the work that was promised at a very reasonable price. I know he lost money on the deal.

My now patchwork-colored teener was back on the road but I wasn’t any smarter at 20 than I was at 19 so my car would again suffer the consequences. It was a cold, snowy, Kansas winter when I was home at my parents for Christmas holiday. I had learned from experience that if I put the 914 to bed in that weather without adding a bottle of drying agent to the gas, she was not going to start. But I wasn’t alone and shop after shop was sold out of HEET. On the fifth stop, I finally found a few bottles and was heading home to my parents when I hit a patch of black ice at low speed on possibly illegal balding tires and wrapped the front neatly around a fire hydrant. Well shit! Here we go again. I was done with body shops and con-men so decided it was time to learn to weld. I found donor parts at the same junk yard as before and set about cutting out the damage and replacing using my brother’s oxy-acetylene torch. Amazingly, I managed to get the car back together in drivable condition. I won’t pretend it was a good repair job, but adequate. I learned a lot about working on 914s because just about every week, something new broke – clutch, torsion bar, struts, and the constant battle with bad wiring in the FI and ignition. I’m sure there is a part on a 914 I haven’t removed and replaced, but I can’t think of what that would be.


About a year later, my then girlfriend and now wife of 30+ years needed to replace her aging Honda and a nice looking 914 appeared for sale. It was a ’73 1.7L and looked much prettier than mine. We shouldn’t have bought it because it had been wrecked and not put back together right. It had a barely detectable sideways crab as it rolled down the road that a 4-wheel alignment couldn’t fix. But it made a good daily driver and was nice enough that when Elizabeth and I were married, her cousin hid the car for us so my original patchwork 70 got the traditional “Just Married” treatment.





Around that time in 1984, I spied an ad in the college paper for a 914 for $500. Always needing parts, I thought this was my chance to get a big pile of parts at a bargain price. After talking with the owner, I discovered this was a 1973 2.0L. (my dream model and year). It had suffered the dreaded hell hole and the RR suspension console was dangling free. The PO (the car's second owner) couldn’t get a shop to even quote her a price on fixing it, and I was welcome to go have a look. I found the car in a parking lot next to the local import car parts shop. I couldn’t believe what I saw. Not only was it my dream ’73 2.0, but it was metallic silver with 4-spoke Fuchs, center console but not appearance group (black bumpers and no targa vinyl). This is exactly the car I would have ordered at the dealership. I knew that the wheels alone were worth the asking price. From 30 ft., the car looked gorgeous. From 10 feet, it looked really good but you could see it had been repainted, and not well. The interior was complete and clean. The only thing wrong with this car was a rotten battery tray and suspension console. And even that rot was limited and hadn’t spread to other bits of the hell hole. I finagled another small loan and didn’t quibble on the price. THIS would be my car.

Back at the junkyard I found a console from the same donor I had taken the front for my 70 from. I spent a weekend in my parent’s garage welding it in and spent the next several years enjoying the hell out of that car. In the meantime, I rebuilt the engine on the old 70 to donate it to a VW bus and sold the chassis for parts. My wife’s ’73 became my project car and I earned my label as a DAPO botching an outer long replacement by overheating the weld and using poorly placed door bracing. The result was an increase in the sideways crab and a passenger door that didn’t close as cleanly as it should. I continued my assault on the car by stripping it down to respray in black lacquer – a purposeful choice to reveal all of the flaws. It was a lot of work and there were many goofs to be redone, but the end result was actually quite stunning. It didn’t last long though since I didn’t have a garage at the time and black lacquer is no match for the Kansas sun. But it did convince me that I could prep and spray a car with respectable results; better than the job on my 2.0L anyway.

I don’t remember the exact catalyst that caused me to tear it apart, but as much as I loved driving the 2.0L, it didn’t always love me and I was frequently stranded – and this was pre-cell phone days. The problem was almost always some damn thing with the FI. Plus, the car was leaking oil badly and there were rust issues that needed repair. I convinced myself it was time for a complete tear down and rebuild, and I commenced to do just that. I was in my mid-twenties and Reagan was President.

