Palindrome 914 Build Thread, now on the chassis jig Options

[Mark Henry]

Aha! That's more like a real 914 ... (IMG:style_emoticons/default/biggrin.gif)


We've all been there. (IMG:style_emoticons/default/dry.gif)

I haven't! My car is 100% rust free (IMG:style_emoticons/default/cheer.gif) ...of course that means there has to be at least a good 30% of rust hiding somewhere I can't see it (IMG:style_emoticons/default/sad.gif)

[SirAndy]

Aha! That's more like a real 914 ... (IMG:style_emoticons/default/biggrin.gif)

We've all been there. (IMG:style_emoticons/default/dry.gif)

I haven't! My car is 100% rust free (IMG:style_emoticons/default/cheer.gif) ...of course that means there has to be at least a good 30% of rust hiding somewhere I can't see it (IMG:style_emoticons/default/sad.gif)

Correction:

A lot of us have been there. (IMG:style_emoticons/default/dry.gif) The rest will be there at some point in the future ... (IMG:style_emoticons/default/laugh.gif)

[Cairo94507]

Kind of reminds me of motorcycle riding: only two types of riders: "those that have been down and those that are going down".

914's:
"914's that have had rust repaired and those that need rust repaired"

[Eric_Shea]

Thanks, it is my first time doing real metal working kind of bodywork and first 914.

Holy $hit... you've got the gift. that's for sure. I have a feeling this is going to be a very cool build thread. (IMG:style_emoticons/default/smilie_pokal.gif)

[roadster fan]

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291419601.11.jpg)

Please put that concrete block on the floor oriented the way it would be installed in wall with a 2x8 on top of it, or better yet get rid of it all together. Any imperfection in that block, and/or the orientation of it as pictured, and down comes car...

Keep up the good work, it is gonna be fun to watch the progress (IMG:style_emoticons/default/smilie_pokal.gif)

Jim

[flippa]

(IMG:style_emoticons/default/agree.gif) Replace the CMU Block!!!! It would be a shame for the car to let itself down on it's own (IMG:style_emoticons/default/blink.gif) .

Looking forward to watching this one restored.

[nathansnathan]

(IMG:style_emoticons/default/welcome.png) keep on going and for gods sake repaint those stands so they dont get permanenlty attached to that little car!
good luck and if you need someone to help you make a mess just let me know
Dave (IMG:style_emoticons/default/beerchug.gif)

hey whered you get those stands btw..thanks

I like the color matching. (IMG:style_emoticons/default/smile.gif) I tried to get 2 more of the blue ones originally - I'd got them at autozone for the bus. I went to 3 different ones but they either didn't have the big size or they had only the lever kind. After the pin-through style, I don't feel safe as much with the other kind now.

I couldn't find pin through style anywhere, so I decided to buy the best jack stands I could. Research on the internet pointed toward flat top jack stands, a company in europe, I forget, but they'd stopped making them or at least that you could buy here and the Esco brand ones are supposed to be the equivalent replacement. I got the from Pelican Parts which offers them cheaper than almost anywhere else.

[nathansnathan]

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291419601.11.jpg)

Please put that concrete block on the floor oriented the way it would be installed in wall with a 2x8 on top of it, or better yet get rid of it all together. Any imperfection in that block, and/or the orientation of it as pictured, and down comes car...

Keep up the good work, it is gonna be fun to watch the progress (IMG:style_emoticons/default/smilie_pokal.gif)

Jim

I've said this same thing to a guy an the bus furum at the samba, and I agree that having superfluous jack stands are not so good an idea. -I wouldn't ever think of supporting the car back there btw; those are there in prep for what's next.

The car is held up thusly:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591184.1.jpg)

and then I've got trailer levelers to hold up the trunk only. I wouldn't trust these to hold the car up even though they say they are rated for it. Actually the back end I can probably lift up in it's entirety with my bare hands, it is that light.

The cinder blocks with the trailer levellers are to keep the trunk from sagging when I take off the rear fender(s). -I don't have a jig; I think it'as mostly only going to be able to go together 1 way.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591557.1.jpg)
Anyway, I had them snugged up back there, then after I removed the fender the trunk ended up lifting up actually instead of drooping down. I've tensioned them up to that for now, as I've got more of the long to take out.

Anyway, thanks for the concern, I think it should be alright as long as the main stands are good.

