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> 1974 914 - Tig welding and Metalshaping saved it! Back on the road!
Dion
post Nov 2 2021, 06:21 PM
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Wow. Just amazing skill set. Metal shaping is an understatement.
Loved how you formed the B pillar door jamb. So looking forward to more.
You covered a lot of ground fast.
Cheers, Dion
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TRS63
post Nov 3 2021, 02:51 AM
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Thanks so much, this kind of comment really motivates ! I love the support here!

Metalshaping isn't my work or my background (I am a mechanical engineer) but I love it so much and really try my best here so really appreciated!

So, now that the car is solidly anchored in the frame and we can go forward.
Before starting on the hellhole, I made one last repair on the driver's B-pillar.
The bottom had some holes:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929485.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929486.2.jpg)

So I built the repair part in two parts as original:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929486.3.jpg)

Adjusted:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929486.4.jpg)

Tacked in position :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929487.5.jpg)

And welded:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929487.6.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1635929487.7.jpg)

Stay tuned, hellhole repair comes next!

Cheers

Antoine
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TonyA
post Nov 3 2021, 07:40 AM
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Great work I just sent you a PM because both of my parents are from south of your area.
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tygaboy
post Nov 3 2021, 08:02 AM
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Great work, great documentation. Thanks so much for the detailed "how to" steps! This is so helpful for others who have to do the same repairs. (IMG:style_emoticons/default/smilie_pokal.gif)

Certainly far more useful than the sorts of things I post!
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TRS63
post Nov 3 2021, 11:55 PM
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Thanks a lot for the support, really appreciated ! Stay tuned, a lot more to come as I had a day free for it this week!

Cheers

Antoine
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TRS63
post Nov 5 2021, 02:41 AM
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So, before removing the paint on the right rear quarter panel, I was'nt sure how to deal with it while repairing the hellhole. I knew cutting it would allow me a better access but cutting good metal is always a hard decision..
Well, from that point of view I got "lucky" (IMG:style_emoticons/default/lol-2.gif) because there is no good metal (IMG:style_emoticons/default/unsure.gif) (IMG:style_emoticons/default/lol-2.gif)
Here without paint:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101714.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101715.2.jpg)

And I have a habit that I built(or make sure I have it) the part before cutting, to ensure I won't miss any measurement/positioning. So here we go !
Making my template :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101716.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101716.4.jpg)

And starting :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101716.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101717.6.jpg)

And after a couple hours:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101717.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101718.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101718.9.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101718.10.jpg)

I left the front part undone to be able to make a good door gap when it comes to that time.

So, now that this is done..cutting!
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636101719.11.jpg)

Stay tuned, the work on the hellhole is going to start!

Cheers

Antoine
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wonkipop
post Nov 6 2021, 02:05 AM
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fantastic.

can see the phoenix red peeking through. (IMG:style_emoticons/default/beerchug.gif)

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Badinfluence1
post Nov 6 2021, 02:38 AM
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You car is really sweet- I'm guessing that their are more 914's in the states, but most are full of rust, The really nice ones that are in Europe. Welcome to 914 world. chris (IMG:style_emoticons/default/welder.gif)
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FL000
post Nov 6 2021, 10:50 AM
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Wow, cool to see you take sheet metal and form those complex parts. Looks like you are using basic hand tools also?
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SteveL
post Nov 6 2021, 11:12 AM
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DAMN, that is a lot of skill with metal.
Nice work!
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Dion
post Nov 6 2021, 02:22 PM
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Awesome Antoine!
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TRS63
post Nov 8 2021, 07:27 AM
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Thanks a lot guys!
@wonkipop : yes, the color is showing through and will be back (IMG:style_emoticons/default/biggrin.gif)

@FL000 : yes, no fancy pullmax or power hammer..a lot by hands and a bit of shrinker/stretcher/wheeling machine (IMG:style_emoticons/default/biggrin.gif)

I made some more progress !
I removed the 47 years old fuel lines: (IMG:style_emoticons/default/smash.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378058.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378059.2.jpg)

Stainless steel replacement is on its way! (IMG:style_emoticons/default/smile.gif)

Then I looked further on the outside part of the hellhole..which doesn't look promising: (IMG:style_emoticons/default/headbang.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378060.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378060.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378061.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378061.6.jpg)

And after checking a bit inside (quite a lot of layers in this badly repaired jack point..): (IMG:style_emoticons/default/huh.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378062.7.jpg)

There were some findings:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378062.8.jpg)

And a lot of rust falling through:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378062.9.jpg)

I did not want to fight forming too much thick metals so I made a small order to save me some time:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378063.10.jpg)

So..time to cut really into this repair..
But before that, I took a bit of time investing in my future partner in crime..my 5 years old boy already wants to learn how to weld! (IMG:style_emoticons/default/wub.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636378063.11.jpg)

Stay tuned

Antoine
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Dion
post Nov 8 2021, 08:22 AM
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He looks well prepared! Hope he has fun. Sorry that hell hole is not looking kind. Good call on getting the new pre-formed metal. Some time saved. Amazing how the grommet made its way down to the jack area! Carry on.
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TRS63
post Nov 10 2021, 06:37 AM
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Yes, it is great to get him a feeling how it works and sharing it with him!

