It's finally coming back together ................

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It's been a long road ...............
But this puts a on my place.

Door alignment is holding perfect.

Finished welding in the left rocker.
Nice .....................

Then moved on to installing the right long inner box.
Pre-drilled the holes.
Sprayed with weld thru primer, again.

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Stayed away from the long seam weld. Rosette welds only. No seam welds.
Finished the night with seam sealing over all the welds and the two edges laying on the bottom of the longs.

Today's lesson. Don't spray on TOO much weld thru primer.
Spitter, sputter .............

Today was the last shop day of vacation. Didn't meet my goal of getting the car off the lift. But I'm close.

Looking good!

I had to learn the same lesson on weld-thru primer during my restoration. Two light coats and go.

Which weld-thru primer are you using? I had problems with the Eastwood Copper, the can kept clogging.

I had been using U-Pol. Which I liked. Their labeling on the spray cans isn't real user friendly. You need to know the product # to what know the product is.

Went to using a can of NAPA zinc enhanced that I'd bought. I'll need to rework my spraying technique. I put it on too thick. Lesson learned ....

I'll add a couple notes :

The upper long did end up coming together fine. Had to do a little reshaping on the upper to get it to align with the lower.

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Final result ...............

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Next lesson learned. Make sure you take more time to align the door hinges. Not only was I off 1mm in vertical. I was probably off 1mm in spacing. If I was too do this for a living I'd build a jig to hold the hinges in place while I welded.

Probably not 1 mm. Just Googled credit card thickness. They are .75mm. So probably more like .5 mm.

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NEVER, NEVER............NEVER
Take the car out of door alignment to tinker with a fit.

I'll let you in on my biggest mistake ...................

First, on both the inner fender corners we created, the bottom edge wasn't perfectly horizontal. This is where the Celette would be nice. Something to measure against.
I'll figure out something for next time........

Second, I was thinking because I didn't have the outer rocker attached I could tweek the long to tidy up the fit. NOT

Here's what I did ........................
Doesn't it look beautiful.

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After I cut out the welds ........... That little bit kept me from aligning the doors.

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Time to prep the right long for closure ..................

Decided to use the Eastwood HD Anti Rust that I'd bought.
So we'll do the test in 40 more years.
Left side is done with Rustoluem.
Right side with Eastwood HD Anti-Rust.

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Then I started installing the base of the left door hinge post.

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Won't be long before I get this thing of the lift.
Then on to the new floor, tunnel repairs and the new pedal box.

Great progress.

Keep away!

Coming together ..............

Wheelhouse trimmed. Took quite a bit fiddling to get the upper edge bent to match.
The next time I'll anchor it to the upper long and do a double cut like you'd cut wall paper.

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Ready to stitch weld on the next trip to the shop.

New tool cart .................
Tired of chasing around looking for clamps and Vice-Grips.

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Super - In - Law project ...................
Just need a divider on the second shelf to separate the small C-clamps and Vice-grips.

I love this thread, great work. you make sorry I cut up a car that was about in the same shape. keep it coming

I keep telling myself the next 4 will be easier. LOL.

Start another vacation on Thursday. Hopefully we'll get it back on the rotisserie by the following Thursday.

Great Day ....................

Finished up welding in the wheelhouse. That's gives me a warm fuzzy.

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Need to finish tidying up the engine bay side.

Here's where I ended the day .............

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Slid the inner rocker in to warm my heart.

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Tinkered with the door gaps and body dimensions a bit.

http://www.914world.com/bbs2/index.php?showtopic=229264

With Rick's help I'm pretty close.

Finally got the car off the lift .............

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Bought some leveling jacks

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Here's where we started .............

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Finally off the lift ........................ now I can get back to work.

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Here's where we start tomorrow ............
Screwed in and ready to weld.

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Adding a new set of door braces.
Kind of a low budget set like Hontek built.

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That way I can take the doors off after I weld in the right inner rocker and recheck the door fit.

Wow, that's some great work right there, keep it going, looking great !!!!

While Super In Law is building our new door braces I decided to do some housekeeping. I needed to cut out a few parts from the sheet metal that will be scraped.

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Here's the new door braces. I want to be able to flip it upside down and not have to worry about everything staying in place.

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Tried some thing a little different. I pulled the puddle up while I was stitch welding the rocker seam.

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Finally putting her back on the rotisserie.

Heading home ....................

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Spent Wednesday finishing up welding in the inner rockers and grinding down the rosettes.

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Then I went after the hinge post bases.
Finished up welding in the left side.

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Then I went after a bad spot on the bottom of the left wheelhouse that I didn't like.
It was just too thin.
So I welded in a patch.

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Before grinder .............

Then I attacked cleaning up my crappy overhead welds from being on the 2 post lift. I haven't figured out overhead welding yet ........
Looks like my farmer welds back in Montana.

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Tidied up ..........

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While I'm doing that. Super In Law is working on the right hinge post base.
Bought a new one from RD. Came off the stiffener.

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Welded in. Before grinder

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Finally we're working on two projects at the same time.

I ended the day seam sealing the long to inner rocker flanges.

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Plus Super in Law fabricated a new fender rocker end cap.

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Who is your friend ??? I need everything behind this, I will send you the leftovers....

Congrats! you saved another one! Whew.. that was a lot of work, just to read the whole 17 pages wore the heck out of me...
Its intimidating and impressive how much work it takes to fix typical rust issues, & how complicated the uni-body design is, doesn't make it easy.

That would be great ...............

Been a couple weeks.

Installed the motor mount that was given to me by worn.

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Having the jig made installing it pretty simple.

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Tidied up the inside of the wheelhouse and installed the hinge pivot.

"Then I attacked cleaning up my crappy overhead welds from being on the 2 post lift. I haven't figured out overhead welding yet ........
Looks like my farmer welds back in Montana."

