Rust repair before paint, Passenger side longitudinal - 73 narrow body/4, now 6 conversion rebuild thread Options

[porschetub]

Time for some overdue update. Although I did work on many areas, mostly trying to salvage rusted donor parts which takes a lot of time (IMG:style_emoticons/default/screwy.gif) (IMG:style_emoticons/default/smash.gif), I will focus on one area for this post.

Last time, I was showing a couple of longitudinal sections that I had began looking into. After a lot of evaluation for the usage, I elected to begin with the small piece.

This one:




This part has been de-rusted in citric acid for a couple of days. First step, dissociating the inside layer from the outside one. My hope is to use the outside one on my car to repair this section.

After many spot welds drilling, the two were finally separated.




After roughly cutting the lower half which I plan on using, the first step was to take care of this nasty cut. (IMG:style_emoticons/default/confused24.gif)




After the repair, no more cut! (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/sunglasses.gif)




Next, let's see how this fit on the car. Here it is simply overlapped on the current opening ("new" piece contoured in red). Clearly, I am missing some metal on the rear end of the piece. In my hand the extension made from 18ga. stock.




Since the end of the piece already looks like Swiss cheese, I took this opportunity to remove this section.




And now the extension. (IMG:style_emoticons/default/welder.gif)




Here the extension is fully welded and you can see the next area to be repaired.




Here the piece is trial fitted on the car. (IMG:style_emoticons/default/smile.gif)




But, as we can see, there need to be an extension in the front too!

Searching through my pile of metal, I found this small section that was actually from the driver's side. It is missing the lower fold/flange, but it does have that shallow step where the floor attaches to. Not great, but I can make it work.




After trimming and fitting, time to extend the part towards the front. Welding setup with copper backing.






Wrapping up this post with the trial fit of the whole piece on the car. There is still some fitting/trimming to be done but this is looking good! (IMG:style_emoticons/default/beer3.gif)

Wow impressive metalworking and welding skills there (IMG:style_emoticons/default/smash.gif) (IMG:style_emoticons/default/smilie_pokal.gif) .