View original topic: Picking up the Pieces. Page: Previous  1, 2, 3, 4  Next
sputnick60 Tue Jun 05, 2018 8:36 am

The work continues on the sills. By now it it time to close up the area but there has to be a precaution for rust. Hence epoxy is sprayed over the whole inside area and weld though primer along the joins. The weld though primer is that orange coloured stuff. There's been plenty of that being used.

Masked off for the spray

Purple tape over the weld through primer before the epoxy get sprayed

Epoxy drying out

The view from below.

Now we deal with the doors and door sills

The door is fitted up and will get its lower skin later.

Same deal has been going on over on the other side

Then there's lots of work down to the front sections.

Then there's rust remediation inside where a part was fabricated....

... to replace the rusted bit

Conversion to RHD for the battery box and surrounding area

Then inserting all that in the nose..

And not to forget the lid ...which looked pretty bad...

until a bit of reshaping...



... and filing..

... took care of it

That's all for now..


Steve F Wed Jun 06, 2018 3:38 am

Awesome work!! :shock: :wink:

63Ragtop NZ Wed Jun 13, 2018 7:56 pm

very awesome!
this thing has me all confused, looks like its a "pan off resto" :lol:

wheel607 Fri Jul 06, 2018 1:08 pm

Steve F wrote: Awesome work!! :shock: :wink:


Jacks Fri Jul 06, 2018 9:26 pm

63Ragtop NZ wrote: very awesome!
this thing has me all confused, looks like its a "pan off resto" :lol: It's monocoque construction. Look it up. :D

roy mawbey Tue Jul 10, 2018 4:59 am


So well done, great to see your progress, the last bit and the hood repair made me grin, how to save money if you know what you are doing!!!

Look forward to seeing the lower door skin repair. Mine looked just the same before I started welding it, had me almost in tears over 40 years ago!! I only had gas then nothing modern like Mig. I am good at making excuses!!

Great job Nicholas. great photo's too!


sputnick60 Tue Jul 10, 2018 8:22 am

Thanks for the favourable comments guys. I'm pleased you are enjoying yourselves.

Did someone mention door skins?

The inners are painted with epoxy primer and so to the inner side of the new skin

The skin is shaped and folds added.

TIG welding begins

More TIG welding and filing

More filing

Drivers door fitted up to the car.



sputnick60 Wed Jul 11, 2018 2:23 am

So this time we assemble the sections in front of the door hinge pillar behind the front guard.
Here, the enclosed area has etch primer sprayed over it and brown coloured weld through primer masked up on the interface to the next panel

The backside of the cover panel shown here is similarly treated.

Then the inner guard panels are faux spot welded with the TIG

Then the grinder smooths the welds over

The same gets done on the other side.....just like every else :lol:

In case it isn't obvious (as it should be) , the floor of the car has been lifted out to provide access to the outer section. It kinda looks "off-the-pan" like a Ghia, but this is a monocoque body so sorry, the concept doesn't apply. The floor will go back on later.


roy mawbey Mon Jul 16, 2018 10:27 am


You make it look so easy!! Please tell me its not !!

Very nice detail work.

sputnick60 Sun Aug 05, 2018 6:49 pm

No, not easy but mostly time consuming.

Here is the latest update.

Getting the door gaps right required adding some metal to the front and rear guard sections on both sides.

..and a bit of rust repair down the bottom corners. No surprise there, huh?

The filing was done off the car being easier to control the tool standing up.

The lip of the bonnet was also addressed with new metal and in the corners where there were cracks, new sections spliced in.

We replaced the top of the rear guards on both sides where it runs under the quarter window

The car looks to have been swiped on the left side in its sadder days.

There will be a fair amount for shrinking and swelling to do to get this all sorted. We solved the doors with new skins but this shape is more complicated. I'm sure we'll get it as best as it can be.

And of course the floor has been added to the car.

Its now looking like that monocoque design and less like a squashed beetle.

Thanks for looking


sputnick60 Fri Aug 10, 2018 7:03 am

There's been a fair bit of welding underneath

The floor is finished and there is not much more to complete under the car..

So now is the time to break out the masking tape and protective plastic

Because the time has come to get the undersides sealed in epoxy and top coated with stoneguard as per factory.

Here is the rest of the undersides sprayed and outside in the sun

Looks good huh.

Next will be mounting up the guards front and rear and applying the same epoxy and topcoat per factory inside the cabin before the dash panel gets inserted.

sputnick60 Sat Aug 18, 2018 3:56 am

This new lot is a little out of sequence being work done before the under coating.
Some ugliness at the foot of the front bulkhead needed action. The pedal cluster mount and footrest bracket were looking rather sad from rust.

So it was obviously needing removal.

Once the floor was put in position some effort went in fixing the outside section

and finally the new pieces welded in.

