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Sat Oct 01, 2011 9:27 am

Hi
Yes, the top hinge is 3 bolt and the bottom a two bolt. I modified the bottom 3-bolt hinge by cutting the tab and one hole off. The remaining holes lined up. I did have to move the driver's side lower hinge because things didn't line up nicely on the door gap.
Dave

Sat Oct 01, 2011 10:36 am

Porschedave wrote: Hi
Yes, the top hinge is 3 bolt and the bottom a two bolt. I modified the bottom 3-bolt hinge by cutting the tab and one hole off. The remaining holes lined up. I did have to move the driver's side lower hinge because things didn't line up nicely on the door gap.
Dave

Thanks for the reply, I'll have to do the same for my notch. I've searched this forum for ideas for the door hinges and this seems to be the best way to save an early car.

Sun Oct 02, 2011 3:13 pm

Porschedave wrote: I have been working on the restoration of a 1965 notchback that I bought as a father-son project. The car turned out to be in much worse shape than we originally thought ...

Man Dave, that's a ton of fabrication you've done. :twisted: Like Brian said, "not bad for a Porche guy". :wink: 8) I really do like that old Bendix tach. Are you going to keep in the car? The current pics you've sent me really don't do justice, compared to the build pics. :shock: Those are the real art work. 8)

Sun Oct 02, 2011 5:56 pm

Hey Bob
Thanks for those positive comments - coming from someone who has done so much with these cars it is especially nice. I'll make the car 12 v so the old tach won't work as it is a 6-volt tach. Actually, there's no evidence that it works anyhow but I've kept it because it is kind of cool. I've got some more pics to upload so I better get on with it.
Dave

Sun Oct 02, 2011 9:03 pm

Happy Sunday evening
I've got some more pics to add to this thread as we get closer to where I am today. Once I had the shell finished I needed to work on the engine area. As you saw above it was also pretty rotten. I decided that I wanted to use an IRS setup because I had a freeway flyer tranny. To do that I had to fabricate the hangers and such. I looked at Bob's setup and went from there.

First, I had to move and repair the water drain and air flow sections (yes, it was very rusty):

And then I reinforced the inner fender well area with 12 a guage plate

Designed and fit my new hanger. It's 12 guage and slides through a slot in the fender well area and is then welded to the reinforced section:

and here is a shot from the inside

At this point I thought that I was mostly done with body work until I polished the roof, only to discover... yes, rust

What else could I do but.. remove it

Cut the section out

repair the inner shelf

layout on another roof

and welded another roof section in place

and painted it.

So, the question is now -am I finished with welding? How many cars contributed to this notch? original shell, pan, bottom section of a squareback, nose from another, roof from yet another - that's 5 so far and we have not yet look at fenders, doors and hoods. This may take a bit longer yet.

I hope that you're enjoying the story so far...

Sun Oct 02, 2011 9:07 pm

dude, that is nice!

Sun Oct 02, 2011 9:10 pm

very much interested... and impressed!

Mon Oct 03, 2011 9:29 am

Porschedave wrote:
At this point I thought that I was mostly done with body work until I polished the roof, only to discover... yes, rust

What else could I do but.. remove it

repair the inner shelf

and painted it.

So, the question is now -am I finished with welding?
I hope that you're enjoying the story so far...

Probably not, but we'll see.
On my sunroof Notch, I just patched in the rust holes, as I didn't have access to another roof. I sure hope you checked the front of the sunroof opening, as mine had rust there as well.
At least your sunroof tray looked better than mine, as on mine, the corners were rotted off/out, and had to be rebuilt. :shock:

Dave, the positive comments are given, as you've done one hell of a good job here on this car. I love these kind of projects, and I admire those who are willing to take them on, and see them to the end. Not everyone can just do this without worrying about not finishing it. There's just the sense of satisfaction you get when taking on a project like this, and actually seeing it to completion. Even IF you don't end up keeping it 100% stock, you've saved one, and you built it yourself. 8) =D> I look forward to seeing it in person (hopefully next year at the Invasion [-o< ). Good job, and keep up the great work.

Mon Oct 03, 2011 7:41 pm

Greetings
Well, I've uploaded the final set of pictures to bring you to where I am at today.

Another 'problem' reared its head. I had thought that I would use a set of rear sets from a squareback but that did not work out. I did manage to get a decent set of notch rear seats but then discovered that my straight panels in the back wouldn't work because VW had this goofy notch in the seat. So I had to make pockets to fit the rear seat

and following, once again in Bob's footsteps, I "made" a fender from two otherwise bad fenders:

Now, I could finally do something other than welding and panel beating. I shifted gears and got ready to blow epoxy primer over the shell. As I was really concerned about the undersides, I rolled the shell over on its side:

blew on epoxy primer, and then seam sealer, and then ...

some single stage Velvet Green (L512) colour

and brought the car upright

and finally back on its pan.

This is where I am at today, only 5 years after starting this project. I have decided to go back to the original colour. The plan going forward is to epoxy primer the fenders, doors, hoods and sunroof and mount them on the shell. I will then use high build to block the whole car and finally get it painted. Of course, there is still an engine to build (1776 I think), ride height to be adjusted, a wiring loom to make and so on. The T3 invasion is possible but only a distant possibility as I still have my day job.

Thanks for joining me. I'll update this thread as I move forward. I appreciate the positive comments you've made and I certainly enjoy the camaraderie on this site. There are many more pics of this build on my site as well as those for the green notch I built for my son Matt- the signature has the link.

Dave

Mon Oct 03, 2011 7:53 pm

Hot diggity damnnn Dave you are making some serious progress!

Tue Oct 04, 2011 6:40 am

between you and bob .... it makes me want to tackle a rusty critter..... i was spoiled and fortunate to have a mostly rust free car.

Tue Oct 04, 2011 9:33 am

VWporscheGT3 wrote: it makes me want to tackle a rusty critter....

haha :D

Sat Oct 29, 2011 5:31 pm

Well, after some delay I have returned to working on the notch. My focus now is to get the fenders ready to mount so that I can blow hi-build primer on the whole car. This fender, however needs some work, like repairing the section over the headlight

and at the lower rear corner

and I had to cut out the front chin section and weld in a section from another fender

and now with some primer
[/img]

Sat Oct 29, 2011 6:27 pm

Wow! That's too much work!!!! But It's worth every penny! My hat's off to you sir! That show's TRUE dedication!

Sat Oct 29, 2011 8:33 pm

Porschedave wrote: Well, after some delay I have returned to working on the notch. My focus now is to get the fenders ready to mount so that I can blow hi-build primer on the whole car. This fender, however needs some work, like repairing the section over the headlight

and at the lower rear corner

and I had to cut out the front chin section and weld in a section from another fender

and now with some primer
[/img]

Dave, all of that looks familiar, other than adding some new metal across the top of the fender. However, that's just part of dealing with these "old cars" that the aftermarket hasn't tooled up for. Like I said, I've done all of that before except the top of the fender part. I have however grafted the entire headlight bucket into a fender before. Makes grafting 2 half fenders seem easy doesn't it? :wink: Good job though, and keep up the good work. 8)

Fri Nov 11, 2011 6:14 pm

I am now working on getting the fenders, hoods and sun-roof section done in epoxy primer. It was a lot of work to get the gunk off the inside of the fenders as the front two had some undercoat sprayed on. Lots of scraping and heat from a heat gun. In the end they turned out pretty clean and now in primer they look pretty cool, although there still needs to be a little hammer and dolly work because the paint shows up some of the rough spots.

Fri Nov 11, 2011 6:55 pm

Porschedave wrote: I am now working on getting the fenders, hoods and sun-roof section done in epoxy primer. It was a lot of work to get the gunk off the inside of the fenders as the front two had some undercoat sprayed on. Lots of scraping and heat from a heat gun. In the end they turned out pretty clean and now in primer they look pretty cool, although there still needs to be a little hammer and dolly work because the paint shows up some of the rough spots.

Yeah, both my 64 T-34 and my 71 Notch had what looked like spray on white/clear under coating (like rock guard), that was put on before final paint. I used a propane torch and a scraper to get it off. Not fun to deal with, compared to regular undercoating, as that stuff comes off very easy. You're really gaining on it though. Won't be long until the outside gets shot. 8) Then the hard work can begin... reassembly. :wink:

Sat Nov 12, 2011 5:40 pm

Hello everyone
I finished laying down some epoxy primer and figured that it was time to bolt everything back onto the shell. The goal now will be to look at alignment of the doors, fenders and hoods. Also, I am certain that I will discover things that ned to be fixed. For example, at the bottom back end of the front fender I noticed one of the tabs has broken off, so I will need to re-weld a tab on.

Overall, I think that it looks pretty good, although I will want to change the ride height.

Here is the first shot:

and from behind

and from the alley, in the rain ..

Sat Nov 12, 2011 6:03 pm

Dave you're an animal! Love to see this progress.

Sat Nov 12, 2011 6:13 pm

Notchboy - thanks. I do feel like I am making progress but it sure is slow. And, of course, when I look at the pics I see that I have different head light buckets and I'm sure other odd bits will become obvious...
Dave