Irish Green '71 "Resto", Update: the 914 has been sold! Options

[jaredmcginness]

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)

There's been a few curse words and tools thrown, but we've made it this far. The way I see it, this is the only thing holding me back from Aircooled Porsche cruising to Cars and Coffee, so lets knock it out.

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

Thank you Phil, what a kind response. Like your daughter, there are those of us that are out there. I have my iron in a lot of fires.

I would love to do a 912 after this. Not sick of it yet..

Really enjoying seeing your progress on this project.

Great thread! Keep up the great work!!
(IMG:style_emoticons/default/beerchug.gif)

Thanks! More to come shortly.

[jaredmcginness]

Happy Saturday,

Lets finish up this passenger side!

Weld on sill and finish lower jamb. What will that take 30 mins?




.... 6 hours later....

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451292.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451292.2.jpg)

I ran into a fork in the road here.

As I ground away the paint to weld in the new body section,
I found about 3/16" of body filler. This goes all the way up to the door handle, following the shoddy jamb repair from earlier. What to do?

Since I do not plan on painting the car right now, (or dig this much deeper!)
I decided to place the remade body panel in, smooth what I can, and use filler for the rest. Not what I was expecting to see or do... Down the road, I would like to replace the entire passenger rear, sail, fender, etc. So I will clean it up and move on until that day.

Sorry to let down any folks, I know this is not doing it "right" and just hiding the inevitable.

Here's the filler.... Lets carry on.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451292.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.4.jpg)

Life goes on, lets weld it up.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.5.jpg)

Grind.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.6.jpg)

Sand a ton, smooth, sand, prime. Still need to sand.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.9.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.10.jpg)

2 hours later:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.11.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451293.12.jpg)

Full shot:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451294.13.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451294.14.jpg)

Little bit to sand left, just eager to make another post. I feel really great about these steps. Passenger side is effectively... DONE!

Serious progress for 5 weeks! I am excited to open the garage door tomorrow and see it with fresh light.


(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585451501.1.jpg)

Whats next:

-Weld in battery tray/support and engine shelf.
-remove drivers floor.
-914LTD reinforcements.
-rebuild flanges around drivers firewall and long.
-replace floor.

Until tomorrow!

Jared

[JOEPROPER]

(IMG:style_emoticons/default/smilie_pokal.gif)

[bbrock]

Sorry to let down any folks, I know this is not doing it "right" and just hiding the inevitable.

To the contrary! You are doing what is needed to save your car the RIGHT way but still get it back on the road quickly. Hold your head high and know that you've proven you'll be ready with your skills when you decide to tackle the rest. I love watching this thread. (IMG:style_emoticons/default/cheer.gif)

[StarBear]

A champion! Loving this thread - better than a Motor Trend TV episode, with no commercials, too! (IMG:style_emoticons/default/first.gif)

[JOEPROPER]

Sorry to let down any folks, I know this is not doing it "right" and just hiding the inevitable.

To the contrary! You are doing what is needed to save your car the RIGHT way but still get it back on the road quickly. Hold your head high and know that you've proven you'll be ready with your skills when you decide to tackle the rest. I love watching this thread. (IMG:style_emoticons/default/cheer.gif)

(IMG:style_emoticons/default/agree.gif) love it!

[jaredmcginness]

To the contrary! You are doing what is needed to save your car the RIGHT way but still get it back on the road quickly. Hold your head high and know that you've proven you'll be ready with your skills when you decide to tackle the rest. I love watching this thread. (IMG:style_emoticons/default/cheer.gif)

True words Brent! Maybe when I add a tough guy motor and GT flares, that would be a good time to tackle that spot. (IMG:style_emoticons/default/beerchug.gif)

A champion! Loving this thread - better than a Motor Trend TV episode, with no commercials, too! (IMG:style_emoticons/default/first.gif)

Haha! I love that! I do have a few product placements, but I'll keep that ads to a minimum.

You guys are great!


----------

Not a ton of fun things accomplished today, but I got some hours in and knocked the floors out! Had to do the labor work, one day or the next... lets get it over with.
There are still some tabs left, where the rotabit didn't get through all the way. But I am tired of laying on my back.... next time, no excuse not to build a rotisserie.

So the floors were so crunchy, I said F it, cut the main square sections out, this way I can sit up (as much as I can) while I work on the spot weld tabs.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585527508.1.jpg)

You could say I had my work........ cut out.... for me.... Get it...? Nevermind

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585527508.2.jpg)

Chop.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585527508.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585527508.4.jpg)



Still need to get the middle section out.
The area near the pedal cluster is in nice shape. So I left that in. I'll stitch in around there, to the new pan.

