Palindrome 914 Build Thread, now on the chassis jig Options

[bandjoey]

Get a Face Mask. Goggles always fogged up so I ended up not using them. A face mask has full protection and does not fog up or get hot. Grinding wheel slag just bounces off. You're really doing a great job. Can't wait to see the new metal going on. (IMG:style_emoticons/default/welder.gif)

[Hontec]

Ha, the last picture is a familiar one.. You're in deep too I see! Nice work!!

The eye thing sounds familiar too, been there 3 times, everytime drilled out and hurts like hell for 2 days.. I never go without goggles again...

[nathansnathan]

I haven't updated in awhile, but I have been busy. (IMG:style_emoticons/default/smoke.gif)

I thought I had gone to the core of it, that no more rust lay hiding, but those 2 little holes kept taunting me.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459732.1.jpg)

Outside it looks solid of course
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459733.2.jpg)

I'm glad at this point that I took it off though it was further than I ever intended to go.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459733.3.jpg)

The console itself being made of thicker metal was not as bad as what lay against it.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459734.4.jpg)

That drip there comes from a hole that comes through the long. Why they would have situated it right there to drip down on those 2 double layer holes is proof that someone was an idiot or that they made these cars to rust on purpose.

deeper

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459734.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459735.6.jpg)

I'd stalled a bit before getting into all that, got some glass beads, 5 gallons. I tried to upgrade my compressor, but not yet, so a lot of waiting for the tank to fill.

I've put my containment chamber about the construction.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459735.7.jpg)

My friend made that for me, the frame of it out of pvc pipe and fittings, as a work table light support. I sewed the drop cloth surround part to contain grinding dust. I played with using it as a paint booth on a small scale. It's getting pretty rough, so I've sacrificed it, I've sectioned it around the 914, trying to contain the bead blasting.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459735.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459736.9.jpg)

There's a glimpse of the 'jig' there for the outer suspension console. I'm trying to make that as short term as possible and also I'll be verifying placement by measurement, before trusting it at all. I may have some questions about that when the time comes (soon!).

Working my way back. The rust is starting to come back already. I'll hit it again before I etch it, got to get my etching stuff. I think I'm going to the paint store this weekend.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459736.10.png)

A little thin in a place or 2 but I've finally reached something solid! The suspension console outer was held on by more than a few welds.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459738.11.png)

Still a little more blasting to do on this but looking much better
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459739.12.jpg)

Blasting without the cabinet is a real pain in the butt. I need a hood! Can't keep the media out of my hair...or my shoes.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1301459740.14.png)

I've been filing that, the inner fender well upper for a few days now. I will start fitting the piece below tomorrow. I have 2 cans of 3m weld thru primer, and if I get the etch stuff, maybe I can be welding the outer suspension console back on this weekend! (IMG:style_emoticons/default/welder.gif)

[0396]

All I can say is – wow, good luck. What you’re attempting to do is not for the faint of heart.
Then it looks as though you have all the resources and skill set to accomplish this project.- all the best!

[Andyrew]

Looking great!

[EdArango]

Nathan....Great job....I'm in HB and would really like to check out your car.

Let me know if this is do-able.

Ed (IMG:style_emoticons/default/beerchug.gif)

[ripper911]

I cant add anything about the build other than "looks good, keep it up" but I know a little about self-surgery, I always like to get drunk first! Absinthe is great because it will numb you nicely while allowing you to keep focus, up to a point.

Also, I don't think that is a black widow. But, maybe thats a california black widow. (IMG:style_emoticons/default/cheer.gif)

[nathansnathan]

About my mess, I've got about a 25' x 25' shop and this is as clear as it gets
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1302145255.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1302145256.2.jpg)

Here's the worst of it. (IMG:style_emoticons/default/unsure.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1302145256.3.jpg)

and this inside the chamber currently:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1302145257.5.jpg)

Got a little progress to show in there, the inner fender well butt welded in and ground the welds smooth. Used the diegrinder and then the flapwheel.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1302145257.6.jpg)

Besides the loft solution, I'm working on restoring a huge industrial shelving unit, so I have someplace to put all this stuff, but meanwhile that's taking up room, too. (IMG:style_emoticons/default/headbang.gif)

I will hit you up when I get back and get this stuff taken care of.

