Just arrived in the garage: 1971 914-4 1.7 Options

[cary]

As I was working on the inside of the trunk. Super In Law went to work on repairing the butchered up tow hook framework.







He's building the extension rather than cutting up the other cut out tow hook.

[raynekat]

Some other back burner items getting finished while Cary works on the metal work.

The fan/shroud from the 2.4 MFI T motor.
Years of decay and corrosion.
Some nicks and chips in the blades.
Etc, etc.

Sent them out to Mark Motshagen for refurbishment.
The end result is quite stunning.

So.....

THE BEFORE:

[raynekat]

THE AFTER:





All new plating and rivets on the center pulley section.
He repairs the chipped vanes and refinishes it all.
Then out for what I believe is some kind of ceramic coating....it's not powder coated.
This is much, much better.
More durable and to my eye, much nicer looking.
Is it concours? Not at all, but I'm not doing a concours restoration.
More of an R Gruppe improvement or hot rod.

The fan is a dark charcoal gray and the housing is done in black as many of the 911 motorsport engines were done.
Combined with a nice amber fan shroud by Damon @900 Series...should look great
with the rest of the refinished MFI accoutrement (my $50 word for the day).

Enjoy

[Gmanscott55]

WOW... Looks fantastic. (IMG:style_emoticons/default/smilie_pokal.gif)

[cary]

Back to the task at hand.

Welded in the left inside trunk corner. Fit real nice.



I added back in/on the tail of the inner fender portion.



Then I welded on the tow hook extension that Super In Law created on Friday.





90 degrees in the shop with all the lights off, and the doors closed

[raynekat]

Last hot day today. Back to cooler temps after that. Sounds like the shop needs a swamp cooler?

[cary]

Still hot ..................90 degrees when we left at 5pm.

Started the day with grinding down the inside trunk corner patches. After the grinding and sanding was finished I coated them with cold galvanizing.





While cold galvanizing was drying I sprayed down the trunk support panel with OSPHO. Getting it ready for a rub down with a red scour pad and an application of cold galvanizing.

[cary]

Then went after trimming down the trunk panel somemore. Reinstalled the taillight panel to check all the edges. I won't install the taillight panel until we change out the back end of the qtr. panels. Don't want to get the cart ahead of the horse ...............



After fitting the trunk panel I decided I'll do a complete extension of corners. The panel is just a bit short in the corners. More to come tomorrow..........

Then onto the inside tie in portion of the tub that welds to the taillight panel. Doug's was squished and over hammered. The ones off the parts car were rotten.


Left side ................... Buckle needed to be cut open and the edge straighten.


Right side ............... pretty messed up.

Left side all tidied up with my electric glue gun.




Sorry for the sideways .....................

Then onto the right side repair. Super In Law created the patch piece last Friday.

[cary]

After extending trunk panel I'll start on the delicate patching of the cowl and windshield frame.

[cary]

Began with cutting the right corner of the trunk panel to create the extension needed to fill out the corner.



Basically cut it right in front of the vertical flange. This will allow me to swing the vertical portion out to the wall were it needs to be.

This is the extension needed to get the correct fit.





I use numerous shapes and sizes of brass backers to assist in welding in the large gaps/areas.



Here is the finished work. Before and after grinding.







You don't need to get too carried away with grinding. Most of the new extension will be covered with seam sealer.

[cary]

The left corner needs a larger extension. But with enough brass bcakers it all works out.







I'll post the work and findings on the left windshield frame/cowl rust tomorrow night.
Heading to PIR early in the am. Rothsport has five car running in the event.
I'll meet up with Doug at the race track .............................

[cary]

While I was expanding the trunk floor Super In Law was cutting some pieces for the right window cowl.





He created what we thought we would need.



But after I cut open the top portion all I found was Bondo. (IMG:style_emoticons/default/sad.gif)




These are shots after Bondo was dug out.

Talked to Doug at PIR before I posted the pictures. Not exactlty what we thought we'd be looking at. He'll get a windshield cowl coming from DC.

