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> Irish Green '71 "resto"
jaredmcginness
post Mar 13 2020, 10:44 AM
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Something else I completed.

The frunk handle was not very functional, as you'd imagine with a hole like this.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117854.1.jpg)

I hammer formed this out of 22g. Weird place to weld, especially from the inside.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.2.jpg)

The sheath (?) for the pull handle had stubs of the bolts rusted to it. (IMG:style_emoticons/default/stromberg.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.3.jpg)

Ground off. Got one bolt stub out with vicegrips. The other was stuck, so I welded a nut to it and she turned right out.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.4.jpg)

Sand blasted, chased the threads and painted at work. Added new hardware.
Need to do the same for the handle

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.6.jpg)

I'm happy with the result, everything works now. Could be prettier, but its very hidden and will (hopefully) be covered in paint someday.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.7.jpg)
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jaredmcginness
post Mar 13 2020, 10:49 AM
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QUOTE(jagalyn @ Mar 13 2020, 08:20 AM) *

Wow... nice job so far. Keep it up!!!


Thank you! The responses I've received here and on the FB group have been very motivating. I figured I'd get a little bit more negative feedback - for not going by the book, and my 'DIY' with all of these harbor freight electric tools. (IMG:style_emoticons/default/smile.gif)
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bbrock
post Mar 13 2020, 11:56 AM
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Nice job on the handle patch (IMG:style_emoticons/default/smilie_pokal.gif) I think that was probably the hardest patch I had to do on my whole car. Like you said, not an easy place to weld... And I did mine while my floor was off which eased the pain at least a little.
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jaredmcginness
post Mar 13 2020, 12:14 PM
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QUOTE(bbrock @ Mar 13 2020, 01:56 PM) *

Nice job on the handle patch (IMG:style_emoticons/default/smilie_pokal.gif) I think that was probably the hardest patch I had to do on my whole car. Like you said, not an easy place to weld... And I did mine while my floor was off which eased the pain at least a little.


I did mine while my rib cage was leaning over the turnbuckle supports I made.

Thanks for the insight. By the way, I have your Rustoration thread bookmarked and refer to it before I fab any parts for this build/save! I really look up to your skills!
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Targa70
post Mar 13 2020, 12:26 PM
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Hey Jared, I'm not up in NOVA. I hang my hat in Williamsburg, a short drive from Va Beach and Norfolk. Being in Baltimore, you should make you way to Hershey. Should it occur...…...
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kroelofsen
post Mar 13 2020, 12:47 PM
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(IMG:style_emoticons/default/icon_bump.gif) Thats very nice work, great speed, will watch this with interest!
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jaredmcginness
post Mar 13 2020, 01:14 PM
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QUOTE(Targa70 @ Mar 13 2020, 02:26 PM) *

Hey Jared, I'm not up in NOVA. I hang my hat in Williamsburg, a short drive from Va Beach and Norfolk. Being in Baltimore, you should make you way to Hershey. Should it occur...…...


Nice! I went to VCU, so I am totally familiar with Williamsburg and it's ghost tours, haha! I went to Hershey last year and stocked up on a few parts for my would be 914, that i purchased a few months later.

QUOTE(kroelofsen @ Mar 13 2020, 02:47 PM) *

(IMG:style_emoticons/default/icon_bump.gif) Thats very nice work, great speed, will watch this with interest!

(IMG:style_emoticons/default/beerchug.gif)
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bkrantz
post Mar 13 2020, 09:19 PM
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Keep up the good work--and the optimism. That's the best way to deal with the endless 914 rust surprises.
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jaredmcginness
post Mar 14 2020, 03:14 PM
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QUOTE(bkrantz @ Mar 13 2020, 11:19 PM) *

Keep up the good work--and the optimism. That's the best way to deal with the endless 914 rust surprises.


Thank you! There's always more...

A little work today. Finishing up the floor seam in the engine bay. Chipped away at eh crusty sealer and ground until I saw fresh metal.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220463.1.jpg)

Barf.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220464.2.jpg)

After filling the flange tabs with some weld, grinding to some extent, tacking in the J pipe, top and bottom, and a shot of filler primer. Seam seal the gaps. A little less sealer than the factory used.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220464.3.jpg)

Fabbed up a quick and dirty pipe tab. Mine was toasted. Not too concerned with making this pretty - just needs to be strong. We'll never see it again. Right?
... Right?

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220464.4.jpg)

NICE to see a whole fresh inner long! Plenty of room to mount a floor:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220464.5.jpg)

Test fit of the tube. I cleaned it out the best I could and sprayed some primer on the outside - to make it look a little cleaner. I need to take it out and rivet or weld the C clamps in place. Ran outta gas!

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220464.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584220464.7.jpg)


Next on the list is the hell hole patches, then the sections at the rear of this long, clamshell, etc.
Awaiting a Sill and Jack triangle from Auto Atlanta.

