Progress, The 2011 Hershey show gave me another shot of motivation Options

[saigon71]

I have now attended the Hershey Porsche show three times without an operational teener...NOT being part of the caravan is getting old. (IMG:style_emoticons/default/mad.gif)

Finally got my new inner long welded in with doubler plates on all seams. Verified the incline of the new long with an incline gauge (with the car level) following Jeff Hails build thread. Door operates well! Entire inner long has been coated with rust encapsulator.

Still have a long way to go but I am hoping that this was the toughest part.

Thanks to Scotty B, Jeff Hail, and everyone else who has posted a build thread on this topic. I have read all of them & learned a lot. (IMG:style_emoticons/default/beerchug.gif)

Bob

[saigon71]

The outer suspension console and engine mount were completely shot on my car, so I bought a relatively rust free chunk of longitudinal from a member of 914world and started disassembly. What a PITA drilling out all of the spot welds and grinding down the outer welds, then beating the pieces apart with a large hammer and screwdriver. My "original" inner suspension console must have been replaced at some point, because it was in better condition than the one I bought as part of the used longitudinal. All three pieces were treated with POR-15 on the inside while the weldable areas were shot with weld thru primer. I continually ran a piece of safety wire through the drain hole of the inner console while treating with POR to make sure the drain remained open.

Parts:




I decided to start with the inner console. It was a real bitch trying to measure exactly 28 1/4 inches from the hole in the center of the firewall to the front of the suspension ear hole with a tape measure while holding everything in place. Plus, this needs to be spot on for proper alignment. I decided to cut a piece of steel brake line to exactly 28.25" to simplify the task.




The inner console had a little bit of "rock" to it on the new long that seemed to be coming from the indent behind the bracket. Had to beat this area with a hammer for proper fit:



Still nervous about having the measurements EXACTLY right before tack welding this thing in place...I decided to call it a night.