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> Gulf Blue Build Thread, The build never ends
PanelBilly
post Jun 25 2010, 10:56 PM
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I managed to find some photos that we had thought were lost. This doesn't take me all the way back to the start of the project, but I've decided to start the photo story of the project.

April 2004

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The 2 liter engine I sold with the fuchs

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PanelBilly
post Jun 25 2010, 11:01 PM
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Here's some shots of the damage that I found when I got the car in the air and cleaned it off

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PanelBilly
post Jun 25 2010, 11:08 PM
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The car was walnut blasted and sealed with primer. Now I could see even more work to be done.
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PanelBilly
post Jun 25 2010, 11:14 PM
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I enrolled in autobody at the local CC and stared working on the doors. Making the metal strips that hold the rubber strip on the doors was my first big job

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PanelBilly
post Jun 25 2010, 11:33 PM
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Flares from AA arrived and I started the process of fitting them. One of the photos shows a view of the work I did on the sail panels. I'll find the photos I took of that process and share them soon.

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PanelBilly
post Jun 26 2010, 09:08 AM
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I cut away the rust holes on the inside of the sail panel and found more rust. Surprise, its a good time to practice welding. I goated everything with POR and then ground it off the endes so I could weld it. I should have used weld ready spray, but didn't know about the stuff at this point.

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PanelBilly
post Jun 26 2010, 09:13 AM
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After I welded I recoated with POR. I purchased some defective sail panel skins from AA and reworked the metal to match my car. My welding skills were poor and I spent more time fixing holes than I did attaching it.

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PanelBilly
post Jun 26 2010, 09:24 AM
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Next came the installation of the Engman kit. I didn't brace the door openings, but the car was solid and I didn't let any one area get too hot. A weld here a weld there. I moved around the car alot. I had ground the surface were exch hole was so I was metal to metal. At this point I had discovered welding paint.

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914rat
post Jun 26 2010, 10:49 AM
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When do we get to the Gulf Blue part?Looks like you did some extensive rustoration.Nice Rotisseri.
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FourBlades
post Jun 27 2010, 05:48 PM
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Great pictures! I have really enjoyed watching your restoration.

John
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jimkelly
post Jun 27 2010, 09:03 PM
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have you checked your door gaps since welding in those reinforcements?
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PanelBilly
post Jun 27 2010, 09:39 PM
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This is a retro thread. I'm going back and shoping what I've already done. And yes the gaps are fine.
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PanelBilly
post Jun 27 2010, 10:03 PM
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I don't have a lot of photos showing the flare installation, but trust me I spent way too many hours attempting to line everything up. I think tacking the flare to the body and then cutting the old part out with an air saw is the best method because it leaves an equal gap for welding.

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PanelBilly
post Jun 27 2010, 10:09 PM
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The entire car was sprayed with fill coat and block sanded

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PanelBilly
post Jun 27 2010, 10:16 PM
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The bottom was coated with Poline. Later I had it coated with kevlar LineX, but this gave the underbody an extra layer of protection.

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PanelBilly
post Jun 27 2010, 10:27 PM
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Here come color, trunks and interior first.

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PanelBilly
post Jun 27 2010, 10:30 PM
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Taping off trunks and interior. Trusty helper who worked for beer and dinner. I did feed her more than tape. (I think she was having fun too)

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PanelBilly
post Jun 27 2010, 10:32 PM
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And now for body color (the first attempt at finding Gulf Blue)

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PanelBilly
post Jun 27 2010, 10:34 PM
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And the color is on (but not for long!)

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PanelBilly
post Jun 27 2010, 10:42 PM
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The color I used was from a code that matched a powder blue, but after it dried, it just wasn't a rich enough color. On top of that I wasn't happy with the clear coat. Out came the sand paper and off came the color.
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