Overhead welding sucks...you figured it out when you put the car on the rotisserie.

Great work! Keep the pics coming.

Back to it ..............
Had to put brakes on the Fusion last week.

Finished up the welding on the right motor mount.

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Then I finished welding the upper long to the suspension tower.

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Finished welding .........................

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Was a good boy and didn't over grind the welds and metal.

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Seamed sealed ..............

Then I get to removing whats left of the floor plan.
Finally I get the tunnel opened up ....

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Don't miss the two spot welds under the corner/foot brace.

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I finished up welding the long to the front wheel well.
This is some of my best welds. Practice, practice ..........practice.

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Now we'll move onto the back of the floor pan. This is going to be tricky.
We really over welded when we built up the car 12 years ago.

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Time fly's. Its been 90 since I've touched the project.

Changed stores again, so I've been busy bringing it up to my liking.
And I dropped the engine in my 911 to put in aluminum clutch parts.
Used flywheel from Rothsport and a Kennedy pressure plate.

Hopefully today I'll get to weld up the clutch tube on my 73. Then I can restart the rustoration project.

Hope to get back to it on Monday....................... Its been along time.
Been working on my other 914 and my 911. 911 is up and running. My white 914 is coming together. Rear brakes are at Eric's getting platted.

I'm finally back. We started working on the clobbered up seam we created years ago on the floor pan to outside firewall. It's going to be a tedious process. I'm going to take it off about an inch at a time. A couple cross cuts got too deep. Today I'll set up more light for the delicate surgery. Or maybe the Dremel if I can't get it right.

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Sorry for the yellow tint. That's what I get if I don't turn off the halogen lamps before I shoot the pictures.

Cary,

It's great to see your photos again. This is magic!

Nice work as always.

It can be hard to make the time to do these projects...

John

Keep after it.
You guys are doing great!

The day went well. Decided to cut out the previous hack job clutch tube repair access panel.

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Super In Law making the pattern.

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New panel welded in ...............

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Next we'll attack the engine firewall. I'm going to cut out the bottom 1.5 inches that contain the fuel lines and clutch cable tube. We'll also need to fabricate a new flange for almost the entire panel.

The dreaded WYIT (while your in there) bug has hit again. I think I'm going to change out the heater wire and accelerator tubes. The rust barnacles are so big I don't even what to touch them. I figure we're going to recreate the bottom inch and half of the engine firewall so we might as well change them out.
Plus it will give me a chance to use my new to my torch set up. (Craigslist)

Floor pan install looks to be pretty simple. Putting in the inside firewall looks like its going to be a bitch. I assume floor pan first, then firewall?

I'm going to try out my Preval sprayer to start laying down U-Pol primer. Hopefully it will begin show we're making some progress.

I have seen people do the pans first then the firewall and I have seen people do the firewall first, especially if they are using the replacement firewall panels.

I think doing the pans first is easier, I did both my cars that way.

John

Super In Law went to reading the instruction book on the torch. He said it's been 40 years since he's used a torch. Then we had to run to AirGas to get the gas tanks filled.

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So away we went. Out came the clutch tube. Ran it over the lie detector (Scotty B).
Looks to be still usable. Gave it an Ospho spray down. I'm thinking it will get Ford Blue Rustoleum. So 40 years from now someone will open it up again and go, What the Hell.

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So here is the barnacles I was talking about.
So out came the accelerator and heater tubes.

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Now we have an emptied out center console. Getting it ready for Rustoluem paint job.
Need to recreate the tube attachment bracket.

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Ospohed .............

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Firewall emptied out ...........
Trying to decide whether to recreate or buy the panel and cut out what I need.

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Make sure you use protection for the wiring harness. The heat and brazing dripping could cause a serious issues.

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As Super In Law was reading I went to getting ready to install the right side suspension console. Super In Law had his measurements on the white car from when we changed it out 7 or 8 years ago. Got the triangle measurement from the World info. Found a piece of all thread and nuts needed to create the measurement.

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We decided that we'll make our own patch. We'll see how that goes. I have a lead on a new panel for $100.

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Spent most of the day measuring over and over. Then tweaking the suspension console over and over. If I had to do it over again, I should have bought a new one. Too many Rosette holes in taking off the old one off. Need to find the MPS plate

I haven't been welding the old Rosettes closed before I put the old parts back on. I might start doing that too. Welds are too big. Don't look tidy enough. After seam sealer and paint they'll disappear, LOL,

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When it is all said and done I'm dead on the 33 5/16 from the shifter hole to bolt and suspension console (Factory, 914 info). From the firewall to center of the hole I'm off just shy of an 1/8". I'm going to use Jeff Hail's numbers this am to double check again. Kind of late now, just being anal

Spent last night reading all 20 pages of a "suspension console" search to see what I could have done different to maybe not have the 1/8". Maybe I should have tacked the suspension console on the upper long when I installed it. It's the angle of the engine compartment long that caused the 1/8".

I had to walk away from the console after measuring it again about 10 times.

Decided to cut and prep the pedal box that I bought from Bruce. Both the pedal box and the area around the fuel line rubber mount/holder are pretty tore up. The pedal box was rusted. The fuel line hole was just hacked up.

Had to remove the pedal support and decided to save the suspension mounting point.

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The cut portion is sitting overnight in the parts washer. Then I'll dip it in my bucket of muratic acid and water left over from the gas tank cleaning. Should come out gooder and new.

Then I'll brew a pot of coffee and start the suspension console surgery.
Maybe I'll sell the 2 frame stiffeners that I bought from RD and I'm not going to use to ease the pain.

Shot of the harness tab locations in the tunnel. They're coming out so I get all the POR15 off.

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Last day of vacation