[nathansnathan]

This pic is from the original eBay photos
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591584.1.jpg)
A bit of probing with my big screw driver and some preliminary cutting and I made it look extremely scary
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591814.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591584.2.jpg)
I contemplated all sorts of ways to handle this mess and, probably contrary to what anyone else would have done, decided to take off the whole fender, sail panel included. (IMG:style_emoticons/default/blink.gif)

Many spotwelds drilled, I took my time with it, taking breaks between the sections of drilling, and then the prying/ pulling. All told it probably took me 7 hours to get it off.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591584.3.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591585.4.jpg)

exposing the crustiness
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591585.5.jpg)

This is back by the tail light. It looks like the factory used expanding foam between the pieces there.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591586.6.jpg)

And then there's like weatherstrip foam between the sail panel and the inner rollbar, still attached to that lip.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591586.7.jpg)

I'm going to have to get real good at the metal working pretty quick to handle all this.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591587.8.jpg)

Here's the inside of the fender itself, still attached to the door well.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591980.1.jpg)

More 'deep end' metal working to be done there. I'm lloking at getting a shot dolly and some planishing and ball peen hammers. I've read the Martin "key to Metal Bumping" book and I've got a set of dolllies and hammers. I was trying to get an anvil but the guy flaked out on me.

The guy down the street was telling me I need to dip the car to get where I want to be, but I have some issues with dipping it, not the least f which is price, and so taking the car apart to this level seems to me the way to go. I can do the work, inspect/ get at everything for treatment. I'm looking for a portable sand blaster pot that is NOT from harbor freight. That and construction of a drop cloth-constructed paint booth look like some of the bigger hurdles right now.

Here's the fender
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591987.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591987.5.jpg)

[Andyrew]

Nice work!! Looks like you have quite the array of tools and can actually get this kind of rust repair done!

[realred914]

I started this, a documentation of my build progress, as a blog on the 914club, but I'm not happy with how the order of posts is reversed, the most current being at the top - it ruins the epic-ness, not starting at the beginning. (IMG:style_emoticons/default/dry.gif)

Also 914club is kinda dead and I would only post over there because my view kept reverting to list on world and I couldn't figure out how to see all the forum responses at once for awhile. (IMG:style_emoticons/default/huh.gif)

So that's why I'm starting this here.

I've been working on it for the past 5-6 months.
(IMG:style_emoticons/default/sheeplove.gif)

uhm, a "420" engine and another post isee recently about a "cracked" crank, maybe we need narcotics annonammus? (IMG:style_emoticons/default/smoke.gif)

[nathansnathan]

Moving slowly along, some more work on the door braces
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380342.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380342.2.jpg)
Getting better with the torch. I do wish I had the smaller torch, a 9 I guess.

I got off the front suspension; really easy surprisingly... except the brake fluid that got everywhere.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380342.3.jpg)

And the wiring Harness, what a challenge that was to overcome, getting that out! That's a gauge cluster in about 10 plastic grocery bags, wrapped in masking tape. (IMG:style_emoticons/default/smile.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380343.4.jpg)

The struggle to envision the completion of the hell hole repair is ... also coming along. (IMG:style_emoticons/default/unsure.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380343.5.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380343.6.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380344.7.jpg)

An unconventional approach undoubtedly. I want to take the floor pan off but I have to wait until the long and fender are together before that happens, and it still seems like a challenge to support it even then.

For now the plan is to take out the entire inner long, heater tube with it. I'm mustering my strength, waiting for more jack stands to arrive before I dive in. (IMG:style_emoticons/default/smash.gif)

Replacement panel sculpture
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380344.8.jpg)

and my suspension ear wrinkle fix
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380344.9.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380345.10.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380345.11.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380345.12.jpg)
Inside
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1292380345.13.jpg)
I' think I will smooth the welds in there a bit , as it is a drain passage there. Access could be better but do-able.
(IMG:style_emoticons/default/wacko.gif)
Jackstands... and a sand blaster. ...need sand blaster (IMG:style_emoticons/default/mad.gif) ..... (IMG:style_emoticons/default/icon_bump.gif)

[Mike Bellis]

Nice welding! (IMG:style_emoticons/default/first.gif)

I wish my skills were that good.

[nathansnathan]

I want to keep the thread updated.
I went on vacation, up to the bay for about a week over Christmas.
Contemplating removal of the passenger inner long in its entirety without removal of the outer the whole time...

I'd got these additional jack stands for the inner long removal. It seems to me that you can only really have 4 jack stands actually holding up a car safely, unless additioanl ones are the leveling type. I found the black ones online. I trust them over the little aluminum ones to be sure.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294592744.1.jpg)

The task at hand, it took me 2 days after work drilling out spot welds, the upper
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294592744.2.jpg)

and lower, many many spot welds
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294592745.3.jpg)



I took my time with it. It's single layer just in front of the lower p seatbelt mount bolt forward to where the front door frame swoops up. Tricky to separate the layers there. I thought of nicknaming the car The Blue Onion... for some reason.

More, grinding at the mig welds that hold it to the front firewall/ rear of the passenger wheel well - complicated by the heater tube at the front being in the way of 1 particularly ( had to do some cuttin' on account of that)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294592745.4.jpg)
You can see where I tried to weld up some damage to the inner inner long there with all that rust. I guess just practice or wishful thinking that was...