Restoration Begins… and Stops… and Stops Again

I made a rookie mistake and started with the engine. I did a complete teardown and had all the bottom end parts machined and balanced at the local machine shop. Although I am kind of regretting it now, I decided to ditch the D-Jet that caused 95% of my reliability woes and opted for dual 40IDF Webers. Carb conversions were all the rage back then and I had lost patience with the FI. If I were to start this today, I’d probably keep the FI which I still have in storage. But to complement the carbs, I installed a “street grind” cam from Automotion. I’ve tossed my old Automotion catalogs and there are no other specs on the invoice. I only remember that the folks there recommended this grind to get the most from my carbs while staying close to the performance of the FI. The other mod I chose for the engine was a new set of OEM euro spec (8.0:1) Mahle pistons and jugs. I’ve always had this crazy idea that the euro spec cars were how Porsche intended and American spec was a compromise. As part of that rebuild, I stripped and repainted all of the tin with high temp paint and replaced the little hardware. Heads had not yet been touched, and Reagan was still the President.

Then life intervened. Elizabeth had put her college on hold while I finished mine, and it was while she was finishing her degree that I tore the car apart. Then it was my turn to go back for a graduate degree so the project went on hold. Time was in short supply. Clinton was President by the time I got my grad degree. Now neither time or money were as much of an obstacle, but having adequate shop space for the restoration was. All I had was an open carport that was not up to the task although I was able to turn it briefly into a makeshift plastic spray booth for the last car which we had since given to our nephew (kicking myself now). So, Elizabeth and I set about building a two-story barn with plenty of space for a large woodshop, mechanics shop, and spray booth. When I say build, I mean we picked up hammer and nails and built the thing. I must say; the thing was a work of beauty. All that was left was to install windows and then my restoration project could resume in earnest. And then I got offered a job in Bozeman, Montana which had been a long-time dream for this wildlife biologist. So without so much as ever rolling a car into the new shop, we packed up and headed to the mountains. That was 13 years ago and I’ve gotten a lot of grief for hauling my little project 1,200 miles across the continent. And she has weathered through many Montana blizzards sitting neglected in my driveway; waiting for me to come to my senses.

And Now…

Maybe I am having my mid-life crisis but the itch to get this car back on the road had gotten too strong to ignore. Over the years, I would periodically cruise the Web for 914 news, but would quickly put it aside with the resignation that I’m back where I was with no good space to work on the car. But then I read Darren Collins’ amazing odyssey on this forum. Not only is it inspirational, but it also gave me an epiphany. The bulk of the work in a restoration is in cleaning and refurbishing small parts. I don’t need a big-ass shop for that. In fact, we do have a 2-car garage but half of it is filled to the gills with woodworking tools and the other half has to remain open for the daily driver so we don’t have to scoop and scrape several inches of snow off every morning, and to protect the car at least a little from the horde of deer mice that plague every vehicle parked outdoors in the mountains. But I have a plan. I purchased a set of 10” pneumatic castors at HF and will build a rotisserie on them. That will allow me to roll my chassis over my gravel driveway and in and out of the garage as needed. That will still leave the challenge when it comes time to paint (I don’t have the means to farm out a $10K paint job). But it will get me through strip, patch, and primer. We have planned on building a detached garage since we built our house. Maybe I’ll figure out how to fund it.

Determined to make progress, it was time to take stock of what I have ahead of me. The car had been mostly stripped prior to our move, but many of the parts that had been carefully stored in sheds wound up strewn haphazardly in the trunks and cockpit during and after the move. The old pitted windshield had been removed long ago and donated to the other car. The plexi I had installed to seal out the rain had cracked to shards and only the tarp over the car kept out rain and snow. The old tires turned to dust years ago, leaving the belly of the car only a few inches above the damp earth. Not the treatment I intended to give my car but it is what it is. I was prepared for the worst last week when I began excavating to survey the damage of years of neglect. The car wreaked of weasel piss and I actually found a weasel skull in the front trunk. But that weasel piss probably accounts for the surprisingly low amount of rodent nests found in the car. Considering the abuse, things could be worse.













Thirty years ago, I had all kinds of plans to modernize this car. But history gains importance as we age so now I want to keep it mostly stock. That’s also the easier and cheaper route given that the car is disassembled, but nearly complete. My rule for mods is to do nothing that can’t easily be reversed to original stock. The biggest sacrifice is that I won’t be blanking out the side markers as originally planned even though I really hate them.
Mods planned are:
Engine: These have already been done. Otherwise I might rethink them.

• Euro 8.0:1 compression pistons
• Weber 40IDF carbs
• “Street” cam grind for carbs.
• Dizzy – I have an unused 050 on it now, but will probably replace with an SVDA 034. My carbs already have vacuum ports.

