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> Irish Green '71 "resto"
bbrock
post Mar 20 2020, 07:28 PM
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Just to be clear. I agree with Rob there is no shame at all in the repair you have done. (IMG:style_emoticons/default/smilie_pokal.gif) When you go back to grinding, just make sure you are grinding only the weld and not the surrounding parent material. You can grind just about any weld to invisibly smooth if you don't mind thinning the metal to become foil. Obviously not good. Better to live with a bit of weld shrinkage and have it strong than pretty and weak. Finding that balance was one of the trickier parts for me.
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jaredmcginness
post Mar 20 2020, 07:37 PM
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Posted and forgot to add the work I accomplished today.

I fit these two panels today. I had to modify them a hair, but over all they fit nice.
I traced these shapes off of the pieces I cut out. Pretty cut and dry - or... weld.

In progress. Ignore the bacon welds.


(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584754673.1.jpg)

A lot of the same sounds echoing from the garage this week... I'm glad I bought ear muffs.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584754673.2.jpg)

Mimicked the spot welds on the bottom. Light coat of SE primer.

I will need to fill in another spot or two, and figure out the transition to the outer clamshell.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584754673.3.jpg)

I have to say I am really proud of how this looks... If you scroll back to the first photos, there was not a lot of meat here!

Factory shape looks pretty close. As a reminder, I am not using the factory jack pyramid (I will be using Brads Meyer's stiffening kit) so this section was left flat.

Dual wall 16g, pain in the D to form.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584754673.4.jpg)

DANG! Nice. Fits up pretty well with the outer clamshell. took a mallet hit or two.
I drilled these holes for the spot welds last night, made a few trims - But it sandwiches nicely in between the dual wall.

Lastly. The girl and I started taping off my Fuchs - for the semi gloss windows. Just like the car... time consuming but worth it for the outcome.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584754673.5.jpg)

P.S. Here is my cat, Oatmeal, in case anyone needed to see this today.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584754673.6.jpg)
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jaredmcginness
post Mar 20 2020, 07:45 PM
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QUOTE(bbrock @ Mar 20 2020, 09:28 PM) *

Just to be clear. I agree with Rob there is no shame at all in the repair you have done. (IMG:style_emoticons/default/smilie_pokal.gif) When you go back to grinding, just make sure you are grinding only the weld and not the surrounding parent material. You can grind just about any weld to invisibly smooth if you don't mind thinning the metal to become foil. Obviously not good. Better to live with a bit of weld shrinkage and have it strong than pretty and weak. Finding that balance was one of the trickier parts for me.


Much appreciated. I dealt with that on the inside of the long. Grind long enough and you can see the weld curling away, while a new hole gets bigger. (IMG:style_emoticons/default/icon8.gif) Certainly has been tough finding the balance. Thanks B!
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jaredmcginness
post Mar 22 2020, 10:54 AM
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Weekend update:

Part 1:


Decided to go at the hole on the Lower front PS fender. This will be my first time ever using body filler. I have nothing but time on my hands today. So I am ready to sand. Nice little spot to try this out.

Here's the play by play....Cut out:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896077.1.jpg)

Trace the shape of the piece you need. This time I used a Yuengling box for a template. The cardboard you use all depends on your beer preference that day. (IMG:style_emoticons/default/beer3.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896077.2.jpg)

Looks good to me.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896077.3.jpg)

Weld, grind, "smooth".

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896078.4.jpg)

Body filler:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896078.5.jpg)

Then you realize you still have the negative stripe vinyl beneath that tape. Grind that off, rather unevenly. Apply another skim of body filler.

Sand for like 40 minutes.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896078.6.jpg)

Voila! I am pretty proud of this! Not horrible for a first time at "body work". Certainly time consuming...

I see a couple dings left. Honestly, I think that's an OK thing - or this fender might stand out like a sore thumb, as compared to the rest of the car. As of right now I am not going for a perfect resto. This will be as original paint as possible.


Gives me a bit of hope for down the road when I take it a step further, with a respray and such.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896078.7.jpg)



Part 2:

I spot welded the outer clamshell in place. This feels great and is so satisfying to see. Weld one, move a foot over, weld another, let cool, repeat.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896078.8.jpg)

Still have a bit of grinding and smoothing to do. A theme for this project...

Now for the big test. Does this door still fit?

BOOM!

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584896078.9.jpg)

Door gap looks pretty damn good and she closes like a German bank vault! Lots accomplished in the last few days, and a lot of stuff checked off the whitebaord list.

Whats next:
Door jamb, and body section.
Door sill
Drop floors
Stiffening kit.
Battery box, etc.

Not really in a particular order.

Thanks for reading and wash your hands.
Jared





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bbrock
post Mar 22 2020, 01:09 PM
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Pure inspiration!!! I love watching this... and look at those gaps. (IMG:style_emoticons/default/cheer.gif)
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Chief
post Mar 22 2020, 01:15 PM
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Great work! And loving Oatmeal!!
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jaredmcginness
post Mar 23 2020, 10:03 AM
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Thanks guys!

Sunday project. My girlfriend and I spent the morning finishing up taping off my fuchs wheels for restoration. Took a while!

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584979435.1.jpg)

Scuff, Prime 2 coats, Semi Gloss black 3 coats, Matte clear over top.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584979435.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584979435.3.jpg)

1 bolt holding it on for the photo (still 4 lug) Just had to see.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584979436.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1584979436.5.jpg)

I am so happy about these.