So the plan otherwise:

-Get that middle section fully out (Some spot welds still hanging on)
-Rebuild the drivers inner long (bottom radius)
-Replace fuel lines - should be here this week.
-Weld in floors.
-Also.. I'm going to need to rebuild that E-brake area, as well as the cable guide sheet metal... Another day, another post.


Cheeeeers,
Jared

[bkrantz]

You are a better (tougher) man than me, getting all that done without a rotisserie. I have certainly gotten worn out at times on my project, but the option to turn the car sideways and upside-down has eliminated most of the grief.

And I feel your pain from the bondo surprise. I had a couple of those, and a few choice words.

[BeatNavy]

You're rocking and rolling! I think it took me like 2 weeks to get the floor pan off with all those spot welds...and I had it on a rotisserie!

Don't beat yourself up about doing it "right" as Brent says. When perfect becomes the enemy of good these projects can get stalled (ask me how I know), or worse, and it sounds like you actually want to be driving this year (IMG:style_emoticons/default/driving.gif)

Glad your pedal cluster area was in good shape. Below is a pic of mine. It was one of the ugliest "repairs" on my project car, and it took a long time to fab up something to go there. Not sure where you learned to fab and weld, but you've got a talent for it.

Sketchy!


and underneath


Keep going, Jared!

[jaredmcginness]

You are a better (tougher) man than me, getting all that done without a rotisserie. I have certainly gotten worn out at times on my project, but the option to turn the car sideways and upside-down has eliminated most of the grief.

And I feel your pain from the bondo surprise. I had a couple of those, and a few choice words.

I'm sure most of these cars have them, after 50 years of shade tree repairs. I'll be willing to bet - even after having most of the car stripped down, there are still a few surprises.

You're rocking and rolling! I think it took me like 2 weeks to get the floor pan off with all those spot welds...and I had it on a rotisserie!

Don't beat yourself up about doing it "right" as Brent says. When perfect becomes the enemy of good these projects can get stalled (ask me how I know), or worse, and it sounds like you actually want to be driving this year (IMG:style_emoticons/default/driving.gif)

Glad your pedal cluster area was in good shape. Below is a pic of mine. It was one of the ugliest "repairs" on my project car, and it took a long time to fab up something to go there. Not sure where you learned to fab and weld, but you've got a talent for it.


Keep going, Jared!

I definitely just want to get the floors out and over with, so I am trying to bang it out as quick as I can.

I shouldn't be so hard on myself I suppose. I love that quote. One of my personal faves now is, "If the minimum isn't good enough, it wouldn't be called the minimum." (IMG:style_emoticons/default/av-943.gif)

Yikes, I am a bit scared of doing that pedal cluster section, but I might bend up something at work to fill in the end of the support that I cut off.

On that ticket, I learned how to mig weld in college, and I tig welded for my job (about 5 years ago) at a well known VW/Audi performance parts company. I haven't really welded since then so I am a little rusty. (and to be frank, not that concerned with pretty welds, because they are getting ground anyways.)

Now, I work at a precision prototype sheet metal shop, I use lasers, 4-7 ton brakes, etc. Here's an example of some test or scrap pieces I made at work.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585571988.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585571989.2.jpg)



Its funny comparing the accuracy I need at work... to me just smashing sharpie lines with a mallet over a 2x4 at home. I call that the minimum.

[bbrock]

Add me to those amazed at your ability to tackle the floor without a rotisserie. When you get that center section out, take a little time to check and reinforce the attachments for the clutch cable tube. It's just a minor little task when the tunnel is open, but a major PITA if it breaks after the tunnel is closed back up.

[BeatNavy]

One of my personal faves is, "If the minimum isn't good enough, it wouldn't be called the minimum." (IMG:style_emoticons/default/av-943.gif)

One of my favorites too. My Army buddy used to say it all the time, and that's why it's in my signature below (IMG:style_emoticons/default/smile.gif)

On that ticket, I learned how to mig weld in college, and I tig welded for my job (about 5 years ago) at a well known VW/Audi performance parts company. I haven't really welded since then so I am a little rusty. (and to be frank, not that concerned with pretty welds, because they are getting ground anyways.)

Now, I work at a precision prototype sheet metal shop, I use lasers, 4-7 ton brakes, etc. Here's an example of some test or scrap pieces I made at work.