Chassis

• Euro lenses
• Black windshield and targa trim. I already sanded and painted my dinged-up trim when I tore down the car. I like the look so will keep it for now.
• Relocate fuel pump to front and replace fuel lines.
• 2-stage paint on exterior. Still not completely married to this but think it will be easier to do and less maintenance than 1-stage. Open to comments though.
• Modern radio or retro radio with modern BT module.
• Hand throttle lever to operate carb chokes.
  

Workplan

1. Stabilize engine – It has been stored in an unheated shed. Checked on it last week and was horrified to find the pistons stuck. Luckily a half hour soak of the pistons with PB blaster and some light taps with a softwood drift freed them up. Cylinders had a little rust crust at the bottom where the rings were sitting. I pulled the worst looking cylinder. Rings look fine. A few seconds with a hone and the bore was shiny like new again. Will do the same with the remaining cylinders and will refresh the assembly lube on cam lobes and lifters. I have a 3-arm engine yoke from VW Alley arriving Wednesday and will move the engine into my heated garage where I can keep a better eye on it. Once inside, I’ll clean it off and brush the case with tectyl, spray Stabil engine fog on the piston tops and cylinder bores, and bag it. I’ll turn the crank once a month to make sure it doesn’t seize again. Open to suggestions on how to protect it until it is ready to go back in the car. I’ll probably go ahead and get the heads rebuilt sooner rather than later so I can get the engine completely assembled and not have a bunch of loose parts laying around.
2. Build a rotisserie and start on rustoration. Here’s what I know I need to do:
   1. Replace front trunk tub.
   2. Repair rear trunk lid.
   3. Repair both door sills.
   4. Repair lower sail panels.
   5. Repair or replace RH engine tray in hell hole.
   6. Replace RH outer long. Won’t know about inner until outer is cut off.
   7. Misc body sheet metal patches, mostly lower edges.
3. Inventory and clean parts. I’ll develop a plan of attack after I have a better idea what I’m dealing with. But this will keep me busy for a while.

Thanks for reading.

[bbrock]

That sounds like weak glue. What are your shop temps. Most glues like to see temps > 60F. Question: do those dimples on the back side play a role in assemble or just molding marks?

I did it in the house. Temps were 68F (shop temps run 64-66). I wish I had taken more pics of the process. I wouldn't say it was weak. It still takes a lot of effort to peel the vinyl off the plastic even with the general purpose 3M. But the way I stretched the vinyl the first time left more tension than the adhesive could hold. It was a little like stretching a skin on a drum and then trying to stick it to the bottom. It just pops back up. More than anything, I think it was my ignorance rather than problems with the glue or plastic. But I'll bet if it was fiber board like the original material, my first technique would have worked.

Good question on the dimples. I pondered them because they look like they could be drill guides for the clips and screw holes. They were close, but didn't exactly line up with my original card, so I ignored them.

[cary]

Brent I did the same repair on Doug's door.
http://www.914world.com/bbs2/index.php?s=&...t&p=2444021



I cut the roller coaster channel off of a spare parts door.
http://www.914world.com/bbs2/index.php?s=&...t&p=2495185

I just couldn't create sometime that I was happy with. Too many twists and turns.

[bbrock]

I cut the roller coaster channel off of a spare parts door.
http://www.914world.com/bbs2/index.php?s=&...t&p=2495185

I just couldn't create sometime that I was happy with. Too many twists and turns.

Thanks Cary, I've read every word of Doug's thread but had forgotten about this. I hadn't looked close enough to think about that front lower corner being a 3-dimensional bend (roller coaster is the perfect term). I wonder if I could get somebody to chop the channels off a donor. That would sure save on shipping and make it economical. Funny how that little strip of angled metal complicates what would otherwise be fairly simple patches.

[bbrock]

Finally got a day to work on the car. I have to admit, the crowded shop situation is wearing on me. But I spent the day working on my Porsche which means I have no reason to whine.

Just did some niggly stuff today, getting closer to putting the sail panels on. There was still some rot on the middle wall of the passenger B-pillar that needed to be addressed.



Patched up the holes and repaired the flange. This was taken before grinding was complete.



Then I rebuilt the little shelf dealy and spent a lot of time grinding and dressing all of the patch welds on the inner wheel house.



