[DonNewton]

My SC needs to be washed and waxed. Could I send it to you? You wouldn't have to cad-plate the bolts and nuts when you disassembled the car for washing or anything. My God, that's impressive. Can hardly wait for this outcome!

[rothaus]

Time for an update.

The section where the oil cooler is located needed some modification. One of the oil line was routed in to the trunk and out again true another hole in the battery box. Since I deleted the battery boxes, I modified the section where the oil lines will be located. Here are some pictures.

The large hole at the left was for the upper oil line.


I cut a piece out.



Fitted in a new piece.





Test fitting the oil cooler and lines.



On the suspension pan, I had some overlap from back than when I replaced it. So I cleaned this up and removed the overlapping section.





I found some rust around the cross member mount.



I decided to remove the section to see what's going on.



Here is one of the mounts removed. I ordered new ones for both sides.



I saw from the inside of the smugglers box some light shining in true some small holes, so I removed the gravel guard of that section.



From the inside there was also some rust and the bottom of the vertical metal was rusted, so I cut out and replaced it with a new piece.





From the outside.



Here all finish welded in.



Next, the bottom section of the smugglers box.



Cutting out some rusty metal until its good material to weld on.



Making a separator piece (or whatever it's called)



Welding in the new outer piece, I also deleted the hole which had a round cover mounted. This just simplifies things.



Finish



Here a view from inside.



To be continued.

Cheers
Engelbert

[Jazzbass]

Wow. Nice work. I'm terrified how much rust is lurking in my car.

[edevinney]

Thanks for the in-progress photos - I need to make some floorpan/scuttle patches for my Volvo and these explained a lot.

[Patrick3000]

Excellent work, please continue to update your progress.

[VaSteve]

Originally Posted by Jazzbass

Wow. Nice work. I'm terrified how much rust is lurking in my car.

Seriously. Looked like a nice solid car from the first post.

[rothaus]

Originally Posted by VaSteve

Seriously. Looked like a nice solid car from the first post.

I'm sure there are old 911's driving out there, they look nice on the outside, but they have much more rust then this one.

[Dr K]

Your work is just so gorgeous. How do you shape those complex pieces?

[pookie]

There is no way I will ever post pics of my car on here. Your work is amazing!

[rothaus]

OK, time for a little update:

I got the support pieces for the cross member. I cleaned up the section and welded in some reinforcement pieces.





Finally welded in the support.



The driver side was actually very solid. Looks like there was moisture in the smugglers box and that's why the right side just rusted away over the years.

So I cleaned up the old weld and added some additional welds.



There were also a few holes drilled in the trunk area, so I closed them as well.





There are always some little holes.



Here I just cut out some old material.



And welded in a new piece.



I decided to add some reinforcement to the sway bar area.







Same thing for the other side.

My new lip piece came in, so I drilled out the old spot welds.





Cleaned up that section and got it as straight as possible.



Fitting in the new piece.



Here is it complete welded in.



Also cleaned up some more in the trunk area.





Cheers
Engelbert