(IMG:style_emoticons/default/beer3.gif)

Jared
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bbrock
post Mar 14 2020, 06:42 PM
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QUOTE(jaredmcginness @ Mar 14 2020, 02:14 PM) *

...We'll never see it again. Right?
... Right?


(IMG:style_emoticons/default/av-943.gif)
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Jamie
post Mar 14 2020, 07:29 PM
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QUOTE(jaredmcginness @ Mar 13 2020, 08:44 AM) *

Something else I completed.

The frunk handle was not very functional, as you'd imagine with a hole like this.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117854.1.jpg)

I hammer formed this out of 22g. Weird place to weld, especially from the inside.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.2.jpg)

The sheath (?) for the pull handle had stubs of the bolts rusted to it. (IMG:style_emoticons/default/stromberg.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.3.jpg)

Ground off. Got one bolt stub out with vicegrips. The other was stuck, so I welded a nut to it and she turned right out.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.4.jpg)

Sand blasted, chased the threads and painted at work. Added new hardware.
Need to do the same for the handle

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.6.jpg)

I'm happy with the result, everything works now. Could be prettier, but its very hidden and will (hopefully) be covered in paint someday.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584117855.7.jpg)

This seems to be a rather odd place to find such extensive rust? Well done repair job! (IMG:style_emoticons/default/welder.gif)
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mepstein
post Mar 14 2020, 08:00 PM
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Actually very common. Dirt, debris, mouse nests, etc. collect in the metal recess above the pull and holds in the moisture that seeps into the cowl.

I like how you lit up your garage. (IMG:style_emoticons/default/beerchug.gif)
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jaredmcginness
post Mar 15 2020, 06:18 PM
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QUOTE(mepstein @ Mar 14 2020, 10:00 PM) *

Actually very common. Dirt, debris, mouse nests, etc. collect in the metal recess above the pull and holds in the moisture that seeps into the cowl.

I like how you lit up your garage. (IMG:style_emoticons/default/beerchug.gif)


I'm sure pulling on the trunk handle adds just the right amount of pressure to pull the rusty steel right through as well.

I love the lights too! I added one hanging LED light from Walmart ($20) right above the engine bay. Very helpful.

I didn't get a ton done today, but I formed the piece above the rear long. Weird shape, still needs some work.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584317912.1.jpg)

Got a new Sill in from Auto Atlanta... Ordered Friday, arrived Sunday, cant beat it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584317912.2.jpg)

Cleaned up the rest of the Fuchs. I'll be doing the windows black, at some point. These are 14x5.5. Not a priority right now. But couldn't pass up the 2010 pricing on the set of 4.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584317912.3.jpg)

More test fitting. All three of these pieces are just clamped on. The clamshell will be under the rear piece before welding.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584318173.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584317912.4.jpg)

That's all for today. Thanks for anyone taking the time to read, and the support everyone's offered for this build.



P.S. Saying "build" is funny because I used to feel like putting BBS wheels, carpet and a H&R Cupkit on a Mk1 Rabbit was a build... How things have changed.
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horizontally-opposed
post Mar 15 2020, 06:34 PM
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Nice work—great to see someone in their 20s working on one of these (said as someone who is still working on one 30 years later...after starting in his teens... (IMG:style_emoticons/default/unsure.gif) ).

Those Fuchs were a great score—there's something about Fuchs without black backgrounds that works. They'd look great on your car, or you can generate additional project funds if you choose to resell that set as-is or properly repainted—as a 914-6 or 911E owner might want correct 14s. Meanwhile, 15x6s or 16x6s are where the good tires are at. What rear tire size are you on? They look beefy...
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jaredmcginness
post Mar 15 2020, 06:43 PM
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QUOTE(horizontally-opposed @ Mar 15 2020, 08:34 PM) *

Nice
Those Fuchs were a great score—there's something about Fuchs without black backgrounds that works. They'd look great on your car, or you can generate additional project funds if you choose to resell that set as-is or properly repainted—as a 914-6 or 911E owner might want correct 14s. Meanwhile, 15x6s or 16x6s are where the good tires are at. What rear tire size are you on? They look beefy...



Cheers! Not a bad tip. I think I would like 15x7 better, plenty of good tire options there. Wasn't trying to spend $1500+ right now on them though (IMG:style_emoticons/default/stick.gif)

The tires I have on these 15s are 195/65. Which is similar to what I'd run on the 14x5.5s I believe that is near stock size, but a hair shorter.
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jaredmcginness
post Mar 19 2020, 07:26 PM
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Hey all,

Hope everyone is doing OK with this Covid virus going around.

Here are a few updates from the past couple days. Firewall and the all mighty Hell Hole! I have been dreading this. You guys have conditioned me to hate it! Maybe it wont be so bad.... (IMG:style_emoticons/default/bs.gif)


Upper firewall rust is cut out.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667601.1.jpg)

Needs some more grinding. Right side looks decent.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667601.2.jpg)

Cleaned and primed. Nice.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.3.jpg)

This piece will serve as the wall and base to weld the lower Hell Hole patches in place.

