Discussion
I thought I’d start the sills today:
So made a jig to locate the flange and top edge to door gap. It bolts to the seat mounts.
First cuts around the edges:
Bacofoil kidney bowl:
All this is coming out, just want to do it step by step. Area of the inner wing behind the kidney bowl is like tissue.
It’s going on a jig once this is all screwed in place, but I hope to get it pretty much spot on.
Lots more cutting to go!
So made a jig to locate the flange and top edge to door gap. It bolts to the seat mounts.
First cuts around the edges:
Bacofoil kidney bowl:
All this is coming out, just want to do it step by step. Area of the inner wing behind the kidney bowl is like tissue.
It’s going on a jig once this is all screwed in place, but I hope to get it pretty much spot on.
Lots more cutting to go!
I really don’t want to piss on your chips, but maybe put her on a jig rather than adding braces to make sure she stays saggy at the rear. Sorry, but I’d hate for you to do so much hard graft and find out later. Lots of info online about 911 saggy bums. Peace, and I totally admire your dedication.
Sounds like you have it all figured out. One tip is to get some glass sucker/lifter things and position the front and rear screens to check for fit every now and then. Sorry if I’m teaching you how to suck eggs, I genuinely mean to be of assistance rather than sniping from sidelines. Good luck anyway!
It’s OK. From now on it’s only being held together with self tappers. Once both sills and floor are in place ready to weld then it’s off to Surrey to sit on a Celette for a couple of weeks and be ‘adjusted’ prior to welding in the rear crossmember, sills and fitting the rear quarters.
The guys that’s doing that bit is a 911 body genius. Unfortunately he gets to see some of my handiwork, which may be embarrassing!
The guys that’s doing that bit is a 911 body genius. Unfortunately he gets to see some of my handiwork, which may be embarrassing!
Fixed:
If only
I'm not going to use most of the rearmost panel in the picture above the torsion bar area, just the lower bit.
Started on an inner wing repair panel today, the part above the inner sill at the back of the B Post that goes behind the kidney bowl. Tricky little part with the vertical pressing in it. No pics yet, more work to be done before it goes public
If only
I'm not going to use most of the rearmost panel in the picture above the torsion bar area, just the lower bit.
Started on an inner wing repair panel today, the part above the inner sill at the back of the B Post that goes behind the kidney bowl. Tricky little part with the vertical pressing in it. No pics yet, more work to be done before it goes public
So here’s the story of the inner wing repair, skipping the countless hours of imperceptible adjustments that finally come together into something that fits. Two weeks of the odd evening and two full days into one post
First task was to make a rib in a sheet, Proper metal workers have a Pullmax press, I have the t
tmax. ie some crudely shaped lumps of angle and a big hammer.
The result is the right shape and depth, but the surface quality is poor. Even with follow up hammer work it’s rough but it will have to do.
I made a location jig and brace combo so I’d have a reference plane for the edge of the flange and started to gently extract the rough original metal whilst preserving the inners.
The repair panel started to take shape, still needs a few hours fettling in this picture before cutting it in, but it sits in the right place, matches the jig and also fits the new rear quarter.
You can sort of make out how the rib fits to the inner kidney reinforcement in this pic:
And oh yes the OE quarter. What a lovely panel. Bloody well should be at the price...
I’ve replaced the flange on the B Pillar reinforcement and cut the new panel to with a mm or so and added the all important dimple at the top which is clearance for the self tapper that holds the interior trim on.
Also test fitted the quarter which sits nicely.
It’s a long slog this one, but now the inner wing repair is all welded in and ground back.
Sits OK on the little fixture and the welds are (sort of) flush. The bottom isn’t welded in as that bit is coming out as it overlaps the big lower repair panel. That’s the next job, but time for a beer.
First task was to make a rib in a sheet, Proper metal workers have a Pullmax press, I have the t
tmax. ie some crudely shaped lumps of angle and a big hammer. The result is the right shape and depth, but the surface quality is poor. Even with follow up hammer work it’s rough but it will have to do.
I made a location jig and brace combo so I’d have a reference plane for the edge of the flange and started to gently extract the rough original metal whilst preserving the inners.
The repair panel started to take shape, still needs a few hours fettling in this picture before cutting it in, but it sits in the right place, matches the jig and also fits the new rear quarter.
You can sort of make out how the rib fits to the inner kidney reinforcement in this pic:
And oh yes the OE quarter. What a lovely panel. Bloody well should be at the price...
I’ve replaced the flange on the B Pillar reinforcement and cut the new panel to with a mm or so and added the all important dimple at the top which is clearance for the self tapper that holds the interior trim on.
Also test fitted the quarter which sits nicely.
It’s a long slog this one, but now the inner wing repair is all welded in and ground back.
Sits OK on the little fixture and the welds are (sort of) flush. The bottom isn’t welded in as that bit is coming out as it overlaps the big lower repair panel. That’s the next job, but time for a beer.
Thanks. It still looks pretty rough by the standards of some I've seen, but it's solid and in the right place, and being honest will never, ever be seen again!
Loads more still to do in every place I look...
The problem with this car is that you never seem to be able to do the job you set out to do as you find ten others that have to be done first.
I'm putting the hours in where I can, but it's hard work and it's nice to complete a tricky panel like this as it keeps the motivation up.
I just need to find a way to persuade my son he wants to spend ten hours with a wire brush on an angle grinder to clean out the luggage compartment, maybe a driving lesson as a bribe...
Loads more still to do in every place I look...
The problem with this car is that you never seem to be able to do the job you set out to do as you find ten others that have to be done first.
I'm putting the hours in where I can, but it's hard work and it's nice to complete a tricky panel like this as it keeps the motivation up.