I'll treat this with Ospho again and then give it a couple coats of epoxy primer. I'm also going to lay down some seam sealer over that shelf and contour it so it sheds any moisture that drips down in there. Then I'll be ready to put the sail panels on.

(Apols to Tygaboy (IMG:style_emoticons/default/biggrin.gif) ) Mmmmm, nice b..b...b...b....bison.

But you know what critter I really want to see..... ? (IMG:style_emoticons/default/biggrin.gif)

Okay Andrew, I'll take a guess. Would it look something like this?



I am not positive that is what I think it is. It was walking down the road in front of our house one morning. Showed the pic to a room full of fellow wildlife biologists, including a couple who were on the Interagency Wolf Study Team that did the science before wolves were reintroduced to Yellowstone. All of them think it probably is, but can't be certain.... but this one definately is - not exactly National Geographic quality, but it's the first wolf I ever saw in the wild.



If that's not the critter you wanted, I have another guess.

[bbrock]

Good Progress

Been a busy week. Didn't receive data from a client when I had hoped, which left me with an unplanned fun day to work on the car. The extra day set me up for steady progress all week. First was trimming the sail panels for final fit. Once they were fit and clamped in place, I noticed they had some slight bulges from the stamping. I decided to shrink as much of those out before spraying primer. Doing it later would risk burning off primer inside the cavity where it couldn't be touched up. This is after 3-4 passes with the shrinking disc. You can see the high spots. At this stage, they've already shrunk out quite a bit.



After about 45 minutes of working the shrinking disc countless times, the main high spot has shrunk down flat. There are still a few ripples in the front corner that will need some work and maybe a bit of filler, but much less than without the shrinker. In hind sight, I probably should have used hammer and dolly to flatten those ripples, but I was afraid of stretching the metal and introducing new warps into the panels that would affect the fit.



Now I was ready to shoot some primer. Put a couple medium coats of PPG DP
LF epoxy on all cavity surfaces and down quite a ways under the quarter panel.





Having a full day to get the paint on set me up to make steady progress over lunch and evenings during the week. I started by doing the plug welds on both sail panels. That went smoothly.

Now for the welds I've been practicing for

With the plug welds done, I loaded a spool of EZ Grind wire for the butt welds. I don't know if it will make any difference. Some people say there is no benefit, others say it hammers out better than normal wire. I figured I could use every bit of help to achieve those invisible welds on these panels. Here's the passenger side clamped and tacked.



About 3 hours later, I had the butt welds complete and rough ground with 36 grit just to take the weld down just proud of the parent material. I'll come back and grind a little more, work it with heat, hammer and dolly, and more grinding and blending later.



On the driver's side, I had to use a little different approach. The lower edge of the sail panel had a bit of a wave in it. To avoid winding up with an oil can welded in, I trimmed, fit, and clamped the lower section of the quarter panel at the same time. I removed a couple clamps before remembering to snap a picture, but here it is tacked in with most of the clamps still in place.



Then the long, slow process of zapping the butt welds shut. Another 3 hours for this. I came very close to getting 'er done before shutting down to go for a walk with the wife and dog and then movie night.



I did not expect to start the weekend this far along. Should easily get the lower quarter on the passenger side welded in the morning and then work on grinding, hammering, and blending. Really hoping to get those invisible welds on this!

[andrewb]

Sorry Brent - I'm being too obscure. I just wanted to repeat one of my favourite lines from Leslie Nielsen https://www.youtube.com/watch?v=wS3LWOTCW4A . (IMG:style_emoticons/default/biggrin.gif)

As for your repairing/welding - it's really opened my eyes to what is possible when it comes to cutting and then refitting panels. I've always tried to unpick whole panels rather than cut across them but now that you've shown what's possible I might be a bit braver.
I certainly couldn't replicate those butt welds just yet - mucho practice required !
Thanks for the inspiration.

[defianty]

Nice work Brent - you're catching me up!

[76-914]

(IMG:style_emoticons/default/popcorn[1].gif)

[ablesnead]

...well you gotta pay some attention to the dog...wife too I guess...but you are now responsible for the emotional travels of all of us that would never do what you are doing , and satisfying that experience vicariously through yours...WE JUST CANNOT BE LEFT HANGING !...Please dont quit on this project , its all about your fans....

[Dion]

(IMG:style_emoticons/default/pray.gif) (IMG:style_emoticons/default/welder.gif) love the work Brent.
Also enjoying all the wildlife keep it all coming!
Glad to see your eyes are better and back in the swing of things.

