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  #31  
Old 05-30-2021, 05:55 PM
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It's time for a little update.

I mounted the doors, fenders and hood, to make sure all lines up.



Then I found something I didn't like.

The right door was worse then I expected.



There was a lot of body filler and the sheet metal under it was really bad.

So I decided to use another door I had. The good thing is that it already has the mounting hole for the right mirror.



So now that it all fits, I can finish the outer rockers and the door lock supports.





Now I started with the fenders. There was some repair need where they bolt to the body. Here are pictures of the section I welded in new pieces.











I also closed the antenna hole.



The right side fender was pretty good, but the left one had some repair many years ago. Someone filled in a big gap with fiberglass filler. I removed all this stuff so I can fix this section. I want to make this correct, so I ordered new turn signal housings seals to make sure at the end all fits nice.



I will continue on the fender when the seals come in. I also ordered a few weeks ago 2 sleeves for the rear torsion bar sections. Since the sleeves are in I can start with that.

I started on the left side and made 2 opening so I have access for cutting and welding.





I welded some braces in, so the tube will not move when I cut the old sleeve out.



I removed all the old section and cleaned up as good as possible. Ready to fit in the new sleeve.





Making a template for the inner section.



Inner section welded in.



Now lining up the new sleeve with the t-bar and spring plate in place, so it will line up OK. Tack weld the sleeve to the tube.



Fitting the outer sheet metal. I had to make it in 2 pieces.





This should be good for another 50 years.





Closed the access holes and this side is done.



The same procedure for the right side.











Next I will go back to fenders.

Cheers
Engelbert
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  #32  
Old 05-31-2021, 11:54 AM
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Simply amazing, as usual.

Question for you on the fenders - I have to do some similar work. How do you finish the INSIDE of the fender? Strip > Prime > Undercoat > Paint? IIRC Porsche painted atop the undercoating.
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  #33  
Old 06-01-2021, 05:14 PM
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Quote:
Originally Posted by Jazzbass View Post
Simply amazing, as usual.

Question for you on the fenders - I have to do some similar work. How do you finish the INSIDE of the fender? Strip > Prime > Undercoat > Paint? IIRC Porsche painted atop the undercoating.
If the gravel guard is in tact I leave it. If it cracks and flakes off I remove it and apply new. I usually taper off the edge so I can see that it still has a good bond to the metal.

Cheers
Engelbert
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  #34  
Old 06-07-2021, 11:11 AM
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Man's spent a fortune in welding rods. . .
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  #35  
Old 06-20-2021, 04:29 PM
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Here is another update on the 911:

I decided to cut out the old rear shelf on the 71 911, and fit in the new piece.





On the left side there was some rust and I had to cut out some old metal and made some new pieces to weld in.











I also needed a new section for the fire wall.





At the right side, I removed the reinforcement piece for the roll bar mounting plate. This is what happen after 10 + years in between the 2 sheet metal pieces.



It was only surface rust, and I was able to clean it up.



I opted for the later model shelf since it's a bit higher and will give some extra space in the engine bay.



Cleaning up the original hinge mounts for the deck lid.



When I had the rough position, I drilled some larger holes in the self, so I could move them a bit to make sure they were in the right position for the deck lid hinges.



A few adjustments and the lid did actually fit nice. I had also to make small piece for the section at the left between the self and the window frame.





Here it is all finish welded in.



Here is my collection so far what I have removed. It should not much be added at this point.



Cheers
Engelbert
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  #36  
Old 06-20-2021, 05:04 PM
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Ha, I always save the cut offs in a corner of the shop pile too. Can’t discard any original metal prior to full completion for some reason.
The Men in Plaid will be on your doorstep over the package shelf. That said, clever addition of much needed access room on the engine compartment. Nice work and documentation as always.
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  #37  
Old 10-30-2021, 04:58 PM
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Here is a little update on the Froggy.

Once I was happy the flare mock-up, it was time to fit the front and rear bumpers. But before I did a little customizing and added a few cooling slots.

At front where there will be an additional oil cooler at the right side.



And on the rear bumper to have some opening for the heat to escape.





I also closed the cut-outs where the left and right exhaust pipe came out. There will be a different system going in, which still need to be determined.



Time to make a mess with fiber glass for the molds.



Next to make the actual flares.





Once I got the flares done, it was time to remove the mock-up from the car.





Getting the car ready to test fit the new flares.



Here temporarily mounted with sheet metal screws.









Now test fitting the bumpers and making adjustments as needed.









Also test fitting the T-bar hole covers.



I had to do some little changes on the front corners. I did not like how they lined up.



Now test fit all the front pieces.







I decided to upgrade the electrical system, and will use the later type fuse box, so I have more space for relays, etc.



So the original Fuse box mount and relay holder comes out.





I also added the RSR strut bar mount.





More to come, stay tuned.

Cheers
Engelbert
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  #38  
Old 10-31-2021, 11:21 AM
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Amazing as usual. Those flares are awesome.
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  #39  
Old 12-01-2021, 06:41 AM
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Admiration on so many levels ! Not often the guy who has those metal working and welding skills has the 3d printer and modeling skills as well. A true renaissance man !
Thanks for sharing all the great details!
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  #40  
Old 12-21-2021, 02:18 PM
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Here is a little update on the 71 911:

I looked into using the later Alu rear banana arms instead of the steel one.



After test fitting them and looking at different things, I decided not to use them. The shock mounting point is further back compared to the steel arm. It would work, however, I would need to leave off the dust cover at the top of the shocks.

So I went on with the old steel bananas. There was something I had to fix, to make the adjustment work as it should.

The Toe adjustment hole was worn out and need to be fixed.





Here it is after repair.



After the repair I blasted and powder coated them.





I also started to clean up some of the suspension pieces. I will try something new this time and coat them with Cerakote.



I cleaned some of the hardware from suspension and brakes.



Zinc plated the hardware.



The inside floor is also cleaned up and I sprayed some self etching primer.





The bottom section is now also sprayed with gravel guard.





Almost getting to the point to pre-paint the inside and under section with Viper Green.

Hope you all have a nice Christmas and Happy New Year.

Engelbert
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1984 911 Targa, 3.4L
1982 911 SC
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1971 911 3.6
1966 912 - Future Project
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