914 2.0 > 3.0 GT Conversion, On the road! Options

[PlantMan]

So with almost everything else completed and stuffed into every nook and cranny in the house it was time to get back to bodywork.

About the only part really left unexplored was the underneath of the floor. The top was almost perfect so I was hoping the underside was in a similar condition.

Looks promising!
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1506874043.1.jpg)

The brown parts are just underseal residue. The floor is again almost perfect - 99% original paint and just a tiny bit of very light surface rust.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1506874043.2.jpg)

Stephen,
I have a similar problem on my car....under coating everywhere. What are you using for removal.....something mechanical or chemical?

Thx,

[defianty]

Stephen,
I have a similar problem on my car....under coating everywhere. What are you using for removal.....something mechanical or chemical?

Thx,

The underseal on my car was quite think and had hardened. I used a selection of paint scrapers but I think the best was a thinner flexible putty knife type just like this.

[PlantMan]

Wow!
You are very diligent with that putty knife! Nice job!
I found that an old wood working chisel works nicely too. I like the extra weight when scraping through the material. I used this approach when removing the tar from the floor boards.

[defianty]

I never finished off my GT style front grill because at the time I wasn't quite sure how to do it. I'm currently waiting on some panels from Restoration Design so I can get the back of the car back together so in the meantime...

I decided to make up another frame to sandwich the grill in place.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221065.1.jpg)

The three pieces together.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221066.2.jpg)

Now that was complete I could set about fitting the front valance.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221066.3.jpg)

The tabs on the valance were moulded in the wrong position so I cut them off and made some brackets. These would also give me some play to get everything lined up well.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221066.4.jpg)

Old bumper used to make sure everything fitted together and lined up.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221067.5.jpg)

With that complete it was time to paint the grill and put it in a safe place until it was time to assemble the car.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221067.6.jpg)

[Lucky9146]

I never finished off my GT style front grill because at the time I wasn't quite sure how to do it. I'm currently waiting on some panels from Restoration Design so I can get the back of the car back together so in the meantime...


(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507221067.6.jpg)

Nice Looking Grill (IMG:style_emoticons/default/first.gif)
(IMG:style_emoticons/default/white914.jpg)

[defianty]

Since the last update I've been discovering more rot. I knew there was a bit but as usual it was a little worse than I imagined. Isn't it always. Most of it had been there a long while and had been disguised with filler and painted over. This time I was doing it properly.

First was the front trunk seal channel another notorious area.

This is the bottom left corner above the headlight.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739911.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739912.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739912.3.jpg)

Looks a little odd finished but it matches the other side perfectly.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739912.4.jpg)

[defianty]

This was totally hidden under high build and paint. Almost the entire length was heavily pitted.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739934.1.jpg)

Just surface rust fortunately - cleaned up and treated before being recovered.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739935.2.jpg)

New channel fabricated and tacked in.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739935.3.jpg)

Finished - nice new metal.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739936.4.jpg)

[defianty]

Next job was on the the windscreen aperture. I wasn't looking forward to this one and I was going to need to buy a Shrinker/Stretcher. As per usual spent a bit of time researching how I was going to make this part. When the Shrinker/Stretcher arrived I couldn't wait to have a go. Initially I used it to put a slight bend in the long trunk channel above and in seconds I had the perfect bend.

So now to make a replacement part for this. You can't beat jumping in at the deep end (IMG:style_emoticons/default/laugh.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739959.1.jpg)

This was my first attempt and I was rather pleased with the result.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739960.2.jpg)

Nice and clean underneath fortunately.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739960.3.jpg)

Ready to stick in on (IMG:style_emoticons/default/laugh.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739961.4.jpg)

Getting there.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739961.5.jpg)

Finished :cheers:
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1507739961.6.jpg)

Really happy with how that turned out. The other corner needs some attention so that will receive the same treatment.

I'm off the see the media blasters and painter tomorrow to discuss my requirements and dates. I'm hoping to have the car painted in the beginning of the new year. Still lots to do though before that happens.

[Lucky9146]

Since the last update I've been discovering more rot. I knew there was a bit but as usual it was a little worse than I imagined. Isn't it always. Most of it had been there a long while and had been disguised with filler and painted over. This time I was doing it properly.

First was the front trunk seal channel another notorious area.

This is the bottom left corner above the headlight.

Looks a little odd finished but it matches the other side perfectly.

Sorry to hear about "more rot" but it sure looks like you know what you are doing. (IMG:style_emoticons/default/pray.gif) Keep up the good work it will be worth it.
(IMG:style_emoticons/default/white914.jpg)

[defianty]

Time for another update. Nothing very interesting though I'm afraid just more body repairs.