They are going to look great on here one day. Not a bad tidy up for a $700 set of fuchs!
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BeatNavy
post Mar 23 2020, 10:41 AM
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Those Fuchs look great. What did you do to the petals? Just matte clear?
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jaredmcginness
post Mar 23 2020, 10:53 AM
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QUOTE(BeatNavy @ Mar 23 2020, 12:41 PM) *

Those Fuchs look great. What did you do to the petals? Just matte clear?


Thanks, they are the raw finish - I believe its factory anodize. I just cleaned them up and cleared right over them. We'll see how it holds up?
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PCH
post Mar 23 2020, 01:17 PM
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Great work Jared! Love watching your car progress and glad to see that spare metal sitting in the garage being put to good use.
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Cairo94507
post Mar 23 2020, 01:44 PM
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You are doing a nice job and that 914 is going to be on the road soon enough. (IMG:style_emoticons/default/beerchug.gif)
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jaredmcginness
post Mar 24 2020, 06:53 PM
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Tuesday update.

I'm ready to weld the sill back in - so I need to get that lower jamb and body section figured out.

I sandblasted my cut-out section, found a ton of rust, body filler (like .25") rivets, and old brazing. Really just a bad repair at some point in the cars life.

Best to just replace the whole section, right?
I made a few threads and posts in that last month+ asking if anyone has a car they are cutting up, but no luck.

I will try and make my own, before I drop $90-$120 on a jamb section.
I got started on this today. Here's the old section that I do not want to reuse.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097628.1.jpg)

Rear. Its like 5 pieces stuck together.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.2.jpg)

I will try to make my own, and see how it turns out. Cave man scribbles...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.3.jpg)

Pain in the butt to bend with my little HF Brake. (IMG:style_emoticons/default/smash.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.4.jpg)

On the right track in a bit under an hour. Jamb will be a different story.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.6.jpg)

Definitely close! With some tweaking, I think this could be a good part.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.7.jpg)



Other bits:

Got the passenger side floor out.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097629.8.jpg)

Received this beautiful part from Auto Atlanta.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097630.9.jpg)

Had a celebratory brew on the defeated carcass of a floor.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097630.10.jpg)

And a final pic, because the light was nice.
Also serves as a summary of some of this weeks accomplishments, so far.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585097630.11.jpg) (IMG:style_emoticons/default/type.gif)
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bkrantz
post Mar 24 2020, 08:02 PM
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Nice progress. And that jamb section could have a place in the 914 PO botched repair hall of fame.
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bbrock
post Mar 24 2020, 09:20 PM
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Of all the horrors I witnessed on my car, I don't think any were as nasty as that jamb. It's one thing when Mother Nature Fs up the car, but... Are you sure that's even filler? Looks like somebody poured concrete. (IMG:style_emoticons/default/lol-2.gif) You patch is pure artistry. That took guts to even attempt. (IMG:style_emoticons/default/pray.gif)
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jaredmcginness
post Mar 27 2020, 06:23 AM
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Edit: Seriously thanks for the kind words guys, it gives me a ton of motivation.


Hey guys, decided to try and tackle this lower jamb.

WORK IN PROGRESS. Man this is a tough piece. Check out the pics for where I am at so far.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311800.1.jpg)

I achieved the rolled shape by clamping my new piece to the original lower jamb, pressing with my thumbs, clamp again closer, press, then hammer form.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.2.jpg)

Outer flange is one piece, and the rolled flat is another.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.3.jpg)

Fit is close... getting there. (IMG:style_emoticons/default/stirthepot.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.4.jpg)

Cleaned up and sandblasted a little more. Now I can see where else I need to spot weld to finish filling this piece in.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.6.jpg)

Shape is there, its a clean fit and the door closes nicely over it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585311801.8.jpg)

3 hours into this pieces so far. Still cheaper than buying the whole jamb for $129. Depending on what I value my hourly work at... minimum wage? (IMG:style_emoticons/default/av-943.gif)

I have not figured out how to blend those tabs at the end into the sill, I will check out a few more photos of others cars.
Little more welding, shaping, drill the spot weld holes... I might be in business. At least its a more honest shot at a repair than what was on there.
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JOEPROPER
post Mar 27 2020, 06:45 AM
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A lot of patience and talent. I wish I had nerve to try this when i was your age. This has turned out to be and inspirational thread. Keep up the good work!! I'm sure many of us are following your progress. (IMG:style_emoticons/default/popcorn[1].gif) (IMG:style_emoticons/default/smilie_pokal.gif)
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DRPHIL914
post Mar 27 2020, 07:15 AM
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thanks for keeping us updated on your project, its great to follow along and see you tackle this extensive of a repair. A car like that would have been scrapped up until a few years ago, by most anyway, I know there are some hear that have rescued some this bad or worse that probably were not "worth it" at the time. AND there are fewer it seems your age willing to develop the skill set to do it. I know my son would not, but my daughter and son-in-law to be want to start one too, so I know there is hope!! anyway just wanted to give you props for saving it. you will enjoy the fruit of your labor soon! I think you could have a future in this if you wanted to, these cars and the other Porsche's are now worth what you put into it so I am sure you can gain back more that just that "minimum wage" you were joking about!!

Phil
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StarBear
post Mar 27 2020, 08:24 AM
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QUOTE(bkrantz @ Mar 24 2020, 10:02 PM) *

Nice progress. And that jamb section could have a place in the 914 PO botched repair hall of fame.

(IMG:style_emoticons/default/agree.gif)
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AZBanks
post Mar 27 2020, 11:30 AM
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Really enjoying seeing your progress on this project.
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pete-stevers
post Mar 27 2020, 12:20 PM
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Great thread! Keep up the great work!!
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