For the hellhole : there is sure a lot to do but if will end up strong (IMG:style_emoticons/default/sunglasses.gif)

So, next on my list was the engine tray on the right..as your might remember it was not nice, so I removed it:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636547862.1.jpg)

But it was even worse than I thought: (IMG:style_emoticons/default/unsure.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636547863.2.jpg)

Almost not enough to use as a template! (IMG:style_emoticons/default/unsure.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636547863.3.jpg)

So I started to make a new one..and I had some difficulties getting the shape with so few left..I made a couple trial and in the end made it in two parts, easier to adjust and tig welded together in the end.
Here both parts getting adjusted:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636547864.4.jpg)

And welded: (IMG:style_emoticons/default/welder.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636547865.5.jpg)

I still need to make the holes for the grommets and build the retaining part for the engine seal but if fits as it should:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1636547865.6.jpg)

Stay tuned,
Antoine
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TRS63
post Nov 17 2021, 07:12 AM
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So, I got a big box:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154774.1.jpg)

With my stainless steel fuel lines:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154774.2.jpg)

And the vinyl for the sail panel:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154775.3.jpg)

And then it was time to start on the hellhole. First making some space in the corner of the cabin..so a part ofthe firewall has to go:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154775.4.jpg)

It had its issue and bad repair:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154775.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154776.6.jpg)

So it was time to remove as far as needed to repair it properly:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154776.7.jpg)

What I discovered behind it wasn't nice either:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154776.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154777.9.jpg)

And the floor "repair" was not butt welded, which showed when I cut here the remain of the firewall and water came through capillarity even if the car did not see any water/rain since end of july (IMG:style_emoticons/default/unsure.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637154777.10.jpg)

So more work on this area..
The next update with some firewall repair is coming, stay tuned !

Antoine
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TRS63
post Nov 19 2021, 03:18 AM
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So, as I said, before going further, I repaired properly the firewall part I did cut.
It had a "repair" with metal over rust... (IMG:style_emoticons/default/headbang.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313486.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313487.2.jpg)

So I made a patch :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313488.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313488.4.jpg)

And adjusting:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313489.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313489.6.jpg)

Ready to weld:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313489.7.jpg)

Tack welded and check:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313490.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313490.9.jpg)

Welded and check:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313491.10.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313491.11.jpg)

And grinded/planished:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637313492.12.jpg)

Cheers

Antoine
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TRS63
post Nov 26 2021, 03:20 AM
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So, next update ! I removed the triangle at the back of the floor and it was damaged/poorly welded but still not really rusted so I decided to save it.
Before:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918436.1.jpg)

During:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918437.2.jpg)

After welding and beadblasting:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918437.3.jpg)

Then it was time to make some space to work on the long. Rust damages were there:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918438.4.jpg)

And when removing you see the old "repair" with metal over rust:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918438.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918438.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918439.7.jpg)


So let's make some space:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918440.8.jpg)

And start to make the repair pieces:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918442.9.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918442.10.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918443.11.jpg)

Test checking in position :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918443.12.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918444.13.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918444.14.jpg)

And soon all of this will be welded together:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918445.15.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918445.16.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1637918445.17.jpg)

Stay tuned, I planned some solid hours on it next week !

Antoine
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wonkipop
post Nov 26 2021, 03:57 AM
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great stuff @TRS63 .

since you are a dedicated L jet owner chopping out all the rust and fixing the dodgy repairs from half a century too far away from german precision - cough up your info on the L jet info request thread i posted. i spied a photo at start of your thread and could see something resembling an intact L jet set up. you might have some interesting info if you look closely at what is left on the car.

keep up the good work. (IMG:style_emoticons/default/beerchug.gif)
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TRS63
post Nov 27 2021, 12:57 PM
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Thanks for the kind words ! (IMG:style_emoticons/default/beerchug.gif)
I did not manage to go to the shop this week but saw your post and will contribute there with my informations !
Bests
Antoine
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TRS63
post Dec 6 2021, 02:59 AM
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So, I finished welding the seat belt mounting point and adjusting my home made part of the long:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781139.1.jpg)

Then time to start on the back part. Plenty of rust:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781141.2.jpg)

Inner suspension console has some rust, see here the holes:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781141.3.jpg)

Some bad repairs with metal over rust, and looks like the long's rust gets up to it :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781142.4.jpg)

So decision was made to remove it to repair correctly..and I opened again a can of rust..
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781143.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781143.6.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781144.7.jpg)

So it's now removed:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781144.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781144.9.jpg)

But it is really rusted through on several places and poorly repaired on others..
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781145.10.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781145.11.jpg)

I think I will order a new one instead of fixing it..will be cleaner, efficienter and easier!
Just for fun made some assembly :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781145.12.jpg)

Then it was time to remove the rusted long. My plan is to remove the rusted part of the inner long, weld the new one in (including engine mount and inner suspension console), and then remove the outer long with part of the wheel tray, and replace it. Even if everything is braced, I feel safer to make it one after the other to keep some sort of stability and measure points. Please tell me if anything speaks against it, I am still new in the 914world!

So here we are:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781146.13.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781146.14.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781147.15.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781147.16.jpg)

Time to remove the engine mount:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781148.17.jpg)

Rust behind it:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781148.18.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781148.19.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781149.20.jpg)

And out:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781149.21.jpg)

The long was really at the end of its life:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781149.22.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781150.23.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781150.24.jpg)

And now the parts ready for blasting:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781151.25.jpg)

And blasted:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781151.26.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781151.27.jpg)

The engine mount showed some issues :
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781152.28.jpg)

So let's fix it:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781152.29.jpg)

Ready to weld:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781153.30.jpg)

One picture with a hint of the color, good for the motivation !
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.thesamba.com-24690-1638781153.31.jpg)

Now this topic is up to date!

Stay tuned,

Antoine
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