I wasn't very happy with the aperture repair, it was close but not perfect and after a few days of it bugging me I had to revisit it. The main problem was a narrowing of the aperture at the bottom of the A post. Once the screen was fitted it would probably have been fine but I knew if I could modify it to be just 2mm deeper it would be spot on. I didn't capture all of the work but below shows the patch that straightened everything out. With that done I could sleep again (IMG:style_emoticons/default/laugh.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861060.1.jpg)

During the aperture repair I only removed enough paint to get the job done. Having now needing to make repairs to the scuttle panel I went ahead and removed the rest of the paint. It did take long to find a big dent in the scuttle stuffed with filler. The metal was stretched and there was no way I was going to be able to flatten it out so I decided to cut out a large piece and drop in some fresh metal.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861065.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861066.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861066.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861066.5.jpg)

[defianty]

The last piece of the bonnet gutter to repair was again another time consuming job. I've spent days now just making small repair pieces (IMG:style_emoticons/default/laugh.gif)

Trying to cut out the rot - Lots of seam sealer on the underside.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861090.1.jpg)

All the offending metal cut out and a coat of weld-thru primer applied.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861091.2.jpg)

One of the two repair pieces in place before welding.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861091.3.jpg)

Piece one finished and more primer applied
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861091.4.jpg)

Last piece in and almost complete.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861092.5.jpg)

[defianty]

With the oil cooler shroud taking place of the spare wheel well I sourced a collapsible spare tyre and set about mounting it upright.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861529.1.jpg)

After a few cardboard prototypes I made this bracket to attach the spare.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861530.2.jpg)

Welded in place it uses the original spare wheel hold down to attach the wheel and leave about half an inch gap under the tyre.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861530.3.jpg)

Spare in place.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861531.4.jpg)

If I was going for more of a race style GT replica I'd have called this complete, but I had in my mind to utilise the original floor board to make two storage compartments. As well as the oil cooler the fuel pump is also going there so I like the idea of a cleaner storage area above. I'd seen this done before on a GT replica at the Nurburgring, just my approach would be a bit different.

Again after a few ideas I settled with a support bar for the top of the oil cooler shroud and a couple of brackets.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861531.5.jpg)

Brackets welded in. The hole in the top are filled with grommets, giving the board something to rest on.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861531.6.jpg)

Oil Shroud support bar painted and in place. The two open grommets allow for pegs on the base of the board to slot in place and stop it from moving about.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861532.7.jpg)

Floor board in place. Eventually this will be recovered in Perlon as per the original.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861532.8.jpg)

With the oil cooler shroud in place the wiring loom will now run across the top of the shroud. The tyre board is short enough not to interfere with it but I wanted a solution to tie the loom in place. Copying the style of all of the wiring loom metal tabs welded on the body I made these to both hold the top of the shroud in place and bend around around loom.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861532.9.jpg)

[defianty]

With that done it was time to install another flare, this time however I took a slightly different approach.

Here's the flare attached to the car with screws, I'd previously trimmed off most of the original arch on the wing. This time instead of drawing around it and trimming the original wing I was going to cut this wing with the flare in place leaving tabs where the screws were.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861547.1.jpg)

You can just about see where I've left a piece of metal near the screw.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861547.2.jpg)

All cut show a few of the tabs.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861548.3.jpg)

I could now place a few spot welds here and there and cut the tabs off when I got to that part.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861548.4.jpg)


The resulting fit was much better than the other side and I'll be using this approach on the rears.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861549.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861549.6.jpg)

With that flare attached and finished the front of the car was done. With that I put the front bumper and valance back on to test fit again and I also cut the front bumper for more airflow.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861549.7.jpg)

Now I need to find someone to re chrome the front bumper and potentially weld up the holes in it too.

I've now started on the rear again now and will post another update in a few days when that starts to take shape.

[Lucky9146]

The last piece of the bonnet gutter to repair was again another time consuming job. I've spent days now just making small repair pieces (IMG:style_emoticons/default/laugh.gif)

Last piece in and almost complete.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.org-6621-1510861092.5.jpg)

Well I'm certainly impressed! (IMG:style_emoticons/default/pray.gif) Looks great! (IMG:style_emoticons/default/first.gif)
I did some of this stuff on my 356 many rears ago so I have an appreciation for this work and the time it takes.
(IMG:style_emoticons/default/white914.jpg)

[defianty]

Well I'm certainly impressed! (IMG:style_emoticons/default/pray.gif) Looks great! (IMG:style_emoticons/default/first.gif)
I did some of this stuff on my 356 many rears ago so I have an appreciation for this work and the time it takes.
(IMG:style_emoticons/default/white914.jpg)

Thanks Jim.

[defianty]

I just want to mention again that I cross post this thread on another forum in the UK (DDK). Most of the members there are 911 owners and for them I tend to state the obvious that almost everyone here knows.

[JmuRiz]

I really like the cooler/spare/frunk-board! Nicely executed

[mepstein]

I really like what you did in the trunk. Great build.

[burton73]

Very nice job. It will be a nice one fixed right.

Thanks for taking the time to document your GT build.

Bob B

[defianty]

Thanks all, I appreciate the comments. This really is turning into a labour of love now but I'm still enjoying every moment. Racing against time now as I'm hoping to get to paint very early in the new year.

The list is getting shorter finally and I seem to actually be crossing more off of it than adding!