Time to un-DAPO the "new" car, Bad things happened to a nice car Options

[BillC]

So, I bought a "new" 914 a few weeks ago (a '73 2.0). When I received it from the shipper, I noticed was the seller was quite artful about his pictures, with what was and what wasn't shown. And, now that I've had a chance to start taking things apart, I have uncovered quite a bit of DAPO-done-damage, and I'm sure there's more hiding somewhere (oh boy! something to look forward too....). Some of the damage appears to have been there for a loooong time.

I've already received a piece from a scrap car to fix this hole:


Once I took the rockers off, I discovered this:

Yes, they hole-sawed through FOUR layers of sheet metal, including the heat duct. Not sure what they were thinking, but there it is.

In the trunk, I found three hole-sawed holes. I think they might have been thinking about mounting the fuel pump in a 75/76 blister, but they never finished the work (and also picked the wrong location).

[BillC]

And now, let's go after this lovely bunch of holes:


First step is to cut access holes in the outer three layers:


I found this little surprise inside the first layer. You can just see it in the bottom of the hole in the above picture. It's one of the bits that was hole cut -- it fell inside and was left there. Unfortunately, it's useless as a patch, so it goes in the scrap bin.


Second layer access:

The cut pieces for the first two layers will be saved and welded back in later.

Then, the third layer.

Once I got a little further into making the patch for the innermost hole, I realized I needed to make the third layer hole a little larger. I'll just make a larger patch later.

Now it's time to make a patch for the innermost layer, the heat duct tube. This is the masking tape method. First, put masking tape over the hole:


Then, use an x-acto knife and cut out the tape over the hole:


Remove the cut piece and place it on a piece of sheet metal:


Then, cut out the piece of sheet metal, and you have your patch:



Since this patch goes on a tube, I found a socket that's about the same diameter as the tube and shaped the patch over the socket.