I just need to find a way to persuade my son he wants to spend ten hours with a wire brush on an angle grinder to clean out the luggage compartment, maybe a driving lesson as a bribe...
So now we are getting serious...
With one 20 second move I removed my previous repair under the torsion bar that took me two weeks to make a few years back.
The big repair panel:
And the bit I’m going to use:
Cut a bit more of the inner sill out and replaced the flange along the edge.
And another dry build so I can see where I’m heading!
The plan is to complete the area around the torsion bar and finish the rearmost section of the seal flange then repeat the whole process on the other side and then do the back half of the floor.
Just one paragraph.
How long will that take
With one 20 second move I removed my previous repair under the torsion bar that took me two weeks to make a few years back.
The big repair panel:
And the bit I’m going to use:
Cut a bit more of the inner sill out and replaced the flange along the edge.
And another dry build so I can see where I’m heading!
The plan is to complete the area around the torsion bar and finish the rearmost section of the seal flange then repeat the whole process on the other side and then do the back half of the floor.
Just one paragraph.
How long will that take
Slight change of plan, took some guidance that I need a proper outer panel dry build before doing much more. However a few jobs on the other inner wing first.
I cut the RH quarter off (much quicker this time!) and set to with heat gun and angle grinder. Hateful job but all clean now.
Kidney bowl is original and in surprisingly good condition, but it’s coming out as the bottom has seen better days from previous jacking point repairs.
There was a ancient patch over the oil tank mounting. I’ve known it’s been there for ever, but always ignored it!
Luckily a big socket and wheel bearing inner and outer races are within a mm or two.
And welded in:
Ground off and flange removed ready for a new strip of steel.
Kidney bowl removed to reveal...
Solid steel! Well apart from the two holes I drilled in it by mistake.
Luckily I don’t have to repeat the big repair I did to the inner wing on the other side as this is all in really good condition. Obviously jacking point etc is coming out. Removing the previously plug welded flange of the old quarter whilst minimising damage to the inner took over an hour...
I cut the RH quarter off (much quicker this time!) and set to with heat gun and angle grinder. Hateful job but all clean now.
Kidney bowl is original and in surprisingly good condition, but it’s coming out as the bottom has seen better days from previous jacking point repairs.
There was a ancient patch over the oil tank mounting. I’ve known it’s been there for ever, but always ignored it!
Luckily a big socket and wheel bearing inner and outer races are within a mm or two.
And welded in:
Ground off and flange removed ready for a new strip of steel.
Kidney bowl removed to reveal...
Solid steel! Well apart from the two holes I drilled in it by mistake.
Luckily I don’t have to repeat the big repair I did to the inner wing on the other side as this is all in really good condition. Obviously jacking point etc is coming out. Removing the previously plug welded flange of the old quarter whilst minimising damage to the inner took over an hour...
The nice non A surface structural work is now on stop until the full panel fit.
First up the new wing, door and offer up the quarter. Bonnet and engine cover also back on.
Looks good from a distance, in reality absolutely no where near fitting!
So angle grind your new £1k panel and take the outer B-pillar off, having made an accurate, but cosmetically challenged template for the window first.
Starts to fit a bit better:
Still loads to do, not least the other side and ripping both sills off before I can commit (self tap!) too much together.
First up the new wing, door and offer up the quarter. Bonnet and engine cover also back on.
Looks good from a distance, in reality absolutely no where near fitting!
So angle grind your new £1k panel and take the outer B-pillar off, having made an accurate, but cosmetically challenged template for the window first.
Starts to fit a bit better:
Still loads to do, not least the other side and ripping both sills off before I can commit (self tap!) too much together.
Astacus said:
Some lovely work there. What do you plan to do to the shell to stop all that awful rust coming back in places you can't see?
Thanks, everything non A surface I can get to will be coated in 2 pack epoxy (the black stuff you can already see in places). This will be applied again after the panels are welded on. Then seam sealed and sprayed with Raptor or similar stonechip, then some top coat. For the cavities I’ve added little holes here and there for wax injection. The backs of the repair panels have been primed with weld through and where I can guarantee it won’t go near a weld it will have epoxy as well.
A surfaces will be spray epoxy, plus whatever the body shop requires.
Then maybe I’ll spray a wax underneath everywhere and refit the wheel arch liners.
Not that I don’t want this to happen again or anything...😂
gary71 said:
Thanks, everything non A surface I can get to will be coated in 2 pack epoxy (the black stuff you can already see in places). This will be applied again after the panels are welded on. Then seam sealed and sprayed with Raptor or similar stonechip, then some top coat.
For the cavities I’ve added little holes here and there for wax injection. The backs of the repair panels have been primed with weld through and where I can guarantee it won’t go near a weld it will have epoxy as well.
A surfaces will be spray epoxy, plus whatever the body shop requires.
Then maybe I’ll spray a wax underneath everywhere and refit the wheel arch liners.
Not that I don’t want this to happen again or anything...??
For the cavities I’ve added little holes here and there for wax injection. The backs of the repair panels have been primed with weld through and where I can guarantee it won’t go near a weld it will have epoxy as well.
A surfaces will be spray epoxy, plus whatever the body shop requires.
Then maybe I’ll spray a wax underneath everywhere and refit the wheel arch liners.
Not that I don’t want this to happen again or anything...??
Must be great to be at a place where you can get those gorgeous new rear quarters fitted?
Your thread and this link are enough to make me cry about missing the boat on a proper air cooled 911.
https://www.pistonheads.com/gassing/topic.asp?h=0&...
Your thread and this link are enough to make me cry about missing the boat on a proper air cooled 911.
https://www.pistonheads.com/gassing/topic.asp?h=0&...
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff