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Picking up the Pieces.
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sputnick60
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PostPosted: Tue Jun 05, 2018 8:36 am    Post subject: Re: Picking up the Pieces. Reply with quote

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.

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Masked off for the spray
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Purple tape over the weld through primer before the epoxy get sprayed
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Epoxy drying out
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The view from below.

Now we deal with the doors and door sills
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The door is fitted up and will get its lower skin later.
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Same deal has been going on over on the other side
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Then there's lots of work down to the front sections.
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Then there's rust remediation inside where a part was fabricated....
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... to replace the rusted bit
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Conversion to RHD for the battery box and surrounding area
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Then inserting all that in the nose..
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And not to forget the lid ...which looked pretty bad...
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until a bit of reshaping...
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...cutting...
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..welding...
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... and filing..
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... took care of it

That's all for now..

Nicholas
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Steve F
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PostPosted: Wed Jun 06, 2018 3:38 am    Post subject: Re: Picking up the Pieces. Reply with quote

Awesome work!! Shocked Wink
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63Ragtop NZ
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PostPosted: Wed Jun 13, 2018 7:56 pm    Post subject: Re: Picking up the Pieces. Reply with quote

very awesome!
this thing has me all confused, looks like its a "pan off resto" Laughing
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wheel607
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PostPosted: Fri Jul 06, 2018 1:08 pm    Post subject: Re: Picking up the Pieces. Reply with quote

Steve F wrote:
Awesome work!! Shocked Wink


X2
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Jacks
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PostPosted: Fri Jul 06, 2018 9:26 pm    Post subject: Re: Picking up the Pieces. Reply with quote

63Ragtop NZ wrote:
very awesome!
this thing has me all confused, looks like its a "pan off resto" Laughing
It's monocoque construction. Look it up. Very Happy
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roy mawbey
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PostPosted: Tue Jul 10, 2018 4:59 am    Post subject: Re: Picking up the Pieces. Reply with quote

Nicholas,

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!

Roy
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sputnick60
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PostPosted: Tue Jul 10, 2018 8:22 am    Post subject: Re: Picking up the Pieces. Reply with quote

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
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The skin is shaped and folds added.
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TIG welding begins
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More TIG welding and filing
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More filing
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Drivers door fitted up to the car.
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Next!

Nicholas
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PostPosted: Wed Jul 11, 2018 2:23 am    Post subject: Re: Picking up the Pieces. Reply with quote

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
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The backside of the cover panel shown here is similarly treated.
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Then the inner guard panels are faux spot welded with the TIG
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Then the grinder smooths the welds over
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The same gets done on the other side.....just like every else Laughing
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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.

Nicholas
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roy mawbey
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PostPosted: Mon Jul 16, 2018 10:27 am    Post subject: Re: Picking up the Pieces. Reply with quote

Nicholas,

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

Very nice detail work.
Roy
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sputnick60
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PostPosted: Sun Aug 05, 2018 6:49 pm    Post subject: Re: Picking up the Pieces. Reply with quote

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.
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..and a bit of rust repair down the bottom corners. No surprise there, huh?
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The filing was done off the car being easier to control the tool standing up.
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The lip of the bonnet was also addressed with new metal and in the corners where there were cracks, new sections spliced in.
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We replaced the top of the rear guards on both sides where it runs under the quarter window
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The car looks to have been swiped on the left side in its sadder days.
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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.
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And of course the floor has been added to the car.
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Its now looking like that monocoque design and less like a squashed beetle.
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Thanks for looking

Nicholas
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PostPosted: Fri Aug 10, 2018 7:03 am    Post subject: Re: Picking up the Pieces. Reply with quote

There's been a fair bit of welding underneath
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The floor is finished and there is not much more to complete under the car..
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So now is the time to break out the masking tape and protective plastic
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Because the time has come to get the undersides sealed in epoxy and top coated with stoneguard as per factory.
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Here is the rest of the undersides sprayed and outside in the sun
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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.
Nicholas
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PostPosted: Sat Aug 18, 2018 3:56 am    Post subject: Re: Picking up the Pieces. Reply with quote

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.
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So it was obviously needing removal.
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Once the floor was put in position some effort went in fixing the outside section
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and finally the new pieces welded in.
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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
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Welds all cleaned up.
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After that it was ready for paint.

Nicholas
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'65 Porsche 356C Coupe...
2014 Passat B7 130TDI wagon (cheats in tests)
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roy mawbey
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PostPosted: Sat Aug 18, 2018 7:36 am    Post subject: Re: Picking up the Pieces. Reply with quote

Nicholas,

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,

Roy
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moogie32
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PostPosted: Tue Aug 28, 2018 6:15 pm    Post subject: Re: Picking up the Pieces. Reply with quote

Nicholas - this is just incredible! You skills and attention to detail are evident in every photo!
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PostPosted: Sat Sep 01, 2018 7:02 am    Post subject: Re: Picking up the Pieces. Reply with quote

Love the Tig work, Nicholas. People don't believe me when I say it's easier and more clean than Mig welding.
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PostPosted: Mon Sep 03, 2018 1:48 am    Post subject: Re: Picking up the Pieces. Reply with quote

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

Keeping things moving along......
.....it was time to let the sun shine on the little car, so it got dragged into the light to see all the imperfections.....
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....except there weren't any.

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

Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2014 Passat B7 130TDI wagon (cheats in tests)
"Have no fear of perfection - you'll never reach it."(Salvador Dali)
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sputnick60
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PostPosted: Yesterday 7:50 am    Post subject: Re: Picking up the Pieces. Reply with quote

I'd like you 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.....
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... 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.
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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?

Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2014 Passat B7 130TDI wagon (cheats in tests)
"Have no fear of perfection - you'll never reach it."(Salvador Dali)
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