Lets burn some metal. Alchemy!!

Grinding the plugs is next. BTW.. the upper flange was welded on the inside as I pre-drilled the holes on the inner long. Makes for a better cleaner finished product on the outside.

I removed the brace just above the inner long before I welded the outer together.
The door gap stayed perfect.

Lot of talk lately on the site about twisted chassis when welding in roll cages and long reinforcements.

The only conclusion is "Occums Razor".. aka welding to fast. I burned the outer long in about 45 minutes while piping in air flow with an air nozzle laying inside the long. Just a bleed of air flow to cool the metal as I plugged along.

I would say I generated the same amount of heat welding the outer long as installing an Engman reinforcement. Weld slowly! Take your time.

Jeff, What method did you use to get the support bar out of the hinge?

(nevermind...upon further inspection, it looks to still be in place.)

Hi Eric

A few mnutes to play...

Final fitting of the rear outer rocker closing plate. Burn it in! I will grind all the welds down tomorrow.

Ok shit that hurts. Anyone who works with sheetmetal is gonna get a "hurts donut" inevitably. Got this one when the vise grip slipped and banged my knuckle on the edge where the qtr panel is cut off for access. Yep it went to the bone and was a bleeder. Probably should have gotten 3-4 stitches. No time but cyanoacrylate closed it right up.

Nice work Jeff! REAlly nice gash!

A little lemon and salt on there and I bet the vodka would go down really fast! Nice thread Jeff, lots of great info for peeps of all levels here. Thanks for all the extra time spent on pics and documentation. It takes enough time just getting the work done.

Wow; Jeff you are one talented man. Any chance you might move to Alamo California anytime soon? I would love to have your skill set.

I WAS married to a red head!! Say no more I fully understand!!!!!

One way to get some "gash"

It was the Nurse's recommendation to apply (cyanoacrylate) to my wound. Reminded me about the movie :What About Mary... "its a bleeder"! Ha!

I said what? She responded "its just Crazy Glue". I said I know but... she said "shut up and do it or your going to the ER"... ER holy crap? Not me...its just a flesh wound. The Nurse said its not a just a flesh wound... its serious because its been bleeding for seven minutes. I responded soooooooo. She said "you're such a typical male".. I responded with yep!

I laughed. I actually know how to install sutures...Ive done it in an emergency situation. Butterfly sutures to be exact. The ER Surgeon was impressed with my sewing capabilities. "He said he would have lost the leg". I responded "Singer would be proud".

Ok! Crazy Glue it is. Made my eyes water. The glue not the Nurse! It's hot... The Nurse not the glue.

The Red Head is still upset with me! Why me?

Grinding of the welds done.
Well maybe not! Ok almost. My knuckle hurts like a mother... " ....

Close enough. I little touchup with the Mig and its done. (unprimed area)

I'm going to bed! Between the Redhead and the Nurse I've just had enough...I'm done for now!

Looking great! Very clean repair. Keep it up!

I just found this thread, been looking through and learning quite a bit. Thanks for all the pics, they're helping a newbie learn some tricks.

BTW... Redheads are crazy.......I mean SCARY crazy................I mean kill-you-in-your-sleep CRAZY!!! I'm just sayin. It's the freckles that pull us in.

My boss is a redhead. Ya just gotta say yes and nice shoes a lot

Redheads never forget.

I know, been married to one for quite a while.

Oh and very familiar with them. I see the humor clearly. Afterall I am also a red head. I won't kill anyone in my sleep though.

I see you have the same MIG welder as I do. Do you ever feel the need for a TIG? I certainly could use one.

I love my Miller 180. It performs very well. No complaints.

I always have a need to TIG. I let my friend handle the TIG for me. He is better than I and his welds look like liquid art. For the cost of a six pack it doesnt pay for me to purcahse a TIG unit.

Funny part is we did a test. I welded 35 gauage sheet steel with a MIG by using a really long ground cable. My welds came out better than his. The TIG could not be turned down enough and the bead was to proud. Everything has limitations.

We then turned to sheet aluminum. I gas welded mine and we did a distruction test which passed. The bead looked more like a blend with gas.

The TIG was a work of art on thin aluminum sheet. Nothing compares.

I always have a need to TIG.

BTW: I started a bathroom remodel so I stepped back from the 14 for a bit.

Oh PS... The Red Head is back!

Still here. Got sacked with some family issues and a bathroom remodel.
The Redhead is gone permanently and for whats its worth... its so peaceful without her drama.

BTW: If anyone is interested I have this for sale in the Ad's

http://www.914world.com/bbs2/index.php?showtopic=108345

You had me worried there for a sec. I thought maybe you had to sell the project.

I never get rid of anything it seems.

Been busy... not as much as I'd like but busy.