Ok, that makes sense. You've got some learnin' in ya! (IMG:style_emoticons/default/biggrin.gif)

[jaredmcginness]

Took Monday night off to hang out and not do any work.

Small update last night:

Got the center floor out - oh how i hate laying on my back under this!
Got her out in one piece, rust, acorns and leaf collection in tact.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585751372.1.jpg)

I believe this is the commonly broken, brazed area, looks to be in good shape, any confirmaiton?

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585751372.2.jpg)

Fuel lines are totally nasty... Must have been sitting for a long time with gas.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585751373.3.jpg)

I am very glad I bought these from Pelican parts! Should be an easy install now.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585751373.4.jpg)

Lastly, I took a few measurements of the pieces I will need to rebuild the inner long radius and lower firewall.
I took a sheet of 18g to work, sheared and bent up some pieces to make my life juuuust a little bit easier at home.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585751373.5.jpg)


So I'll rebuild this section, I might lap weld the firewall, maybe put a coating of POR15 between the two firewall sections, install the fuel lines,
line the floor up and start getting it attached.

Exciting stuff. Glad to have a creeper.

[JOEPROPER]

Man, you're a handy guy to have around. (IMG:style_emoticons/default/popcorn[1].gif)

[BeatNavy]

I believe this is the commonly broken, brazed area, looks to be in good shape, any confirmaiton?

Yes, and it looks in surprisingly good shape.

I wish I had the machining tools and expertise to use them available!

[bkrantz]

Got the center floor out - oh how i hate laying on my back under this!
Got her out in one piece, rust, acorns and leaf collection in tact.

Where's the required mouse nest?

[jaredmcginness]

Where's the required mouse nest?

There were two under the gas tank! I had a nice afternoon with the vacuum and a bottle of bleach. (IMG:style_emoticons/default/smoke.gif)

[bbrock]

I believe this is the commonly broken, brazed area, looks to be in good shape, any confirmaiton?

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1585751372.2.jpg)

That's one of them. The other place they break is where they go through the firewall. I would reinforce them while you have it open regardless of their condition. Mine were perfectly attached too but after doing some cutting and patchwork on the front end of the tunnel, my front one had broken loose from the vibration. Made me realize how fragile those brazed joints are. I welded the front in and welded a little reinforcement loop at the rear firewall. Just a little extra security to hopefully not have to cut open my tunnel later for repair.

[jaredmcginness]

Hey guys,

Here is today's diary entry. (IMG:style_emoticons/default/smash.gif)

Spent the last two afternoons in the garage rebuilding the firewall flanges.

I lap welded the fire walls and butt welded the driver's long.
Here are some photos. Ran out of 1/2" sanding belts, so all of the corners of the inner firewall still need sanded. Ignore these for now.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1586039747.1.jpg)

Ugly, but honest.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1586039747.2.jpg)

Ahh. This long is a pain in my ass. This metal is so easy to burn through. I'm mostly done, still have a few spots to fill in. I should have extended these, top and bottom to make it a lap weld.

It will be covered with carpet anyways right? I hate to make excuses, but that's the fact of the matter. Cant beat myself up over stuff I am still learning/perfecting.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1586039747.3.jpg)

As recommended from my internet friends above, I made a little bracket and tacked the clutch tube in place. Hopefully this will help disperse the load, and neither of these will break. I brought the heat down a lot on this, does not seem like a good tube to blow a hole into!

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1586039748.4.jpg)

I found this stuck under the dash carpet. I assume this is the shift knob badge.
Also a metaphor for the condition of this vehicle. (IMG:style_emoticons/default/dry.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1586039748.5.jpg)

A photo I grabbed. Cluttered, tired but a bit hopeful.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i.imgur.com-23209-1586039748.6.jpg)


Certainly leaving the garage today frustrated. Welding on your back SUCKS. It is so easy to blow through your new metal, but you cant really tell you are.... because you neck is getting covered in sparks and glowing slugs.

If anyone reading this is on the fence... build the rotisserie!

All that being said - another good few hours out there and the floors should be ready to go in.

Thanks for reading! (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif)

[BeatNavy]

Ugly, but honest.

(IMG:style_emoticons/default/smile.gif) Honest is better than pretty. Good thing you reinforced that clutch cable. And yes, welding on your back sucks. I once basically set my crotch on fire (I was wearing overalls) welding underneath the car to anchor the clutch tube at the firewall.

Thanks for reading! (IMG:style_emoticons/default/beer3.gif) (IMG:style_emoticons/default/beer3.gif)

(IMG:style_emoticons/default/beerchug.gif)