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294592746.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294592747.6.jpg)

now that's a hell hole
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1294593003.1.jpg)

Can't wait to start putting it back together.

[silver74insocal]

(IMG:style_emoticons/default/yikes.gif) you werent kidding about going deep!! keep up the work and pics . its inspiring (IMG:style_emoticons/default/beerchug.gif)

[porsche_dreamer]

I have to say good job! Keep up the (IMG:style_emoticons/default/sawzall-smiley.gif) . Ill be watching this one.

[Root_Werks]

(IMG:style_emoticons/default/w00t.gif)

Wow!

Looks like another 914 will be saved from the rust monster!

[Dr Evil]

Ya, balls deep. Yikes.

[nathansnathan]

Balls deep, indeed. (IMG:style_emoticons/default/dry.gif)

(IMG:style_emoticons/default/sheeplove.gif)

Thanks for the comments, guys.

I almost got the impression I'd gone past the line of it being scary. The surface rust in the outer long isn't flattering. I sanded a bit of it, quite a lot of red powder, but I think I can save it. I put some rust dissolver phosphoric acid gel on it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535786.1.jpg)

I welded up the places where I drilled too far and smoothed em out. I had to do some pretty good metal adding as it did get kinda brutal.

I need to get media, I'm thinking glass bead so as not to make it any thinner... I have acquired this.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.tptools.com-11782-1296535787.2.jpg)
(IMG:style_emoticons/default/rolleyes.gif)
I can't wait (IMG:style_emoticons/default/chowtime.gif)

I got a gun to shoot, I think I'm going to shoot both the primer and the paint with it. My friend said I should get like a $40 gun to shoot primer with and use the good gun only for paint. It's a Sharpe Razor HVLP gravity feed, 1.5mm air nozzle so it's set up to do both. ..
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.northerntool.com-11782-1296535787.3.jpg)
That is another story, still figuring it out.
(IMG:style_emoticons/default/wub.gif)

The meat and potatoes of this post was to be about my metal-working conquest. I finally started actually fixing something, instead of just taking things off. Doing the hard stuff first, (IMG:style_emoticons/default/icon8.gif)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535787.4.jpg)

Oops I drilled through. I was supposed to be fixing like issues on the side of my firewall today, but I'm actually ill, sort of congested in my head (on one side only?)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535788.5.jpg)

Another story is about how I have 3 driver doors and none of them will work for me. The original one, the skin is f'd. I got another one at a junk yard. Have I told this story? It ended up being a late door because I didn't know what to look for. I decided against using it for the various reasons, and I got another door. This kind guy, I think his name was Brett gave me (as well as the lower pdash pad previously mentioned) a perfect driver early door. Now the problem is that the bottom is out by an inch and a half when the top is about right, this at the back. I'm leaning toward removing the skin from the tweaked early door and putting it on my original door frame, though I haven't committed to that.

I've already removed the original door skin, but I'm saving it for part of the hellhole, so I've cut up the late door, too. Sorry if this peeves anyone. I was a bit leery of putting some crap metal home depot alloy steel in there, so ...

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535788.6.jpg)
Use of dirt to form a paper template

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535788.7.jpg)
A little foreshadowing

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535789.8.jpg)
I figured out on the 2nd attempt at this that chemical stripper will leave you with more metal than removing the paint with a wire wheel.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535789.9.jpg)
Alas, it got a lot uglier before I abandoned it. (IMG:style_emoticons/default/sad.gif) I ended up grinding down that lump on the column part and going right through. It was too 'thin and thick' everywhere, and I decided to o it again. Took me all day and it's still not done.

The template for mk II involved masking tape, and I did the joint of the 2 pieces a bit better.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535789.10.jpg)
A bit more to do. I'm waiting for my girlfriend (no longer ex - I got her back, the one from the dream (IMG:style_emoticons/default/smile.gif) ) to send me her drummel tool to more precisely take the welds in the nook down. Hopefully there will be no need for mkIII.

Other happenings, sort of unrelated, I was standing there looking at her (the 914) thinking, I'm gonna have to get the cross support under the passenger seat welded to the inner long (that I've taken out) before I take out the floor pan, when from the sky 2 feet in front of me drops this
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1296535789.11.jpg)

right on to the support with a sort of thud/ chink. I probably should have whacked it, because while I was busy taking this great picture of the adhesive residue on my floorpan (note blurry black widow?) He crawled into my tunnel (hopefully) never to be seen again?
(IMG:style_emoticons/default/unsure.gif)

[Zimms]

What did you use to cut around the windshield frame? Cut off wheel, sawzaw, or airsaw?

Thanks,

Mark