A couple more shots. I'm hoping with the new cowl I can save us from removing the fender.





Here's Jeff Hail's work on his car.
http://www.914world.com/bbs2/index.php?sho...dead&st=240
Starts at Post #262

Off to 3 day's of rally car prep at Rothsport. I'll be back on Thursday night.

[cary]

Yesterday was a short day at the shop. Time for the every other year oil change on the 911. Mobil One V-Twin. Plus I installed the Rothsport oil tank check valve.
http://www.rothsport.com/Products/Engine/O...heck-Valves.htm

Doug stopped by to drop off the fiberglass front hood to put into safe storage and the new to us exhaust heat shield (DC). I'll get the heat shield sand blasted and reworked with my removal set up. I think then Doug plans on having it ceramic coatied for heat dissipation.

[porschetub]

Just got back my newly recovered steering wheel from Autobahn Interiors.
Did the double wrap in leather.
Pricey but "oh-so nice."
They found that part of the wheel had been broken in the past so there was some welding repair necessary that is all hidden by the new grip.

Also just received from Hungary (less than 10 day shipping) a nice Hockey Puck reproduction that really looks great for the money.
Total of $170 (plus shipping which wasn't bad).
Got it off the "Bird" from a guy named Antony.
Easy transaction (Paypal I think) and received the item pretty quick.

Will definitely dress up the interior of the car when complete....

Nice,notice the embossing of the leather is a little heavier than the leather ones currectly sold on ebay,not sure which is more authentice but I like it.
My wheel isn't quite up to your standard as it needs a repaint,all the $$$ stuff has been done however.
Double rap leather on the wheel is the way to go for sure ...much better grip.

[cary]

Looks like Doug's rear qtr. panel sections and windshield cowl will be coming off a donor car I'll be picking up on Thursday morning. I didn't look at the other sections too closely because I was focused on what I need. But both longs look pretty good.

I'm not one to cut into tubs that could be restored. But his car has been hacked up for some sort of V6 conversion.



California car that has only been up here in Portland a couple years. No rust bubbles in the sail panels either.

[raynekat]

While Cary continues on with the metal work on the body, I've been working in the background with more of the subsystems.

Just got most of the dash restored.
Frame was painted a nice satin black by the local auto paint shop.
Added some of my own pseudo basket weave for the dash face....same stuff I've put on the door panels.
Hand repainted the fresh air/defrost levers.
Purchased a nice reconditioned Becker Europa II stereo...actually stereo, many are just mono.
Reflected the glovebox....DIY.
Newly refreshed glovebox lock the is rekeyed to match the rest of the car.
Topped off by a new 914 Rubber dash top.
Sneaked in some new switch centers/inserts.
Some of those have come from VW vendors as our cars share a lot with those guys.

[raynekat]

In addition, I just received back my newly rebuilt alternator.
Some guy has a buddy through 911 S Registry....yada yada.
Anyway, the alternator reappeared in mint condition.
Cosmetically and functionally.
I had bad diodes, brushes, etc.
All replaced with new bearings plus a cometic restoration as well.

Combined with the restored fan/shroud from an Early S vendor, and that part of the engine is looking brand new.
Shame it will be buried in the engine compartment never to be seen.
Guess I'll just print out a poster sized pic of the finished engine (Rothsport) to put in my man cave. (IMG:style_emoticons/default/tongue.gif)







Guess I need to post pics of the amber fan shroud the Damon at Series 900 built for me.
Really goes well the the fan/shroud.

[Mr.Nobody]

Awesome thread so far. Really enjoying all the metal work details. Car is going to be phenomenal when finished.

[jmz]

Doug, can you share alternator rebuild source? blue car alternator needs service.

Car is going to be AWESOME!

[raynekat]

Doug, can you share alternator rebuild source? blue car alternator needs service.

Car is going to be AWESOME!

David with 901.services@gmail.com

I think the bill was something like $250 and they'll check out your voltage regulator as well.
My alternator was pretty old and crusty looking.
Came back looking nearly brand new besides all the refurbishments they did.