Finally got it finished.
Replaced all the hoses, except the $200 upper one.
If it wasn't for bad luck I wouldn't have any.
That hose let go three days after I finished it up.
Damn it ..................

Glad they hadn't taken it home.

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Finally back to the shop ................
And back to work (play) .........................

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Next order of business.
Measuring the inner/engine long.
I'm using the hinge studs as a point of reference.

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It was about a 1/4 off ..........................

So I had to fiddle with the top end next to the back shock tower.

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Still didn't fit. Had to recut the flanges.

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Now it matches the drivers side.

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Here's the virgin divers side.

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Now the passenger side after I finish tinkering.

Now measure, measure & re-measure ................

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Align bottom edge ....................
Everything is starting to come together.

Now we start to work on the the two pieces of the wheelhouse.
The two pieces overlap each over. So using both, I'll need to lap them together.
Measure FOUR, times cut once.

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So I measure the upper wheelhouse so I can cut off the lower portion.

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So we start the lap weld after we crimp a flange on it.
I think one is a AA part and the other an RD part. I'll let Pete answer that.
Right about were the AA part is wavy. They don't line up perfect.

Master grinder should be able to tidy it up. LOL.


I still have trouble seeing, even using the $200 helmet.
I'll get it figured it out. Over over-welded it in a couple spots.

I'll take a picture of the penetration when I come back to pickup the enclosed trailer.
It is freeking cool. Perfect.

All in all, a good day ............ Had a great time. Left the shop with a big smile.

Back to work.
Back on the lift it will go.
It want to make sure everything is aligned perfect before I tie these three pieces together.
Kind of a slow process. But part of learning what you can and can't do.

Plus I'll get Super In Law to drill some new holes in the rotisserie so it goes on the lift perfectly flat.
Meaning, when the car is perfectly flat on the lift. We have to lift one end of the rotisserie up to bolt it on. Which tweaks the nose a couple MM.

Well, back to work again.

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Getting tired of getting poked in the back.

Getting ready to put the car back on the lift and get it back into alignment.

So we're building a couple more lift jacks.

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Cutting patch patterns ...................

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Test fitting the outside suspension console.
Getting aligned back on the jig.
Getting closer to welding in back together.

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So it's s back on the lift.
Now the tedious job of getting the doors gapped to 5mm.

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I need to start looking for a used bench ...................
This is a PIA.

Now to start adding parts.
First is RD P351 Inner longitudinal member, engine compartment, Right side.

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Gave up on trying to weld up against the shock tower on the inside.
I'll tack it at the top. Thought about some self tapping SS screws. But the rosette and hole punched welds are some much larger that the spot welds I think we'll be ok.

Thoughts ???

Going to have to do some tweaking on the P351 to get it to align with the P331.
Inner wheelhouse, lower right.
The flange on the long is wider than the flange on the wheel house.
So we'll squeeze the long a bit to get the fit we want.
Should have squeezed the long BEFORE I welded it in.
Only looking for a couple MM's so it was no big deal.

Did use Pete's self tapping screw idea. Worked great.
Looking forward, I'll use it when dry fitting multiple layers/pieces together.

I'll get a picture of the box of screws I got at Home Depot. #10 wide & flat.

Let my son have the white 914 to drive the last couple weeks at Oregon State. Graduating Summa Cum Laude in a couple weeks.
Getting a BS in Finance. Should hear back on his CFA Level 1 test in June.

He has been accepted into the School of Law at the U of 0.
Hopefully he'll get a spot. Applied late. Was hoping to go to Sanford.
But his LSAT test was 2 points too low to even attempt to get it in.

Born leader ...................anything less than becoming a CEO will be a let down.

Oh yeah .............I miss the car. Even though its only been a couple weeks.

He took it to the beach from Corvallis last weekend. Dad what did you do to the car? It runs like a dream.
I explained the MPS and AFR adjustments.

He's the son that drove it all 4 years of high school in Montana.

That was a real 914 thriller.
Getting it all together and seeing expert craftsmanship in a real timeline.

Thanks to you and your Great In Law for sharing each moment in your skills of keeping your 914 alive with us.

MikeCool
TN.

I am glad to see someone else tennis balling their project. I figure I have it coming if blood is running into my shirt, but the helpers don't deserve it. Steve Zissous said it best when he said you didn't point a gun at an intern.

Great work, and a great deal of work. You really saved this one.

I'm back ....................
We'll get back to it for a couple days.
I've been busy.

1. Took a backpacking trip with my brother.
2. Got told that the supermarket that I manage was going to close and I would be moving to another store,again. Another one they're talking of closing or selling.
Hmmmmm, not good at 57 years old.
3. Two hours later I have a new job. Going back to Albertsons where I started.
4. Start liquidating the inventory of the store. Tough duty. All that work going down the drain.
5. Watch my son get his BS in Finance at Oregon State.
6. Give two week notice at old job. Going to take the two weeks as vacation.

Hopefully I'll get to burn some metal tomorrow. Its been a month. Seems like forever.

It may be joe albertsons supermarket, but I'm glad you are on your feet. Wish we had em out here, and great that you get two weeks.

Might not, waiting for the text to tell me when they what me to start.

It could be Monday.
Hopefully I can negotiate taking a couple weeks unpaid after I get things figured out.

Oh well ......................

Finishing my coffee. Then we'll be heading out to the shop.

4 months later and I finally get a chance to get back to work.

Working my way thru the new job.
Returning after 21 years

Already promoted and making more than the job that I left. All is good.
Now its time to burn some metal........................