With that the front braces could be welded in. A number of faux spot welds were also finalised at the front around the outer parts of the battery box and the area under the nose

Welds all cleaned up.

After that it was ready for paint.


roy mawbey Sat Aug 18, 2018 7:36 am


Wonderful work, really fabulous restoration. You need a Gold medal just for the effort and the explanation and photos. This alone takes much time to collect and insert on a forum !!

Well done,


moogie32 Tue Aug 28, 2018 6:15 pm

Nicholas - this is just incredible! You skills and attention to detail are evident in every photo!

Gary Sat Sep 01, 2018 7:02 am

Love the Tig work, Nicholas. People don't believe me when I say it's easier and more clean than Mig welding.

sputnick60 Mon Sep 03, 2018 1:48 am

Thanks guys for the favourable commentary. We aim to please and there is plenty to be pleased about, particularly with how this project progresses. For example, we hung out the washing.... oh ok. ...we didn't hang out the washing. We hung up the things that open and shut......

... and gave them a squirt of epoxy primer.
now everything's gone green!

Keeping things moving along...... was time to let the sun shine on the little car, so it got dragged into the light to see all the imperfections.....

....except there weren't any.

Then into the spray booth it went to get its own covering in that green epoxy

So now its time to bolt the doors and lids onto it and it will be ready for the high build and lots and lots and lots of sanding and more sanding.


sputnick60 Wed Sep 19, 2018 7:50 am

I'd like your uncoloured opinion about the Porsche colour, Signal Red. As previously discussed, this car was ex factory in Signal Red 6407.

I have a section of the car interior that sports the original paint. I used a spectrometer to make a paint formula from that. This was sprayed onto a test card and laid over the original paint. Here it is.....

... and it is a rather exact match.

Next, I used a formula for Signal Red 6407 and sprayed that onto a test card. Comparing the original paint you can see a slight difference.

Sure its almost impossible to be sure given the discrepancies between various computer monitors and the camera.

However, my question is about the best most accurate to the original. Has the original colour changed over the years? Is the formula Signal Red the correct one to use?

What's your view?


roy mawbey Fri Sep 21, 2018 4:42 am


Your own sample looks the best compared to the original sample. This does not surprise me! My 356A is Meissen Blue and in 50 years I have re-sprayed it twice in 1979 and 1989. The interior is original as is the Meissen blue dash panel.

First time in 1979 the match to an original painted part proved to be incorrect but I used it as it was only then an old car. Second time I was more careful, and chose a company in Liverpool over here to provide me with a sample swatch.
This was 100% perfect placed against my dash panel. So I bought the paint cellulose of course and its been on the car now for 29 years.

The company I used no longer exists but... a number of guys have supplied me with Meissen blue swatches to compare against my dash panel. None were prefect, one was very close some were along way out.

Meissen blue has a touch of green in the formula it makes it special I think
My dash has not faded in the past 29 years and likely not faded in 50 years since I bought it. Sure I don't have the sun beating down on it and that might help.

I would personally in my opinion go with the sample colour you produced as I think from my experiences all samples can vary. I guess in the first place Glasurit supplied the signal red.

Lovely work Nicholas


Angus Dowrie Sat Sep 22, 2018 4:50 pm

Hi Nicholas

Tricky one! Due to variations in the paint manufacture and recipe translations over time the standard signal red is unlikely to be the same as original as you have found. I went through this with my Karmann Ghia, sea blue. Even from the factory there would be a slight variation from year to year in the same colour. I had no original painted piece to refer to as I was changing the original pearl white colour.

If the sample piece you sampled from is from an area of the car not hit by the sun I think the best method is to use your colour sample match. Make sure you hang onto the recipe though for any future paint repairs required. That way it is as close as possible to how it left the factory.

The flip side of that is that once you've painted it in the standard signal red it will still look good and I don't think anyone could reasonably hold you to account for it!

Weighing it up I don't think either way is 'wrong' or 'bad', but I'd tend to the one you made up from the colour sample.

sputnick60 Fri Sep 28, 2018 5:14 am

Taking these comments into consideration I also took the samples with me out and about during the week. I asked people the question Red! which one?.
Two people chose the red from the formula. Whilst ten people chose the spectrographed red, or the colour derived from the originl paint.

Interestingly, for work Ive had a fire supresion system installed in this small satellite ground station Im building at the moment. The key elements are painted..... signal red. Whoda thunk it. This signal red is something other and heads towards orange but it matches the primer on the backside of the 356s dash. How odd. It some other signal red. Sigh

Im settling towards the popular choice. I liked it immediately and just about everyone seems to agree. So this car will go with the spectrographed red on the dash. Like Angus says, there is no right or wrong. Its a matter of getting it close.


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