[bbrock]

You guys are too kind. I've been cracking up about that Leslie Nielsen clip all day. So as not to leave anyone hanging, here's today's progress.

First I lowered the skirt on the passenger's side. It was a bitch getting that panel fit and clamped in place, but I persevered.



Then a couple hours of slow welding and it was in. Those zits in the middle were from filling in the holes left from the PO's body work.



Attempting the vanishing act

Now to get serious about grinding and see if I can make those welds disappear, but first, a word about safety.



We'll see if this keeps the shit out of my eyes. (IMG:style_emoticons/default/laugh.gif)

Grinding, grinding, and more grinding. Hours later, here we are.





Not invisible yet, but it's looking promising. There are a few pinholes to fill, but not too many. Hopefully with hammer and dolly and judicious use of the torch, I can make even these remaining googes disappear.





Now for the important stuff. Despite living within eyesight of a chain of beaver ponds, they have so far eluded my haphazard attempts to capture on camera, so no beaver shots today. (IMG:style_emoticons/default/av-943.gif) I've managed to snap shots of ripples on water just after they dove, and once got a fantastic shot of a beaver dam a split second after the beaver jumped off. So, the best I can do is a shot of one of the ponds.



And a muskrat swimming in it.

[andrewb]

no beaver shots today. (IMG:style_emoticons/default/av-943.gif)

(IMG:style_emoticons/default/biggrin.gif)

Ah well - there's always the sandbox.

On less important matters - what worries me about the welding/grinding thing - with my rubbish welding - is that I never know how much thickness of weld is left after I've ground the top off. Lots of practice required on bits of scrap I guess.
Keep going with the master class.

[Cairo94507]

Really nice work. (IMG:style_emoticons/default/beerchug.gif)
I really would like to see a beaver in the wild though..... but I appreciate the Muskrat.

[tygaboy]

"The ever elusive Beaver..." Reminds me of my college days.

Brent - Glad to hear your eyes are all good. Great work on those fenders! There's a part of me that almost wants to leave the weld lines visible and go with a Frankenstein theme... OK, maybe not.

Here's hoping that getting the fenders back on is one of those points in time when you can step back, feel it's all worth it, and appreciate just how far you've come. We sure do! (IMG:style_emoticons/default/beerchug.gif)

Again, great work and thanks for taking us along with you on your rebuild/rebirth journey. Keep it coming and best to you, my friend.

Chris

[mb911]

Looks great.. Someday I get that far grinding. Not at that stage yet..

[bbrock]

I like this crowd (IMG:style_emoticons/default/beerchug.gif) OT warning: Quick beaver diversion. Years ago when the beaver moved into the valley, the dam caused some minor road flooding during spring snow melt (which always happened but had become worse because of the dam). The then chairman of our road maintenance committee took it upon himself to whack a chunk out of the beaver dam with a backhoe in November just before winter freeze. That left the beaver lodge high and dry, which left the little buggers no choice but to burrow into the bank for shelter - in this case, the bank being under the road. Of course, the road collapsed. The next road meeting was all about what to do about "the beaver problem." Most were concerned for preserving the beaver, including the land owner where the pond was built. I stood up and explained why whacking the dam caused the worse problem of burrowing under the road, and offered up a device called the "Beaver Deceiver" as a solution that would let the beaver stay but also maintain the water level where we wanted it. I also rattled off some facts about how beaver are good for our wells and had built a very nice fire protection pond for free. Immediately people in the crowd started calling me "Beaver Man" to which I responded that I didn't think my wife would care for that nickname at all. Stone silence from the crowd. It's nice to be in a group that appreciates good beaver humor.

BTW, we never needed the Beaver Deceiver. By that time, the beavers were well on their way to building a chain of dams that slows down the snow melt and the road hasn't flooded in years because of them. As usual, beaver is the solution, not the problem.

Now back to the regularly scheduled program.

[mb911]

Lol that is hilarious.. Love it..

[bbrock]

On less important matters - what worries me about the welding/grinding thing - with my rubbish welding - is that I never know how much thickness of weld is left after I've ground the top off. Lots of practice required on bits of scrap I guess.
Keep going with the master class.