Thanks for the encouragement, everyone. She's finally coming back together! (IMG:style_emoticons/default/sunglasses.gif)

[nathansnathan]

 It's been awhile since I made an update. I can never accomplish as much as I'd like to it seems. I'd hoped for an attached outer suspension console by now, but.... well not yet. (IMG:style_emoticons/default/dry.gif)

I did get my tank refilled with argon yesterday, and hooked up with a #9 smaller torch for my tig, but forgot to buy back caps for it (IMG:style_emoticons/default/rolleyes.gif) I have ordered some from cyberweld, got long, medium, and short. The short are like nothing so I should be able to really get in there.

I sort of lost some motivation, was really bummed out about losing my girl again. We're totally incompatible, despite that she's been my girl for ...11 years? - It's been a rough 11 years. (IMG:style_emoticons/default/blink.gif) Yeah, I came back early from my little vacation, lasted about 3 days of the 14 I'd planned. The bus drove awesome though both ways, and I got a chance to work on my own projects so that's a plus.

I got my mezzanine up, took me like a week. I got the 2 units for $80 a piece of craigslist. The wood was more, even, got 3/4" plywood. I've still got to paint the rest of the floor up thereg. Got to make room for the containment chamber so I can really get my mess on. (IMG:style_emoticons/default/happy11.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305088954.3.jpg)

It's still a bit crowded in here, but it's not ridiculous like before. Organized some parts.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305088954.4.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305088955.5.jpg)
And some more parts, still need to organize a bit more.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305088955.6.jpg)


Oh, I found 1 of these. I had no idea there was anything supposed to be there, even! Is it called a splash pan?
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305088955.7.jpg)

It took me forever to build up the inner inner long to get it ready for the lower inner fender well piece. I filled in like 25 holes on this thing, and built up the thin bottom section. This pic, it's not quite done. I should be putting the piece on soon so I'll have better pics then.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305088956.8.jpg)

[dheming]

Nice job on the mezzanine! Must be nice to have some more room now. Speaking of which I'm about to start on my mezzanine this weekend. Are you going to enclose the top part in to keep dust out? (IMG:style_emoticons/default/beerchug.gif)

[nathansnathan]

Nice job on the mezzanine! Must be nice to have some more room now. Speaking of which I'm about to start on my mezzanine this weekend. Are you going to enclose the top part in to keep dust out? (IMG:style_emoticons/default/beerchug.gif)

Thanks, Derek. I am pretty happy with it. (IMG:style_emoticons/default/piratenanner.gif)
I've oiled the joints and don't notice much movement when I'm doing my dance. (IMG:style_emoticons/default/biggrin.gif) I am thinking of putting in cross braces in places to tie it together, also of constructing caster mounts. (IMG:style_emoticons/default/happy11.gif)

The plan as far as enclosure is to divide the 2 halves of the shop during the sanding and primer stage with a heavy drop cloth curtain.

Currently I'm in the process of putting up the containment chamber on its own this time, need to make room by the cabinet (make the materials storage rack so I can slide the workbenchh down?) so I can blast the my valances and rockers, backs of bumpers etc.

I had been waiting the last 10 days for the parts from cyberweld, some mixup at my mailbox. They do have hookas for sale right in the place, the pack & ship.

Finally got the back caps, the small ones they sent me were wrong, were for the 17 torch instead of the 9 so pictured are the medium. Both of those are #7 cups.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947534.1.jpg)

I hooked up with some weld backing options also, these from Eastwood. The triangle is my favorite so far, used it a lot for the inner inner long.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947534.2.jpg)

During the wait though to do more welding, I've been detailing the outside of my engine case. Various methods employed have included a bit of acetone with lots of cotton swabs and paper towels, a bit of paint thinner and a brush, simple green some.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947535.3.jpg)

Still coming along. I won't be able to finish until I put it on the stand and that I won't bother with until I've modified it. I've purchased this yoke:
(IMG:http://www.914world.com/bbs2/uploads_offsite/images.thesamba.com-11782-1305947535.4.jpg)
I have 2 of these coming.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.mcmaster.com-11782-1305947536.5.jpg)
I need to go to Industrial metals to get a cross beam for the front of this fan shroud murderer.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947536.6.jpg)

Besides that, I've been blasting a piece or so of the tin each day.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1305947537.7.jpg)
It does take awhile, the compressor is always running. (IMG:style_emoticons/default/smash.gif)