Ok been too busy at work to pull the JPGs off the phone.

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Regap the doors ...............


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Gettin back into the swing of things

So I begin to fit the passenger long .................

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Not liking the fit to our original get it on the road repairs 10 years ago.

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Needed to reduce the long opening about 3/8 of an inch.
Easy deal ................claps did the job.

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So begin I to cut out the corner ...........

So here's where we left off.

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We spent most of the afternoon forming the new corner.
Didn't take any pictures.

Next time I'm going to strip the entire car first .................

But this started as a while your in there project............... Lesson learned.

Might have to start saving for the small Dustless Blaster.

it does seem that a stripped and sand blasted tub is the best way to begin.

I have to say, this is one of the most metal-removed long/hell hole repairs in recent memory.

Back to work ....................
I'm going to go to work on the inner box for the drivers side.

Went back in and reread Jeff Hail's Dead thread.

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Finally using my Hot Spot at the shop.

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Reworking a few of the patch seam welds on the long.

Practice, practice, practice.

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Decided that I needed to cut off the lip.
Just couldn't get it to fit with the lip attached.

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So I decided to cut the holes in inner box.

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Free-Handed I'll have to come up with come sort of jig gadget.

Time for lunch ................... Off to Subway

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Back to work on the inner box on the drivers long.
My welding is getting much better. Almost know what I 'm doing on good metal.

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Weld thru primer sprayed on. Rosette holes drilled.

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Didn't like the self taping screw technique this time. The hole on the old long needed to be bigger. There was no where to start the weld on the new metal inner box.
So welded from both sides.

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Now ready for seam sealer and primer ..................

Had a good day. Super In Law made good progress on the right side front inner fender .... Didn't shoot any pictures.

A month has passed since we've accomplished much. Yesterday was a good day.
I'm working on the extending the outer drivers wheelhouse that was removed due to the cars medical condition.

So I start with making a cardboard pattern.

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Here's where I'm working.

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See that little magnetic light. Way cool. Bought it at Bi Mart here in Oregon. It has improved my welding about 100%. $13. When I get a chance I'll post the manufacturer info so it can be Googled.

Tool Whore bought a second one. I just leave it attached to the welder. Easy to find that way.

Here's the completed extension.
Being that its the drivers side, no RD parts available. I know, most smart people would have walked away.

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Here it is test fitted.

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Tool Whore side note :

Built another jack stand so I could get the lift arm out of the way.
Ducking in and around that thing puts me in a poor mood.
Man, I want to get this thing off the lift.

I think I'm going build the jig Jeff Hail built for the next one.

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Don't worry, that is jack point #8. It's not going anywhere.

Super In Law is working on the other end.
The inner fender that the front of the long attaches to. Both sides of the this car had the disease real bad. So this repair is more about strength and function.
I'm building this car to be my daily driver when finished. Rain, sleet or snow.
Oh yeah, we're going to call it Icicle to match my white and blue Carrera.

We'd already done one patch. But it didn't align with the new outer long.
So we cut into it again and added another patch. Not exactly they way you'd want to do it on a customers car.
I don't imagine anyone else we be where we are. But its something to look out for.

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Still struggling with welding old metal to new. But we're getting it. Zig zaging really helps. Then not being a dumb ass and take your finger off the trigger. LOL.

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Here's the fit we're working on.
Plus keeping the door gap at a perfect 5mm.

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Seam sealer and under coat will make the less than stellar patch disappear like magic.
But I'll know its there.

Here's the test fit at the end of the day.

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Prepped the heater tubes for installation.

Next step is to encapsulate the inside. Finish up welding on the patch on the heater tube corner in the engine compartment. Get that all sanitary and seam sealed before the heater tube is tacked in.

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Awesome thread man!

You are really getting there.

I always found using the bzzt bzzt bzzt technique of just making one large tack weld after another to be the easiest way to deal with the old metal on these cars. You start the next tack weld while the previous one is still red hot. Putting the next tack on the edge of the red hot one prevents any problems getting the arc going cleanly.

It ends up looking like this. This was tacked at 3 inch intervals all the way around and then filled in slowly.

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Looking forward to seeing your car back on its wheels again.

John

Nice work. Thanks for the tip.

Had another great day.
Spent most the day just puttering in the shop.
Tidied up the office shop. It had six months of just sitting things down everywhere.
Now we're all tidied up.

Then I went after finishing up heater tube corner.

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All seam sealed up.

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After smoothing out the opening. I test fit the heater tube.

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Then I test fit the muffler.

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Now its time to seal up the long.
Going to be spraying in Eastwood Antirust.

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The Eastwood kit worked pretty good. A little too cold for the extensions and the tubes to work. Hopefully it will be a little warmer on my next day off.
Then I can spray the inside of the wheelhouse. The one flex tube sprays like lawn sprinkler. Should work perfect.
Might need to cut it with solvent it it doesn't get warm enough.

Most of the day off was spent re-leveling the car. It still amazes me how flexible it is without a long on the passenger side. This time a few less jacks. Added some weight to the trunk. Hillbilly bench adjustment

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Inner long is fitted, welded in and sealed up on the drivers side.
One thing to remember. Don't forget to install the front heater tube into the long before you weld it back in.
Welded in the heater tube to the engine compartment.
After the struggle getting the front heater tube in. It's ready to be welded.

So now its time to get back to the passenger long. Right now its disconnected at the front fire wall, mid fire wall and the wheel house.

Wow, I hadn't checked your build in a few month's and you've got a lot done. Nice work. Wish I lived close enough to view in person.