Cary's 73 1.7 Rustoration Thread Options

[Luke M]

Make sure you weld the square tube in place before the cover plate..

[JoeDees]

I gratefully request you to post pictures of the ties before you weld them on. Thanks

[cary]

I gratefully request you to post pictures of the ties before you weld them on. Thanks

Will do. Stopped by the dealership this am.
All four parts are NLA. So fabrication is the only answer.
The 12 guage is over our paygrade, wish we had a forge. So the big ass hammer is the tool of choice, leaves it kind of ugly.

[cary]

Started the day with welding in the jack posts.

[cary]

Super In Law finally finished the upper tie. A little crude, but it will work.







He built it a little bigger than the factory one on the other side. I predrilled 5 rosette holes. Then it was ready to weld.





I know its over welded. But I just can't help myself. I just love melting metal. LOL.

I drilled a drain hole thru both layers. I also opened up the drain on the suspension console.

[JoeDees]

For working with 12gauge, I don't consider that crude at all. I'm dreading having to make them in the coming months and almost wonder if doubling up 18 or 20 could accomplish the task.

[cary]

After a couple other family automotive issues we got to spend the afternoon back on the car.

Super In Law (Grandpa Jack) went to work on the suspension console tie.
It was created in two pieces like the one on the web hypertext.

Test fit .............



As far as I got welding before it was time to head home.

[cary]

I decided to dissect the crappy patch job on the right front fender.

Starting point.



Kind of hard too see because of the steel color. But I cut it out in 2 pieces.That made it easier to get at the back of the spot welds.



Then I made my Ed (Wheeler Dealer) pattern. That technique comes in real handy.



Went to my sheet of 18 gauge. Laid the tape on the steel and cut it out using my HF shears. I hate to admit it but the HF one cuts better the our Old Milwaukie pair.

[cary]

Then on to welding it in.
I could have used 2 or 3 of these. The pair I have are too small for the right side. The 4" ones worked great for the left side.
http://www.cometsupply.com/mp/IRWIN/pm/IRW...6bCgaArxg8P8HAQ





Looks like I'm on the right track. Taking my time, cooling with air, moving all around the piece. The bottom piece is kind of crappy. As you can tell from the holes blown thru it.
I think I'll hold off on the grinder until I'm finished. I'm a little grinder happy

I'm challenging myself to be able to put my cut off fenders back on without a huge amount of filler. Using Jeff Hail's example as my goal.

[JoeDees]

That's purdy. And your suspension ties look about as good as the factory ones on mine.

[saigon71]

Excellent work as usual! (IMG:style_emoticons/default/beerchug.gif)

Those console ties look great. I found them to be a challenge to fabricate as well & ended up doing each one in three sections.

Keep on truckin!

[cary]

Thanks for the words of encouragement.

I think I'm going to add another piece to the top.

[cary]

Another day at the shop. I would call this one a so so day.

Started by finishing up the welding in of the suspension tie. Just for fun I decided to give the Millermatic function a try. On the 12 gauge stuff it worked like a dream. Unbelievable.

I should have tightened up my E's to stack the puddles a little tighter.



So I decided to try it on the front fender is was working on. BIG MISTAKE. I blew a hole with the first weld. It went form bad to worse. Today was a turd. I had visions of grandeur of getting it welded in perfectly with invisible welds.

Now that I now where the crappy steel is. I'll cut it out AGAIN and do it over. (IMG:style_emoticons/default/mad.gif) (IMG:style_emoticons/default/mad.gif)

[cary]

While I was cussing up a storm. Super In Law was creating a new end cap for the long/rocker panel.







Once the welds are ground down I'll seal things up with brush on seam sealer. Then we'll spray it with 2 coats of epoxy primer. Then we'll apply spray on seam sealer.

[cary]

While he was finishing the end cap. I welded in the patch on the bottom of the fender.

[Cairo94507]

(IMG:style_emoticons/default/popcorn[1].gif) Lovin' it.

[cary]

Another episode of Tool Whore





Ran across this manufacturing oven while looking for a frame rack. Building a powder coating oven was one of our next projects. This will give us a good start. Its about the same size as our wall oven here at the house 19*15*18.

I still want to get a frame bench before I restore my 911. So I keep an eye out on Craigslist every once in a while. I've conceded the fact that I'll never be able to find or afford a Celette.
http://www.ebay.com/itm/USED-CELETTE-SEVEN...512&vxp=mtr

I'm most interested in the table and pinch weld mounts. I know I'll have to create my own shock towers for both a 914 and 911. The search continues. I low balled a price on one in Seattle. Pissed the guy off. We'll see if he comes back.

[cary]

Left front fender round two. I cut out the section again. Just didn't like it.

A shot of the cut out. Then a shot of the patch all set up and a couple opening tacks.
Last grind on the right side was a bit too much. Wish me luck. Plan on backing every tack with a brass backer.





I thought I should go into a little more detail on the patch panel. We used the cut out section as the pattern. Dah. But we needed to create the folded over seam edge for strength. So I decided to use the air flange tool to start the fold. Then moved to the metal brake to bend it. Then we flattened it with a hammer. Then we finished it off with the 12 ton press. Using the blocks that come with the press to sandwich the patch.
So next we needed to create the radius in the fender. Once again we used the cut out section as the pattern. Ground the double edge down to match the pattern. Then welded the edge closed. Ground the welds down to bring in back to a finished edge. If needed I'll use All Metal to final finish the edge.
That isn't a very good shot of the fender edge. You see the hinge post in the background making it look like I left the welding.

Below is the flange tool.
http://www.restoration-design.com/store/product/PP207AL

[cary]

Slow and steady wins the race....................





The day went real well. I took my time welding it in stitch by stitch. A couple spots got a little too hot. But in the end it went in relatively flat.



I'm a little paranoid on over grinding. Thins the metal too much. I'll use All Metal to smooth out the imperfections.

[cary]

New Episode of Tool Whore .............

Magnetic Welding Backer from TP Tools. Worked great. Keeps the back real tidy.



Then I bought a bottle of cooling gel. Its working good too. Not sure how it works. But it does.