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roy mawbey
Samba Member
Joined: May 21, 2012
Posts: 397
Location: Sussex England
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 Posted: Sat Aug 18, 2018 7:36 am Post subject: Re: Picking up the Pieces. |
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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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Roy
RHD356A super75 106954 |
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sputnick60
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Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Sat Aug 18, 2018 3:56 am Post subject: Re: Picking up the Pieces. |
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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.
Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Fri Aug 10, 2018 7:03 am Post subject: Re: Picking up the Pieces. |
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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.
Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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sputnick60
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Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Sun Aug 05, 2018 6:49 pm Post subject: Re: Picking up the Pieces. |
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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
Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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roy mawbey
Samba Member
Joined: May 21, 2012
Posts: 397
Location: Sussex England
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| Posted: Mon Jul 16, 2018 10:27 am Post subject: Re: Picking up the Pieces. |
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Nicholas,
You make it look so easy!! Please tell me its not !!
Very nice detail work.
Roy
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Roy
RHD356A super75 106954 |
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Wed Jul 11, 2018 2:23 am Post subject: Re: Picking up the Pieces. |
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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 
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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'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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sputnick60
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Joined: July 22, 2007
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| Posted: Tue Jul 10, 2018 8:22 am Post subject: Re: Picking up the Pieces. |
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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.
Next!
Nicholas
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'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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roy mawbey
Samba Member
Joined: May 21, 2012
Posts: 397
Location: Sussex England
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| Posted: Tue Jul 10, 2018 4:59 am Post subject: Re: Picking up the Pieces. |
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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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Jacks
Samba Member
Joined: July 15, 2006
Posts: 2348
Location: San Clemente, Ca.
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| Posted: Fri Jul 06, 2018 9:26 pm Post subject: Re: Picking up the Pieces. |
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| 63Ragtop NZ wrote: |
very awesome!
this thing has me all confused, looks like its a "pan off resto" |
It's monocoque construction. Look it up. 
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wheel607
Samba Member
Joined: May 30, 2004
Posts: 1847
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| Posted: Fri Jul 06, 2018 1:08 pm Post subject: Re: Picking up the Pieces. |
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| Steve F wrote: |
Awesome work!!   |
X2 |
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63Ragtop NZ
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Joined: December 04, 2007
Posts: 895
Location: West Auckland
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| Posted: Wed Jun 13, 2018 7:56 pm Post subject: Re: Picking up the Pieces. |
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very awesome!
this thing has me all confused, looks like its a "pan off resto"
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Steve F
Samba Member
Joined: June 26, 2005
Posts: 19
Location: Vista,Ca.
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| Posted: Wed Jun 06, 2018 3:38 am Post subject: Re: Picking up the Pieces. |
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| Awesome work!! |
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Tue Jun 05, 2018 8:36 am Post subject: Re: Picking up the Pieces. |
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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...
...cutting...
..welding...
... and filing..
... took care of it
That's all for now..
Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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sputnick60
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Joined: July 22, 2007
Posts: 3916
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Jon Schmid
Samba Member
Joined: May 29, 2012
Posts: 2039
Location: Southern California
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| Posted: Sun May 20, 2018 10:29 am Post subject: Re: Picking up the Pieces. |
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| sputnick60 wrote: |
| PorschepowerGhia wrote: |
Hi,
Would you be interested in selling the wheels you have?
Im interested in them because they are 4.5 inch.
Thank you. |
No problem with asking. I need five wheels and I’ve got four. My 100% perfect would be five wheels all of the same type date stamped late 64. However, until I find my perfect set its better to hang on to these. But then I have a buddy with a 356sc seeking exactly these, so in keeping with the principle of “a priori” he has first right of refusal. It seems everone wants these wheels
Nicholas |
Contact Adam Wright at Unobtanium and tell him which date code wheels you need. He should be able to get back to you with what he has available for sale. [email protected] He is located in New York so I don't know if the shipping charges will pencil out for you. Good luck. |
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Sun May 20, 2018 6:52 am Post subject: Re: Picking up the Pieces. |
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| PorschepowerGhia wrote: |
Hi,
Would you be interested in selling the wheels you have?
Im interested in them because they are 4.5 inch.
Thank you. |
No problem with asking. I need five wheels and I’ve got four. My 100% perfect would be five wheels all of the same type date stamped late 64. However, until I find my perfect set its better to hang on to these. But then I have a buddy with a 356sc seeking exactly these, so in keeping with the principle of “a priori” he has first right of refusal. It seems everone wants these wheels
Nicholas
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'66 Karmann Ghia Cabriolet...
'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
Stop dead photo links! Post your photos to The Samba Gallery! |
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PorschepowerGhia
Samba Member
Joined: May 19, 2018
Posts: 14
Location: Victoria Australia
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| Posted: Sun May 20, 2018 2:55 am Post subject: Re: Picking up the Pieces. |
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Hi,
Would you be interested in selling the wheels you have?
Im interested in them because they are 4.5 inch.
Thank you. |
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roy mawbey
Samba Member
Joined: May 21, 2012
Posts: 397
Location: Sussex England
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| Posted: Sat May 19, 2018 9:27 am Post subject: Re: Picking up the Pieces. |
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Nicholas,
Some very nice neat work there on the rear heater pipes I easily can see it taking a day as nothing looking as good as that can be done in a short time.
I am convinced the factory never expected many 356 cars to be still on the road after 60 years or so. Those nooks and crannies so in-accessible to get at even just to rust protect, they are everywhere even when looking not that hard!!
Roy
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Roy
RHD356A super75 106954 |
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sputnick60
Samba Moderator
Joined: July 22, 2007
Posts: 3916
Location: In Molinya Orbit
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| Posted: Fri May 18, 2018 5:11 pm Post subject: Re: Picking up the Pieces. |
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| finster wrote: |
| when you see a 356 without the outer panels you realise that those porsche designers seemed to love making mud traps under that lovely bodywork |
I’m learning to agree. I thought Ghias were bad for it but the 356 design is something else when it comes to rust catchers.
Anyhow, the tasks are being done and the remediation continues. This week we are dealing with the heat pipes in front of the rear wheel house region.
The piece is fabricated from two bits tacked together on the car
Then welded together on the bench
the welds are filed out, the hole added, the piece attached to the car and the heat pipe slid through...
....and finally the pipe welded in position
That’s a day’s work in itself.
Nicholas
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'65 Porsche 356C Coupe...
2005 Mecedes Benz C180 Kompressor Estate
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finster
Samba Member
Joined: May 26, 2012
Posts: 7951
Location: north o' the border
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| Posted: Tue May 01, 2018 11:34 am Post subject: Re: Picking up the Pieces. |
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| when you see a 356 without the outer panels you realise that those porsche designers seemed to love making mud traps under that lovely bodywork |
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