[nathansnathan]

To update, it was definitely fun, meeting up with David yesterday, checked out his roller at his work in Orange. I should'a brought my camera. I got a few minor things like a seat rail with the adjustment handle intact, I finally got a replacement for the oh-so-elusive door striker back plate casting that I'd broken off a tap in the original of, I cut out this replacement section of the drivers headlight side marker light wiring harness
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129150.1.jpg)

the original had got a bit toasty at some point
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129151.2.jpg)

The first thing I did when I got back was cinderblock mockups of the mahles.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129153.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306129154.8.jpg)
I have been just looking at them fondly from time to time. (IMG:style_emoticons/default/drooley.gif) I got the lugs also, minus 4 of them. I need to find 4 more 38mm ones and I think I have 2 but need 2 more 19's for the spare I realize now. ... details. I'm pretty happy just to have them. (IMG:style_emoticons/default/biggrin.gif)
I got a really good deal on all of it, $420 discount. Thanks again to David for the the good times, like I'd said, my first 914 engine compartment outside my own. (IMG:style_emoticons/default/smile.gif) (IMG:style_emoticons/default/beer.gif)

[nathansnathan]

I've finished enhancing my engine stand and thought I would share. I just need to paint it, maybe shorten some bolts, and weld up the T handle to lock the yoke.

As I'd mentioned in the previous post, I'd ordered the 4 arm yoke off the guy on the samba, but did it off ebay actually. The description talks about how it will fit in a 'standard' 2 3/8 inch hole. The swivel on my empi knockoff stand is like 1 3/4 inch.

I'd thought about how easy it would be to just buy a new stand. So I talked to a bunch of people off Craigslist who were selling mostly the harbor freight stand and it seems that 1 the hole measures 2 1/4 inch? Maybe they were measuring it wrong...

With this complication, I went back to plan A, to modify my stand, and with a half day of work on friday for Memorial day, I was able to go to the metal place.

Getting started, the old swivel would have to go, thankfully.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769877.1.jpg)

I don't have pics of it specifically but I drilled off the old swivel caster that was at the front (honestly 1 supporting leg it had out front with a swivel caster! Check the pic, that had actually broken, the pin came 'unswaged' and the wheel had fallen off (IMG:style_emoticons/default/bootyshake.gif) )

Probably the biggest improvement was the stability added by the wider track front.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769878.2.jpg)

I decided to reinforce the joint between the vertical member and the lower part (previously just one bolt went through holding all pieces together, and then a flimsy cross brace above). (IMG:style_emoticons/default/aktion035.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769878.3.jpg)

I welded in through-tubes to reinforce both the members were the cross beam clamps down on them.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769878.4.jpg)
Welded, ground and sanded down
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769879.5.jpg)

And the yoke swivel enhancement. I found the perfect stuff in the remnants section, DOM tubing, or 'drawn over mandrel' there is no weld crease evident on it and it is quite hard, maybe 1021 the guy was saying, just short of the hardness of chromoly, but weldable as a mild steel. The stuff is thick walled!
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769879.6.jpg)
The bolts coming out are made of phosphor bearing bronze and there are 3 at 120 degree intervals at the front and the back. I'll put nuts to lock them in position. These take up the ~.015" play on either side; the difference in the id of the pipe and the od of the yoke swivel is pretty good but still a little play. 'I honed' the barrel of the yoke with fine sand paper. I think I may use way lube to check rust between. There is no drooping with the engine on it, no tendency for the engine to slide forward and out as before.

It's amazingly rigid. It feels awesome to be able to trip over it and not worry about having to 'catch' the engine or to have to leave it only in the 1 position that the yoke ears aren't strained being attached at only 2 independent points. I'm pretty happy with how it turned out.
Before: (note the tiny flat cross bar supposed to be bolted onto those tabs, is missing in the pic)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769879.7.jpg)

After:
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1306769880.8.jpg)

[Beach914]

The Mahles are going to look great Nathan. They definitely look better on your car than that black roller. I think that the original color was L96D.

I've got some misc short Lugs that you can come over and pick through when you want.

Dave

[saigon71]

Nathan:

Great work man! I too am attempting a teener restoration in a one car garage...it is quite challenging sometimes! My ceilings are not as tall as yours though, so I had to pick up a shed that someone was giving away for parts storage.

Keep it up!

