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  #21  
Old 03-11-2021, 10:31 AM
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Wow. Nice work. My car wants to go live with you.
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  #22  
Old 04-09-2021, 05:39 PM
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Here is an update.

Since I waiting for some metal pieces to come in, I took a look at the fender flares. Since the extensions were added on top of the Carrera flares, I want to make them in one piece.

Here is what the looked like with the extensions.



So I removed the body filler around the flare, and taped the extension on.





Now I can make the plug for the mold.





When I did the left side I found some holes from the past, when somebody did body work.



So I welded the holes and got it straight.





Got the plug almost done.



So, I got back the the sheet metal. I know, back when I build the car for Autocross, nothing was perfect, just a racecar, LOL. So this piece comes out.



I removed careful the rocker.



So there is some work needed.





I removed the inner rocker section, this will be replaced with a new piece. Also I get better access to see what's going on in there.



I removed the bottom section of the door post.



As well a section of the inner wall.



Made a new piece and welded it in.





Then I made a new piece for the bottom of the door post.









I found some rust at the top section of the door post. So I started to look into that.





And before you know it you are deep in it, LOL.

So I just cut out bad sections, made new pieces and welded it back in.













Done





So back to the rocker. After spraying the inside with some green stuff from Eastwood, I installed the heating tube.



Primed the inside of the inner rocker panel. And welded it in.







Next, a new rocker support and test fitting the outer rocker.









More to come.

Cheers
Engelbert
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  #23  
Old 04-09-2021, 05:53 PM
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Just amazing!
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  #24  
Old 04-12-2021, 01:39 PM
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My 911 just asked me if you would adopt it.
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  #25  
Old 04-12-2021, 02:07 PM
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forget that -- I want to adopt Engelbert.
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  #26  
Old 04-18-2021, 04:05 PM
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Time for a little update.

I started on the driver side with the rocker area. The old door lock support, outer and inner rocker is removed.



I checked out the lower section of the door post, and decided it must be removed.







I cut out a piece of the inner wall behind the door post bottom section.



I made a new piece and welded it in.





Also made a new bottom section and welded it in.



The rear section of the inner rocker needed also a new piece where the inner rocker ends.



The top section of the rear quarter needed some repair.







The heater tube end plastic pieces were falling apart, so I made some new ends with the 3D printer.





I also replaced the jack support in the left side and welded the inner rocker panel.





Here is it all finish welded.





Here with the outer rocker support and some primer.



Next I will install the doors, fenders and hood to fit the outer rockers and the door lock supports.

Cheers
Engelbert
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  #27  
Old 04-18-2021, 05:32 PM
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Do you need/want an apprentice?! Amazing work.

Serious question - why do you think Porsche used a Paper/Plastic heater tube along the rockers? It seems like it'd be a moisture trap, where a solid pipe would do the job as well.
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  #28  
Old 04-18-2021, 08:18 PM
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Quote:
Originally Posted by av8bpilot View Post
Serious question - why do you think Porsche used a Paper/Plastic heater tube along the rockers? It seems like it'd be a moisture trap, where a solid pipe would do the job as well.
The paper tube is a muffler, to reduce the amount of mechanical noise coming from the engine & exhaust that would get carried into the cabin. The tube is actually two layers of tubes (inside & outside) with insulation in between to absorb noise.

Quote:
Originally Posted by rothaus View Post
The heater tube end plastic pieces were falling apart, so I made some new ends with the 3D printer.

Making your own end caps is a great idea. What type of plastic did you use? Are you concerned about how well the end caps will hold up to the heat flowing through the tubes?
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Last edited by BillC; 04-18-2021 at 08:27 PM.
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  #29  
Old 04-19-2021, 09:24 AM
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Quote:
Originally Posted by BillC View Post
The paper tube is a muffler, to reduce the amount of mechanical noise coming from the engine & exhaust that would get carried into the cabin. The tube is actually two layers of tubes (inside & outside) with insulation in between to absorb noise.


Making your own end caps is a great idea. What type of plastic did you use? Are you concerned about how well the end caps will hold up to the heat flowing through the tubes?
The original were also plastic, they were just brittle, so I think these will be also good for the next 50 years or so.


Cheers
Engelbert
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1984 911 Targa, 3.6L
1982 911 SC
1978 1303 Kaefer Cabrio
1976 914
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  #30  
Old 04-21-2021, 01:03 PM
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I am reminded of this:

Except rothaus would be done in a few months...

Have you heard of tiny Melinda Mae,
Who ate a monstrous whale?
She thought she could,
She said she would,
So she started in right at the tail.
And everyone said, "You're much too small,"
But that didn't bother Melinda at all.
She took little bites and she chewed very slow,
Just like a good girl should...
...And in eighty-nine years she ate that whale
Because she said she would!
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