Rust repair before paint, The quest for solid metal in the driver side Long - 73 narrow body/4 rebuild thread Options

[Montreal914]

Edit: I might as well make this my rebuild thread...

Original post; I got side tracked on my Microsquirt build as I have decided, after 11 years of ownership, to finally get my car painted to get her ready for her upcoming 50th birthday. (IMG:style_emoticons/default/smile.gif)
Knowing these endeavors can take a lot more time than initially planned, I hope to make it in time... (IMG:style_emoticons/default/wacko.gif)

Originally bahia red 73 1.7. The goal is a narrow body 2056 Microsquirt, VW Tornado red, 5 lugs conversion with 16" Fuchs.
Front: 914-4 A arms with rubber bushings, 911 3" pin struts, Bilstein inserts, Alfa Brembo, vented rotor, stock torsion bar, 19mm sway bar, turbo tie rods, and 19mm master cylinder.
Rear: Drilled hubs, 914 PMB stock calipers edit: 914-6 calipers replica, 914-6 solid rear rotors, 140lbs springs, stock sway bar, rubber bushings.

But before I get the pleasure of installing all of these beautiful fresh goodies, I need to tackle the not so fun stuff... (IMG:style_emoticons/default/headbang.gif)

I have already started fixing some of the rust issues and will share that progress in the near future but right now, I wanted to post some of the issues i have on the passenger side front fender. (IMG:style_emoticons/default/sad.gif) I have searched and read many of the builds here but I would like some inputs from the people who have gone through this mess.

I am trying to understand the construction of the rear part of the fender, more precisely the area joining the front cowling.

Below is a sketch of how I think it is made but i would like someone to confirm...



Having removed the seam sealer in the upper rear area, I have discovered "this" (IMG:style_emoticons/default/dry.gif) which is not really unusual, but clearly a pain to fix. I am not sure though what I am looking at. If my sketch is correct, I guess the inner rusted layer is from the fender rear bulkhead that actually becomes an inner layer on the rear upper point of the fender by the door and cowling junction.





I might be able to cut this from the underside preventing me from cutting the outer surface of the fender. But I would like to better understand what is happening at the junction to the body.
How many layers are there from the fender, one or two?
Is the metal peeling off at the joint to the body the metal from the bulkhead/inner layer, or is it the outer fender layer?

As a reference, this if the situation of the channel, surface rust, but how bad? Is there a way to better know without destroying? Maybe poke with a screwdriver? (IMG:style_emoticons/default/confused24.gif)



Comments appreciated (IMG:style_emoticons/default/smile.gif)

[Montreal914]

Happy New Year!

Being stuck at home for the Holiday's, I had the chance to work on the fuel pump relocation. I went the route Porsche did for the 75-76 models. Having bought a pump panel a while back from Bruce Stone, this was the foundation for this little project. I also have all of the hardware to install the new 2 port Bosch pump.

New fuel pump assembly on my 75-76 panel (IMG:style_emoticons/default/smile.gif)



As mentioned, in 75 Porsche relocated the fuel pump to the front to eliminate the common fuel vapor lock issues that many of us have already encountered. (IMG:style_emoticons/default/rolleyes.gif)

Below is a picture of a stock 75-76 setup. We can see the pump on the access panel, and the filter mounted on the opposite firewall. The fuel filter featured a tab on one of the mid plane ridges that would slide into the fork shaped bracket. Unfortunately these filters are very hard to find now. Since I plan on putting a lot of miles (IMG:style_emoticons/default/driving.gif) on my car over the next 30+ years (hopefully), I want to use the readily available square filter which looks identical to the rare one with the tab, but without the tab. (IMG:style_emoticons/default/smile.gif)


Stock 75-76 fuel pump/filter setup:



Hard to find 75-76 fuel filter:



Based on Porsche's concept, I decide to removed the filter bracket located within the passenger side engine body mount as seen on the right side of this borrowed picture. I will recycle this filter mount and install it under the fuel tank.



After cutting, straightening, and modifying the attachment points of the bracket, I tried my cheap and readily available square filter in it. Very nice snug fit, this will work as it was designed to work.


Now, on to the body modification. First step, establish the location for the 75-76 pump access panel and drill pilot holes in the firewall. Next, using a hole knockout tool, I generate the four corners.


Then I cut the opening leaving about 1/4" metal to create a folded edge like the factory did, but not as nice though... (IMG:style_emoticons/default/rolleyes.gif)



I should have kept material to create the folded corners but I thought it would be difficult to achieve in this tight area and without the proper tools. So instead, I welded in four strips to make the corners. Then I drilled the four holes and tacked M5 nuts to mount the pump access panel on the bulkhead. After some trimming and massaging, here is the final result with the pump access panel installed. The opening is pretty much the same size as the panel flange:



Trunk side view:



Last task, install the recycled filter bracket. Measure twice weld once... Using the new firewall opening, and installing the fuel tank back in, I carefully established the best location for the filter bracket, making sure there is enough space above the filter to remove it once the tank is in place.
Mock up before welding in place. Notice the edge of the black fuel tank running above the filter.



After fixing the filter bracket with a few tacks, here is the final result:


And now with the pump and filter in place:



Another angle:



Front trunk view:



Another item crossed off from the list! (IMG:style_emoticons/default/beer3.gif)