1973 2.0L Rustoration, Restoration turned OT garage build Options

[Superhawk996]

I purchased my first 914 back in 1987 (1973 1.7L) and had that car for nearly a decade and I personally put over 100,000 miles on it before it ultimately fell victim to a negligent driver that drove into the back end of it at about 40 mph while the vehicle was stopped at a red light. That rear end crash totaled the vehicle but what is amazing is how well it crumpled (early crush zones!) due to the kink in the frame where the halfshafts are. Everyone walked away unharmed.

I replaced it with a 1991 Miata. Great car in its own right but I've always missed my 914.

Purchased this "replacement" in May 2018 as a known poster child for a complete right side longitudinal rustoration.

This vehicle had been put into storage inside a pole barn around 2004 as far as I can tell.

Vehicle initially purchased in non-running condition:
Engine couldn't be started.
Transmission shift linkage was disconnected
Half shafts and CV's were in pieces, and the wheel stubs were not installed therefore the vehicle couldn't even be rolled without risking having the rear wheel separate from within the bearing.
Fiberglass laid into the floorpan . . . that can't be a good sign.

Vehicle looks great . . . until I got under it.

I spent the better part of the summer putting the items above back together and trying to confirm that it would:
1) Run under its own power
2) Drive though the neighborhood and shift though all gears.



Looks pretty nice eh?

Here is what is lurking underneath once the rockers came off.



and when I started cutting back the rust. Oh my . . . .

[Superhawk996]

The other thing that led to rushing the job was all of this welding is out of position welding and needed to be done with me sitting or kneeling in uncomfortable positions on the floor while working in this area.

Nothing leads to rushing more than being uncomfortable.

The other key thing is that is worth repeating is you can't weld what you can't see. some positions that I was forced into obscured my visibility to to the weld puddle. Not being able to see the puddle is a great way to let it get too hot and to burn through.

To top all this off, my cowl area has an abundance of holes (other than rust) that needed to be fixed.

1) A/C holes were cut for lines to pass through.
2) Sheet metal screws were randomly punched though the cowl area to support the A/C unit itself under the dash.
3) whenever a previous owner wanted a ground connection, they just shot another screw though the cowl.

I've started to address the large A/C line holes. The only problem here is this is overhead welding. Even more fun!



These holes are tucked right into the corner of the cowl & fender area.

I tried to weld this in from above but my welding helmet prevents me from getting my face in a good position to see the weld puddle. You can see this by the tack weld at about the 7:00 position of the hole -- completely missed the weld gap! Cannot weld what you cannot see! . I resorted to doing the other tack welds from inside the passenger compartment and from below.

I don't like this solution. I think my next try will be to use a gas lens and hang my Tungsten as far out as I can hoping to get better visibility to the weld. Trying to be slow and patient and find the best welding position to do this. If I start blowing holes in this area I'm screwed.