My Hellhole Repair |
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My Hellhole Repair |
Tenner |
May 13 2019, 08:33 AM
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#1
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
As I have written before in Superhawk996 thread, I build the inner longitudinal myself. However, it took more than 6 months for me to come to a useful conclusion and 3-4 attempts with different approaches. The aim was to form the longitudinal from one piece of sheet metal to have as few welds as possible at the end. The starting point was, except for the first attempt, a 1000x500mm large, 1.2mm thick steel sheet. At the first attempt, I first put down the lower edge and then brought the rounding into the metal sheet with a stretching and compression device. At the end of the procedure, the lower edge lay flat on the repair panel of the inner wheelhouse.
In the next step, the second "edge" had to be bent. Since this edge is less an edge than a curve, I built a tool to bend the sheet. The top edge / rounding and the first attempt was done ... basically quite good, but unfortunately I had to realize that the part was a bit short. When fitting, I noticed that the sheet metal at the longitudinal in the passenger compartment was very thin. I had to cut much more out of the longitudinal. In addition, my repair sheet was 1.5mm and not as original 1.2mm. The second attempt was a single failure, too short at the front, too long at the back and too little material in the width. For the 3rd attempt, I ordered 1.2mm sheet metal and started again. Since the 1st edge already has a rather complex shape and the forming with the stretching and compression tool was a pita, I made a knocking mold out of a 1m long angle iron. The sheet metal is clamped in between and the sheet has its profile. Then the edge is shaped with a hammer. |
Tenner |
May 13 2019, 08:40 AM
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#2
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
Also very tedious, but the result is good.
The next steps I did exactly as I did on the first try. But the sheet was useless too. At the last edge (Welding to the inner wheelhouse) I confused the dimensions front / rear, so that the box in the front of the engine compartment was too wide and too narrow at the back. Stupidly, I had already cut off the excess material, otherwise I could have straightened the edge again and turn again. Despite the failures my motivation was unbroken. 3. Attempt. This time I built a second knock mold for the upper edge. In the last 3 weeks I have adapted the new repair sheet to the body, and vice versa. I started with the inner longitudinal. At the front it fits quite well. Since I wanted to save as much of the internal reinforcement as possible, I peeled off so much metal that only healthy material was left over. The overlap of internal reinforcement and the sill should be sufficient to stabilize the weld. The weld between original sills and repair panel is then hidden under the rear axle mount. After a bit of grinding and filing, the sheet was in the right place. |
Garland |
May 13 2019, 08:46 AM
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#3
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Restoration Fanatic Group: Members Posts: 1,370 Joined: 8-January 04 From: ......Michigan...... Member No.: 1,535 Region Association: Upper MidWest |
Love it, keep it up.
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Tenner |
May 13 2019, 08:47 AM
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#4
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
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defianty |
May 13 2019, 09:27 AM
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#5
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Senior Member Group: Members Posts: 659 Joined: 9-August 06 From: Essex, UK Member No.: 6,621 Region Association: None |
Crikey that's a lot of work. Nicely done though!
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dr914@autoatlanta.com |
May 13 2019, 09:47 AM
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#6
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914 Guru Group: Members Posts: 8,055 Joined: 3-January 07 From: atlanta georgia Member No.: 7,418 Region Association: None |
certainly some excellent work, you talented guy!
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76-914 |
May 13 2019, 09:54 AM
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#7
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Repeat Offender & Resident Subaru Antagonist Group: Members Posts: 13,611 Joined: 23-January 09 From: Temecula, CA Member No.: 9,964 Region Association: Southern California |
Nice work and great attitude. I usually have a grand size temper tantrum when doing something for the 3rd time! (IMG:style_emoticons/default/beerchug.gif)
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Superhawk996 |
May 13 2019, 11:49 AM
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#8
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914 Guru Group: Members Posts: 6,469 Joined: 25-August 18 From: Woods of N. Idaho Member No.: 22,428 Region Association: Galt's Gulch |
(IMG:style_emoticons/default/welcome.png)
I love seeing how folks attack similar problems and making the tools they need. Love the angle iron forming tools. This site has so much information on how to make do with what you have. Nice to see another skeleton being brought back to life! Keep up the good work and keep posting your progress! (IMG:style_emoticons/default/smilie_pokal.gif) |
mbseto |
May 13 2019, 12:42 PM
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#9
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Senior Member Group: Members Posts: 1,257 Joined: 6-August 14 From: Cincy Member No.: 17,743 Region Association: North East States |
Man, that's some beautiful work. Valuable thread.