Okay, back OT. This has been my nemesis from the start. It took me awhile to figure out how much harder the weld filler was than the surrounding material, and that the weld usually winds up in a little valley thanks to the shrink. Ben's tutelage has been a huge help understanding this. Being able to scrutinize and copy the work of Ben, Stephen, Chris, and others has also been important. And then there is the work Kent is doing on Michael's car which I think is the gold standard and provides a, perhaps unattainable, goal to chase. And of course, lots of practice that you get plenty of working on a project like this.

The EZ Grind wire is interesting. It's a bit of a misnomer. It isn't that much easier to grind. But it does make a softer weld that grinds flatter to the parent material and also seems to lay a bit flatter in the joint. I was happy to see that once I ground down to the level of the parent material, much more of the weld had disapeared than with the regular wire. I've read claims that it also hammers out easier to let you restretch the shrink. Hopefully I'll find out today. In general, I think experience would trump any advantage of the softer wire, but for a bumbling idiot like me, I do think it has helped. I'm not claiming victory here yet, but I'm not defeated either!

BTW, it is amazing how much your mind wanders during the slow process of welding and grinding. It can almost be hallucinogenic. This weekend, Sebastian Cabot has popped into my head a few times. (IMG:style_emoticons/default/WTF.gif) Anyone remember him? Man, that dates back older than my car.

[altitude411]

This weekend, Sebastian Cabot has popped into my head a few times. (IMG:style_emoticons/default/WTF.gif) Anyone remember him? Man, that dates back older than my car.

(IMG:style_emoticons/default/blink.gif) The butler from family affair? Uh... startin to worry about you brother. It's that time of year here in Montana... cabin fever? or in your case garage fever?!? Go outside and take some deep breaths man, go for a long walk. your not getting your drinking water from the beaver pond are you? (IMG:style_emoticons/default/drunk.gif)
Seriously, your doing a really fantastic job. I should see you cruising your ride in Southwest Montana this summer. Thanks for the thread!

[bbrock]

This weekend, Sebastian Cabot has popped into my head a few times. (IMG:style_emoticons/default/WTF.gif) Anyone remember him? Man, that dates back older than my car.

(IMG:style_emoticons/default/blink.gif) The butler from family affair? Uh... startin to worry about you brother. It's that time of year here in Montana... cabin fever? or in your case garage fever?!? Go outside and take some deep breaths man, go for a long walk. your not getting your drinking water from the beaver pond are you? (IMG:style_emoticons/default/drunk.gif)

I know, right? (IMG:style_emoticons/default/screwy.gif) (IMG:style_emoticons/default/lol-2.gif) I wish I could blame it on flashbacks, but I think I was the only kid in school not dropping acid. And yes, we are talking about the one and only Mr. French. How random is that?

Now how about a mid-day update?

More on the driver's quarter - knowing when to quit?

Started this morning grinding the backsides of the welds in prep for plannishing with hammer and dolly. We never get to see the seamy underbelly of these patches, so here it is before grinding.



Notice the plug welds inside the door jamb? Those were a PITA but I did it that way to leave nice, factory looking spots on the front. I think they look good anyway. (IMG:style_emoticons/default/shades.gif) This pic also shows an example of what I meant a few posts back when I said I needed to be careful not to get excited and skip a step. The step I skipped was trimming the weld flange on the RD sail panel to match the factory quarter. Would have been easy before the part was welded in, not it will require some delicate surgery with the Dremel. (IMG:style_emoticons/default/blink.gif) I'll weld that seam between flanges after the surgery.



After grinding the backs of the welds and plannishing with hammer and dolly followed by just a touch of grinding with an 80 grit disc, I had the welds 98% invisible (sorry, forgot to snap a pic). Then I needed to fill pin holes. Zapped them with very quick bursts to keep the heat down.



But dang if those didn't create a few boogers that don't seem to want to hammer and grind out. When cold hammering didn't work, I tried heating them to dull cherry with a MAP torch and hammering. It sort of worked, but I was stretching metal in areas I didn't want in addition to the booger spots. I don't know if it is because the MAP flame heats a wider area compared with O/A, or maybe I don't know what I'm doing. Anyway, if you run your hand along the seam, it feels like it has been hit by a bunch of golf balls. I think the magic shrinking disc will pull a lot of that out, and more hammer and dolly work will probably finish it up, but there is a good chance I'll need a thin skim of filler over the joints. Still, I'm pretty happy with where I left it.



Now back to the shop to work on the passenger's side.