Left headlight box.

Detail:

Right headlight box:

More ugly details:

Time for surgical removal. I am trying to minimize replacement.

More:

And more:

The biggest section I removed was the inner side of the front edge. As always, the tools pile up during a job.

Today, the hero tool was the Dremel. We will see how long this one lasts.

I started piecing the channel back together today, with the new stock from 914 Rubber. Thanks, Mark.

The piece cut for the front left corner.

I managed to get a bit of curvature, to match the original arc.

Fit in place.

And welded in. I had pretty good luck with the thin gauge metal edges, even a bit of corrosion.

Right front corner piece.

In place.

I started to tack weld this, and...the wire ran out. Always at an inconvenient moment, right? I had one more spool in my stock.

Back to welding. I can grind these first corner pieces tomorrow, and get on with the next bits.

Your work is inspiring and will be a reference when I finally start my 914. I have a question though and I am sorry if it is a silly one but here it goes: why didnt you have the shell blasted before you started all the work? It seems to me that it would have been easier to see all the problem areas and would have helped with the welds? Again, this is a question from a soon to be first timer....

PS: You make a very good case for a rotisserie. But it is so expensive....

Cheers

My delay in blasting was a combination of poor planning--and not expecting to get this deep. By the time I realized I was into a complete tear down, it was too late to get any external sources for paint stripping.

As for the rotisserie, I am hoping that when done I can sell it for a good part of my purchase price (unless my son claims it).

Back to work, just an hour yesterday and a couple today. For me, short stints seem to work better for small pieces.

Grinding the first bits from Sunday. Left side:

Right side:

Next piece for the left side.

Welded in place.

Same piece for the right side.

Welded in place.

Inner corner piece for the right side.

Welded.

Last piece for the right side?

Welded.

Here's the right side, almost done.

First, I caught up with grinding the pieces from yesterday.

More grinding.

And more grinding.

The last bit is the inner edge of the channel all along the front. I had to cut down the stock width of the L, and give it the same curvature as the front of the car.

Got it tacked in place before quitting time.

I finished up the frunk channel today. Before final welding along the front, including the latch mounting plate, I made sure I had the same angle across the channel from left to right.

Here's the latch welded on. Don't worry, I ground this into something pretty.

After welding the front channel "seam" and grinding that.

Frunk channel all done, and another item crossed off the list.

With the frunk channel done, I switched to the read panel. This was the last bit of bodywork with significant filler (than know of--knock on wood).

Here's the panel before grinding off the filler.

And after.

Some dents and dings, and holes from the PORSCHE reflector panel installed by a PO.

The reflector panel holes will get welded, and the stock holed for the original insignia will get cleaned of bondo.

For access to the inside of the panel, I removed the trunk lock mounting plate.

Here's the mounting plate. Pretty lumpy.

Hey, I like my smashed pototos lumpy.

Looking good there Robert with all your progress.

Thanks, Doug. Still thinking positive here, lumps and all.

For better access I unbolted the rotisserie rear upright, with the car on jack stands.

Now I can see the worst spots.