[BillC]

And on to the next steps:

First step was to install the jackpoint tube. Before I cut out the old tube, I took careful measurements to make sure the new tube ended up in the same position. So, once the new inner pyramid was in, I started fitting the new tube. I held it in place and put a single tack weld. Then, I moved the tube to position and added two more tacks. Unfortunately for me, the tube moved a little while tacking and I had to cut the tacks, reposition the tube and re-tack it. Second time got it right, so I welded it all up. Then I painted the entire area under the outer pyramid with high-zinc paint. Here's how that came out:


While I was waiting for the paint to dry, I prepared the outer pyramid part. This consisted of punching out twenty 1/4" holes along the perimeter and then drilling two 3/8" drain/vent holes near the bottom. Here's how that looked:


Once the paint dried, I tried fitting the new outer pyramid. But, unlike the passenger side, this side wouldn't quite fit without modification. I used the dremel tool to cut two little slices, to tweak the upper lip out enough to clear the post:


Here's what the pyramid looked like when fitted into place, with "fuzzy" magnets holding it in place:


I then plug-welded the mounting holes. Then, I used an old cold chisel and a hammer to close the opening around the jackpoint tube, and then welded that up too. Finally, I ground down the plug welds with the little belt sander.


And, before anyone asks, I welded up the three rear top plug welds inside the rear quarter, through the rear wheel opening. It's very tight in there, and it was a real PITA, but it's better then cutting the quarter open.

I got the front two plug welds through the hole cut in the door sill. That hole was cut because of the rust holes in the corner. Otherwise, I would have had to do all five holes through the quarter, like the passenger side.

[86911TLCAB]

All looking good Bill..keep at it. Soon enough you will be zipping around town.

[BillC]

Managed to sneak in some time on the car last night and tonight.

Time to patch what appears to be the last big hole on the car, at the bottom of the door opening:


This will get two separate patches, one on the bottom and one for the curve. Here's the bottom patch fitted:


And then welded in and ground down:


Last thing I was able to do before having to call it a night was to fit the second patch:


I'm hoping to be able to finish the second patch before the weekend.

[BillC]

Welded in the patch last night, and ground it down this morning. With any luck, this is the last large patch I'll need to weld into the 914 (at least for a while).


Now I need to prep and paint the door opening. Unfortunately, this is my least favorite part of working on a car. Also one of the slowest parts, since it requires waiting for everything to dry and/or harden -- not good for those of us who are patience-impaired.

[Dr K]

Are those patches steel (which I would guess from the weld and location on the car)? They look like aluminum.

[BillC]

Originally Posted by Dr K

Are those patches steel (which I would guess from the weld and location on the car)? They look like aluminum.

Yes, all the patches are steel. They are a type of steel sheetmetal called galvaneal. The zinc in the surface layer is what gives the steel that aluminum-ish appearance.