[86911TLCAB]

Unbelievable work. Thanks for sharing.

[Dr K]

I wished you lived closer! I would so love to watch you do this work. Amazing.

[rothaus]

Thanks for the nice comments.

Yes, I use a MIG welder. For the spot welds I pre-drill the sections and use the MIG welder. Like this one.


I think this is much cleaner as just weld along the edge of the new parts.

I have one more update this weekend, and then I have to take a quick break, because I have to do the coolant pipes on the Cayenne.

Cheers
Engelbert

[B r i a n]

Thanks, great work! Look forward to you posts!

[rothaus]

Here is a little update:

Cut out some of the bad sections on the left side rocker section.



Making and fitting in a new piece.



Here is it welded in and cleaned up. I also had to cut out a small section of the fender mount section.



Next, I want to reuse the door post, since it was in good shape. Cleaning up and the crap from the backside.



As well the metal from the rear quarter panel.



Cleaned and blasted to be fitted back in.



I also cleaned up all the crap under the quarter panel.



Here is the mess that came off.



The old and new Rocker support. The old one looks like somebody beat the $hit out of it.



For the front I had to make a new piece, based on a picture I found on the net.



Now things coming back together, just for fitting for now.



Rocker is on as well the inner. All with sheet metal screws for now.



Fitting the new section of the quarter panel, and found that it's a bit short at the bottom, so I have to add a piece.



I also had some issues at the top. So I had to slot it and fit. The other side was better, anyway, still better then making it from scratch.



Once I got it all aligned, it was tiome to take it all back apart and start welding in the bottom piece of the door post I made.



Next is the inner rocker to weld in.



Then the Jack support.



The new rocker support is next.



Looks like I'm ready now for the outer rocker.





The outer rocker is welded in now.



Now I can go and extend the bottom piece of the quarter panel section.



As well the top section I had to slot and fit.



Getting there, the piece is almost done.



Done, next some more details to do.



Cheers
Engelbert

[Jase007]

Great stuff!

[catron1]

You are truly amazing at metal work Engelbert!

[cmartin]

Really nice work, thanks for the details. When fitting the outer rocker do you hold it in place with screws or clamps and fit the door?

[Dr K]

I noticed the black pain on the inner rocker. Do you do some treatment to the inside of these panels before you close them up?

And thanks for this great story!

[Rob VN]

Awesome work.