This is what I was working with.... Yikes. Lets cut some more away.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.5.jpg)

Engine shelf removed. What was left of it anyways.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.6.jpg)

"Lets form some new metal." - Probably Bob Ross

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.7.jpg)

This is all 16 gauge. I bent the large shapes over my thigh, tack welded a few spots and hammer formed to get the fit better.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.8.jpg)

Grind for 1 hour. Prep with Metal Ready. This is how it looks after:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.9.jpg)

Self etch primer, and some filler primer on top. This is the result:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584667602.10.jpg)

I got a little "trigger happy" and sprayed some primer over all the fresh metal, not thinking that I still need to weld (and purchase) the engine shelf.
Regardless.... There have been prettier repairs, but its a good deal better than no metal there at all!

There is still a hole and thin area that needs patched (lower right of the last photo)

Question: Would you guys recommend a skim layer of body filler to smooth the gaps out on the hell hole? I have never used the stuff before, but I'd like to finish with a nice repair.

Overall the hell hole wasn't the worst thing ever. Would not look forward to doing it again though. I have about 6 hours straight into the repair. What a pain in the butt it is getting in and out of there. 28 is too young for my knees to feel like this.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584668054.1.jpg)


Thanks for reading!
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BeatNavy
post Mar 20 2020, 05:53 AM
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Wow, I just noticed this thread. You're doing great work, and your fabrication skills are excellent. I found that to be a HUGE asset (or in my case mostly, a liability) in terms of repair. Great welding can't makeup for crappy fab skills. The 16 ga will hold up nicely.

I suppose you could body filler on the hell hole there if you want it to look nicer, or, if later, you don't want it too obvious that it was repaired. But I don't think there's any "dishonor" in that repair, and in fact it is evidence of all the good work you did/are doing. OTOH, you're most interested in driving this thing (IMG:style_emoticons/default/driving.gif)

I spent last 25 years (or so) in NoVA, but just relocated mostly to Easton in the last year. My daughter went to VCU (probably a year or two behind you), and my wife is from Stoneleigh. The neighborhood and garage pics remind me a bit of her old house. (EDIT: Forgot to add that her dad let me store an old MGB in their garage that was similar, but smaller. I did an engine rebuild and some other work on it out of that garage while stationed at Aberdeen. Brings back memories.)

Lastly, I've got an Irish Green '72 (that became something like guards red at some point) and a '75 that I'm stalled on. It was in similar shape to yours, and I made a lot of progress and then hit a wall for a while. Last week with help I managed to get it to Easton, so maybe I can (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/welder.gif) again!

Good luck -- maybe we can catch up at some point.
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AZBanks
post Mar 20 2020, 06:12 PM
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Instead of body filler, I would spend a little more time with the grinder to smooth out the rough spots.
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bbrock
post Mar 20 2020, 06:41 PM
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Nice work! (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/smash.gif) It isn't a bad idea to put a skim of fiber reinforced filler over the welds anyway just to make sure all pinholes are filled and eliminate depressions that could trap moisture. @mb911 pointed me to Evercoat Fiber Tech and I really liked it.
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jaredmcginness
post Mar 20 2020, 07:19 PM
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QUOTE(BeatNavy @ Mar 20 2020, 07:53 AM) *

Wow, I just noticed this thread. You're doing great work, and your fabrication skills are excellent. I found that to be a HUGE asset (or in my case mostly, a liability) in terms of repair. Great welding can't makeup for crappy fab skills. The 16 ga will hold up nicely.

I suppose you could body filler on the hell hole there if you want it to look nicer, or, if later, you don't want it too obvious that it was repaired. But I don't think there's any "dishonor" in that repair, and in fact it is evidence of all the good work you did/are doing. OTOH, you're most interested in driving this thing (IMG:style_emoticons/default/driving.gif)

Good luck -- maybe we can catch up at some point.


So many similarities! Thank you for the kind words. We can certainly link up at some point. I know there's a good few shows and cruise ins over the bridge.

I bought filler today, and will experiment a bit this weekend. (IMG:style_emoticons/default/beer3.gif) I'll need some regardless on a few sections of the car. I might attempt some more sanding to smooth this area out for now.


QUOTE(AZBanks @ Mar 20 2020, 08:12 PM) *

Instead of body filler, I would spend a little more time with the grinder to smooth out the rough spots.


Good plan. I will get get back in there with a fresh set of eyes, when it comes time to mount the battery tray.


QUOTE(bbrock @ Mar 20 2020, 08:41 PM) *

Nice work! (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/smash.gif) It isn't a bad idea to put a skim of fiber reinforced filler over the welds anyway just to make sure all pinholes are filled and eliminate depressions that could trap moisture. @mb911 pointed me to Evercoat Fiber Tech and I really liked it.


I appreciate the link and plan to pick some up. There's plenty of other spots on this '71 that needs attention.



Thanks for the recommendations, guys. After looking at the hell hole repair a new day, without dust in my eyes, I could do a little better - if I rush just a bit less.
(IMG:style_emoticons/default/welder.gif) Happy Friday.
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