In addition to adding the new metal, I needed to make another hole for the fresh air elbow and test fit the door jamb.

Trying to line everything up. Talked with @bbrock for a few ideas.

Door jamb positioned and clamped. Welded it in.
Some of the outer edge will need to be ground down as it sits too proud and pushes out the rear fender.

Seam sealed around air tube. Still need backing plate for latch to go on and placement f the sill & triangles. That’s up next.
As well as need to drill out the holes for the six oil tank.
Thanks for listening.

Are you now welding aluminum cans also ?

Yes, need to recycle!

I don’t know Tony, better see what’s lurking in those LE’s !

Nice work, Dion! That's a ton of progress. That door jamb piece would really worry me, but it looks like you have it under control. And Brent is a great guy to consult!

Wow, you have been quite the busy boy! Great progress.

@tygaboy Chris, truth be told.
As crazy as it sounds, ... I was furloughed by the hospital for April & May. So made very
good use of the time, in addition to a bathroom renovation.
Thanks again.

Thanks for the kudos @BeatNavy

Some updates.
Welded on the new sill and triangle supports.
still need to make one for the very front of long and make another triangle for the passenger side. Right side has been without one for the past twenty plus years!
I’ll venture to say not needed but I’ll make one anyway. Just want to wait now till temps drop. It’s been 90 plus degrees all week here. Humidity is off the wall.
Anyway some pics:

Triangle supports

Moved on to opening up the oil tank bosses. Anyone who drilled these open with an engine in place or the fender still on.... well ... hats off to ya! That 4” hole was a mother!

Test fit the tank. All is well.

Welded in the door catch plate.

Door and jamb seem to be good. Rear fender needs some more TLC before I place it back on, so that’ll be up next.

Fin

Holy cow, Dion. That's a lot of work, and a lot of new metal! And in areas where there is no room for error.

Nice job!!

Wow! That's amazing. You will have the buttoned up in no time. Great work.

Had some time today and made up those sill triangles.
As I said my right sill only had one support all these years after being worked on back in the 90’s. I’ll need to primer them yet. One more item off the list.
Made a small template then crudely cut out a shape. Started forming it using a small brass hammer and my vice/anvil.

Then tacked on a base plate.

Positioned and then welded it on.

Right sill support. Now onto the Left rear fender. That won’t happen until after
The Northeast 914 gathering
Look forward to seeing some of you guys!

Impressive work Dion! You are on a roll. Can't wait to see this thing back on the road.

Update time.
After a nice break at the 914 NorthEast Gathering was inspired to get back to this project.
Minor in the scheme of things but necessary.
Epoxy primed the left longitudinal and left rear of chassis. Followed that up with Eastwood’s chassis black paint.

Chassis black

Chassis black

Brent @bbrock I have to apologize. The small part of the sail panel I wanted to use didn’t
fully cooperate. Was prepping the rear fender for the chassis black.
Scuffing up the epoxy primer and discovered more rust in that vicinity of the sail where
the handle and snorkel sit. Uggh! Hit it with grinder and it revealed more issues.
I went ahead and cut out the metal, I had nothing to weld to. It was so thin. Just blowing holes on the minimal settings. The foam backing did it in all those years.
So ordered a new sail panel from Restoration D.
While that waits at the border I can clean up my flooded basement and remove a tree!
Thanks tropical storm Isaias! Always something.

Bad sail

Isaias handy work. The end of the tree is on top of my shed. The John Deere is in there
so I need to rescue him.

Not the biggest tree, just landed wrong! Be nice if it just fell in the woods!
Ok hopefully more 914 stuff soon. Stay safe and dry.

Yea. Isaias sucked.

Wow. Incredible you guys. Stay safe.

Hackberry? At least the bird house is okay.

I had forgotten all about that sail panel piece. Jogging my memory, IIRC it was too trashed to use on my car but we thought the small area you needed might be okay. Good call on getting an RD panel. Made life a lot easier for me.

Glad you are safe!

I have two chain saws

That bird house has survived many a storm! Boy Scouts made that one.
Hackberry? I don’t know. I liked it. Was only around 5 feet tall when we moved here 22 years ago. Right on the woods edge. Sad ending.
Yes Brent thought we’d get lucky but more little rust damage than I thought. The edge toward the door jamb is almost pure seamsealer, after skimming more metal away.
The “meatier” side of the sail looked ok. Unfortunately SO thin. It just kept disintegrating
with every trigger pull. Yes new panel. The right call now.
Cheers Brent, Michael, Mark!

@TonyA , well get down here!

Time for an update. So I received the Restoration Design sail panel. I kinda cheated and used only the section from it to do repairs on my fender. I wanted to keep the original
outline of the sail so it would match up to the chassis without a lot of fettling. I’m not a body shop guy so trying to make it easier on me. Concentrating on that task I didn’t
take a lot of pics, oh well.

Securing the fender/trunk area

Fender

Fender/Trunk seam

After scuffing the epoxy primer in the trunk, gave it a coat of Marathon Blue and clear coat. This is more the true colour than the overall body colour currently on my 914.
I intend to get the body sprayed in this hue. The body colour has way more blue in it than should be. The last paint job when the flares were done was in 2004.
Amazing the difference in colour. I do prefer the more silverish .Which is more proper
to Marathon.

Trunk

Trunk seam

Fantastic work Dion!

I may contact you the next time I need to paint something.

Nice job Dion. Glad to see you're still rolling along.

That sail panel replacement is in my future. Hopefully the RD sail panel doesn't require too much fiddling for a good fit.

Looks fantastic but I am sure even better in person. Ill bring the beer.

That's a lot of great progress. Looking great!

Had some time recently to throw some colour on the firewall, engine bay and the cockpit floor.

Underside

Cockpit ...before