Bob

[nathansnathan]

Nathan:

Great work man! I too am attempting a teener restoration in a one car garage...it is quite challenging sometimes! My ceilings are not as tall as yours though, so I had to pick up a shed that someone was giving away for parts storage.

Keep it up!

Bob

Thanks, Bob. (IMG:style_emoticons/default/smile.gif)
Even as the parts are, I want them to be more 'out' so I can go over them in good order instead of just what I can get to. I can't recall where my glove box is... (IMG:style_emoticons/default/unsure.gif) (IMG:style_emoticons/default/biggrin.gif)

[nathansnathan]

Picking up here, update the thread.
I met up with David again, I'd been thinking about the fresh air vents on his roller ever since I'd seen a week or 2 before getting the Mahles. I got some pics this time.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842265.1.jpg)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842266.2.jpg)

The car is pretty crusty at the longs and jack point is floating in the rocker, lower firewall is bad, and floors. She was well done, and so with the fresh air vents being very good compared to mine
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1291591584.2.jpg)

Rather barbaric, I used a .40" cutting wheel on my 4 1/2 inch angle grinder.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842266.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842266.4.jpg)

I got the seam sealers all out with the heat gun and scraping screw driver, some rust in there but solid. I've started blasting and it's looking great.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307842267.5.jpg)

Will get a picture of after blasting and how I'm gonna install later.

[nathansnathan]

It does look rusty, but honest, just a bit of pitting.
Anyway, going stronger than that, (IMG:style_emoticons/default/smile.gif)
taking it to the next level, another car has come to me. (IMG:style_emoticons/default/beer.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844936.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844937.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844937.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844937.4.jpg)

It's funny, I realized after contacting the po that it was a guy I got a $2 door handle off of the first week I had my 914, Paul, who works at Rancho Transmission in Santa Ana. He is exactly 16 miles from me and I got it towed here this morning much more affordably than the first one, thankfully, though we did have to wait it seemed 2 hours for the guy to come on his 'day off'. Good stuff though to talk shop with a guy that knows about these things, or Volkswagens anyway.

Tuning was so so, probably would have idled if it got warm. It runs, I should add. The carb is, he told me, a real one out of an actual Pinto. The valves sound good though. I will have to do a compression check. Thinking I may get it rolling with that engine while I put mine together.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307845285.1.jpg)

Body is pretty crusty on this one, too, mostly down low though where mine is worse above, well except the hell hole, this one is the worse, the 420 car seems solid in comparison.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844938.5.jpg)

A lot of the interior is there
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.914club.com-11782-1307844938.6.jpg)

It's got some really good stuff that came with it, all 4 rotors are German and new for 1. The driver door may be the one to use. The deck lids are better than both of what I have I think. It came with a a new carpet, black though, not sure how nice it is. The windshield is what I was looking for when I found it. I'd seen it before of course, but it really made sense more looking for a windshield. It looks to be very good, PPG. The top of the front bumper is straight and solid if I can get the chrome off. My plan is to d the bumpers the same as the wheels, in 'wheel silver'. I know it's not stock but I on' like the body color plan and have qualms about the re-chroming chrome route.

Other stuff that came with but probably won't use new-in-the-box 911 ate master cylinder, also in the box the front euro lenses, seemingly more brake calipers than the 4 (no brakes on it now), stainless soft line new. The backpad is pretty nice, early though as it's a 71.

It's pretty exciting just to have an assembled 914... to sit in. (IMG:style_emoticons/default/driving-girl.gif)
Just wait until the battery charges (it sit's in the trunk (IMG:style_emoticons/default/dry.gif) ), I'm ganna start it. Maybe tomorrow after the Classic (IMG:style_emoticons/default/aktion035.gif)

[dheming]

Nice score on the parts car. BTW, something like this is what I was talking about for a simple engine run stand: http://lainefamily.com/EngineStandProject.htm

[nathansnathan]

Nice score on the parts car. BTW, something like this is what I was talking about for a simple engine run stand: http://lainefamily.com/EngineStandProject.htm

You call that simple? (IMG:style_emoticons/default/biggrin.gif)
Here's a pic I had saved, he's got the fuel injection partially attached to it, too, 914 stuff there.
(IMG:http://www.914world.com/bbs2/uploads_offsite/www.eggscollective.org-11782-1308005510.1.jpg)