Trouble I have now is all the stuff from the house remodelling in the garage.

Whats my tag line?

Shiny things are good.

A little time out for play.

Stopped by my friend Chris' house for an overdue visit. Hey and it only has just shy of 4700 miles on it.

Legend...

How the hell did I miss this one? Fantastic work.

Filling up yesterday. Very cool pump display. 911 Turbo!

... especially the part about filling up the gas tank in the rear of the 911! Like that's gonna happen.

Things that spin!!

Most people don't think about this or even know about it. 1st and 2nd order vibrations. When things that spin go round and round they generate vibrations. Crankshafts, cams..etc. What you don't want in something that spins is an orbit or spinning off center due to imbalance by whatever cause. This creates a whole mess that I understand mentally but would rather not deal with. So I leave this to the professionals.. The guys who balance stuff that spins.

This is where the drag racing guys come into play. As they say if it spins balance it! We all understand that balancing is not just cool but critical.

Flywheel machined and brand spanking new Sachs Aluminum Power Clutch. Lets see how good the Sachs quality control is from a dynamic standpoint? Surprisingly it was lackluster.

Enter Dave Kemblowski aka "The Balance Shop"

Flywheel, ring gear and pressure plate balanced as a rotating assembly. I was surprised at how much material was removed to properly balance the new Sachs pressure plate. For the whopping sum of $45 Dave balanced the entire indexed assembly to exceed Porsche specification which normally is just the flywheel.

Check out the bore's that were drilled. Thats a lot of material. Small price to pay. Some may recall that Porsche had an issue with flywheel bolts loosening. This was rectified later with revisions and adding 3 more bolts to the flywheel. Like I said small price to pay.

Ron......that's a '72 911 and they are putting gas in the oil tank......that's why it was changed and only that way in '72 only.....

Damn Red Heads again. This one showed up at 3:00am and didn't leave for two days. Made all sorts of racket. They have an odd Narcissistic sense of entitlement. Go away!!!!!!!!!!!!!!Enough.......

Made some room in the shop. Enough to fend off garage fever.

Cut off the old left outer console.

Measure everything nine times. Remeasured again and triangulated again from every control point. Used Chris's supplied templates which so far are dead nuts.
Its cutt'n time.

Seems like you got rid of the RED HEAD ... hair color doesn't necessarily make the situation any better, or worse - women are women.


Don't know how I missed this before. Excellent thread.

Product Placement (of the Foley kind)

Left pickup test fit...

Funny thought.. the rear suspension hardware was one of the first box's packed away when I tore down the car. Smartly labeled took me just a minute to find those 3 console bolts.

Cut out the right long and test fit the right pickup.

Dimensionally width wise its less than 1mm and height side to side is dead nuts.
Took some measurements in process and need to move the pickups forward 5mm to correct the wheelbase length to spec.

(Another plug for Mr. Foley and his precision. I call it Lana but he deserves the mention - Thanks Chris!!!!!!!!)

Moving the pickups 5mm forward to match factory wheelbase base will also separate the pickups by the desired 1/2 inch (1/4 inch per side). This will result in a total 1/2 inch wider track over stock. (think ahead?? wheel spacers maybe/ maybe not with 9 inch rear wheels). Worry about that when I get there. Also with a 3.2 six a little bit to spare is a plus.

Foley Pickups squared and tacked in.

So.... I need to build a Dummy Shock. How about a Multi-Tool instead???

Combo Wheel Bearing Puller -Dummy Shock ( 2 Inch Adjustable)

Went to trial fit the control arm... and snapped the zerk fitting.. Stuff happens..oh well.

Need to trim a bit off the long anyway to clear the pivot axis of the arm as it sits 2 inches higher now.

Amazing work!! I love this thread!

Trimmed the longs enough to mount the arms. Wheelbase is dead nuts. Total increase in track width is 24mm (12mm each side).

Checked camber without any shims. Left rear is 1-3/8 degree. Right rear is 1-1/2 degree.

Wiggle room. I'd rather have more camber without shims than less so I will tweak the left rear inner pickup downward prior to final burn in.

I will need to pull the hubs into the bearings next. To check the toe I would like to mount wheels so I can measure bead to bead.

Maybe I missed something. Why are you moving the trailing arms out? Great work by the way.

Mr. Hailpern, Hale-Bopp will be back before this thing is done! Worse yet... "my" car might be done before this one!!

Hurry up damn it and... don't blame it on the redhead!

(keep up the good work chief... always an intriguing thread)

Love you too Eric!!

Pulled the frozen 911 hubs into the bearings. But first applied thread lock and torqued the bearing retainers. Everything that gets torqued to spec gets marked. No hindsight and oh Shi# did I do that crap? Cant forget the 5mm spacer.

In