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bbrock |
May 13 2019, 04:28 PM
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#10
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914 Guru Group: Members Posts: 5,269 Joined: 17-February 17 From: Montana Member No.: 20,845 Region Association: Rocky Mountains |
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billium01 |
May 13 2019, 05:38 PM
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#11
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Member Group: Members Posts: 136 Joined: 12-April 13 Member No.: 15,764 Region Association: None |
Looks great! Just FYI for anyone reading this and looking at doing the same repair......When I was looking for parts to get my hell hole redone I found that Restoration Designs only offers this part now. The version that had more of the sheet metal that extended up the wall is not being produced anymore because the dye wore out. Now they only offer this shortened version. The older and bigger piece IS still available though Auto Atlanta.
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Tenner |
May 14 2019, 12:47 AM
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#12
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
Thank you for the kind words and the encouragement! I learned a lot from you, people. The forum is always an inspiration and all the building threads motivate me to go on.
I will try to keep you up to date. |
Tenner |
May 23 2019, 03:52 AM
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#13
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
only small but steady progress.
I've been working on the sill for the last few days. Everything is welded and the gaps closed. A few more adjustments and now the sheet sits quite neat. But I'm not 100% satisfied yet, the long weld annoys me and I think that I can do better, so it only has to be welded on the top and bottom. What do you think? Next, I need to press in recesses for the service hole (or what is it called?), The heater tube holder, and the structure at the bottom. I then worked a bit on the old oil tank ... recently I was able to buy this here for not too much money. Original / 6 engine 901/38. |
Jeff Hail |
May 23 2019, 08:43 PM
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#14
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Senior Member Group: Members Posts: 1,141 Joined: 3-May 07 From: LA/ CA Member No.: 7,712 |
The high road always has the better view. That's how the coach builders did it, start with one big piece of sheet metal. Nice job.
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Tenner |
Jun 25 2019, 01:59 AM
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#15
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
Hello Jeff, thank you, guys like you, bbrock, Superhawk996 ... inspire me to do the things myself. I've been told by several people "give it to a professional restoration shop, that's a number too hight for an amateur", but I always want to say, "I did it myself!".
As with my Motorcycle, all custom parts, exept tank and wheels, were made by myself with a little bit help of a freind (aloy welding). But back to the 914. Have not done much in the last few weeks. A little bit disappointed, a little bit lazy, waiting for new parts. Since the Long had to be welded in the middle of the car, I decided to by a new long from Mittelmotor. The long is essential for the stiffines of the car, and I dont want to have a weld at that point. cut out the old test fit the new Not welded in yet, the new long needs a little bit of tweaking and I have to shorten my previous build part to fit. |
saigon71 |
Jun 25 2019, 05:18 AM
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#16
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Advanced Member Group: Members Posts: 2,006 Joined: 1-June 09 From: Dillsburg, PA Member No.: 10,428 Region Association: MidAtlantic Region |
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Cairo94507 |
Jun 25 2019, 06:46 AM
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#17
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Michael Group: Members Posts: 10,022 Joined: 1-November 08 From: Auburn, CA Member No.: 9,712 Region Association: Northern California |
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Krieger |
Jun 25 2019, 07:17 AM
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#18
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Advanced Member Group: Members Posts: 4,754 Joined: 24-May 04 From: Santa Rosa CA Member No.: 2,104 Region Association: None |
You have excellent metal skills. I am glad you decided to take on the challenge yourself!
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Tenner |
Feb 11 2021, 05:53 AM
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#19
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
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Tenner |
Feb 11 2021, 05:57 AM
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#20
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Newbie Group: Members Posts: 20 Joined: 22-June 10 From: Germany Member No.: 11,863 Region Association: Germany |
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