*Project 2.4* • Dion’s endeavor • Six conversion, Rustoration & transformation Options

[Dion]

Thanks, Ben. Appreciate the feedback. I do need to get more supplies. I'm
Finding out how much more I need the more I'm getting into repairing the
metal. This is all new territory for me.
So grind welds down "better",then flap disc.
Is that better than using a wire wheel when cleaning up the welds?
Thanks.

[Dion]

Ok so not much gonna get done over the next couple of weeks.
Family vacation time. Heading out west to see some of the National Parks including Yellowstone & Bryce as well as the Grand Canyon. So...
Forgot to share this neat silencer I obtained. Can't wait to hear it. NOS! Pretty neat.
May not make the greatest HP gains but I thought it be cool.

[Dion]

Original advertisement came with it.

[mb911]

Thanks, Ben. Appreciate the feedback. I do need to get more supplies. I'm
Finding out how much more I need the more I'm getting into repairing the
metal. This is all new territory for me.
So grind welds down "better",then flap disc.
Is that better than using a wire wheel when cleaning up the welds?
Thanks.

The best advise I can give anyone when grinding is to just grind the high spots pf the weld down until it is flush with the Parent material. then use a blending disk, Soft pack, Flap disk. Wire brushes are only for removing paint, and rust etc.

I like to to use a die grinder with a thick abrasive wheel on it to bring all high spots down then I use a soft pack which is a glorified sanding disk with a rubber backing that flexes to the contours 36 grit then 80.. this allows it to look virgin..

[Dion]

Thank you Ben. Going to head to the local hardware store and get some supplies.
Get to some finishing work tonite. I'll post pic, hopefully see improvements.
As you said, it takes time. Hopefully my skills will be improving.
Thank you again.

[tygaboy]

Go Dion - You're making good progress (unlike some of us...)
LOVE that exhaust! And that advert is very cool. It's great to have those sorts of goodies to go along with the parts.

[Dion]

Progress is a strong word Chris! Hehehe
Thanks though. It be nice to button this car by
the challenge's allotted time. But....
Yeah I grabbed the silencer cause of its rarity.
I've only seen one on a racing 911. So I thought it was cool.
The fella in Holland could only give me an estimate on decibels
and HP changes. It is literally NOS. A neat find.

[porschetub]

Progress is a strong word Chris! Hehehe
Thanks though. It be nice to button this car by
the challenge's allotted time. But....
Yeah I grabbed the silencer cause of its rarity.
I've only seen one on a racing 911. So I thought it was cool.
The fella in Holland could only give me an estimate on decibels
and HP changes. It is literally NOS. A neat find.

Hi mate ,like that muffler,it will be load and fun (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/aktion035.gif) .
Good score on the welder ,I think for rust repair you need the advantage of a better welder,hope you have more luck than I did with my new 180....crapped out after a week and they give me a replacement (IMG:style_emoticons/default/headbang.gif) ,new one seems fine.
Keep up the good work (IMG:style_emoticons/default/beer.gif) .

[Dion]

Ok per Bens advice. Obtained some flap discs. Trying to correct my sins. Welded some pin holes and reground, then flapdisc the area again. No one will see the amateur job but it's giving me practice. This patch will get cut open again for the snorkel tube.
At least it's a rust free and solid area. Not the prettiest.

[Dion]

For your viewing pleasure and critiquing:
Heeding the advice of the experienced on this board, I went back to my trunk floor repair. It improved a little. I'll need some body filler to smooth out for better aesthetics
and then paint. I know it gets covered by the mat and carpet. My concern is being watertight. I do like summer but working with the safety equipment on when it's 85F and
90% humidity , whew! A new appreciation for those that do this for a living.

[Dion]

Top:

[Dion]

Bottom:

[tygaboy]

Dion - It's hard to tell from the pics but it looks like you may have the repair piece not quite aligned / in level. It looks like you're ending up with a step where your weld is.

I know I've got it "right" when I can use a 1/4" grinding wheel to knock down the majority of the weld bead and not get into the parent material of either side.
I use the grinder to get close then hit it with a 2" or 3" abrasive wheel on an air angle grinder (depending on the available clearance) to take it almost to the parent material level.
If I have the room, I then do 80 grit on a d/a sander. If no room, 100 grit on the 2"/3".

On the water tight: get a powerful light and shine it on one side of the weld while viewing from the other side. You'll see pinholes where there are, well... pinholes!
buzz them closed and check again til they're all gone.

And remember: It's only metal!

Keep up the great work.

[Dion]

Chris, you are correct. Slowly getting there. Yes I have a halogen work lamp under the car shining up. Pinholes revealed themselves. Closed them, found another after I hit the area with some primer. Yep it's only metal. I'll still need to address it. But it's way better than my previous attempt. Thanks for the encouraging words.

[Dion]

Rescuing an early bumper. Rusty backside. Sandblasted, some flap disc work. Rust encapsulater from Eastwood. Then some paint. Chrome side is.... well it's better than
my scratched and dented one. This one has a few dimples but less obvious than my previous bumper. Took a buffer to it. It's a 10 footer. Good for my driver. It has built in
patina (IMG:style_emoticons/default/biggrin.gif)

[mb911]

Dion - It's hard to tell from the pics but it looks like you may have the repair piece not quite aligned / in level. It looks like you're ending up with a step where your weld is.

I know I've got it "right" when I can use a 1/4" grinding wheel to knock down the majority of the weld bead and not get into the parent material of either side.
I use the grinder to get close then hit it with a 2" or 3" abrasive wheel on an air angle grinder (depending on the available clearance) to take it almost to the parent material level.
If I have the room, I then do 80 grit on a d/a sander. If no room, 100 grit on the 2"/3".

On the water tight: get a powerful light and shine it on one side of the weld while viewing from the other side. You'll see pinholes where there are, well... pinholes!
buzz them closed and check again til they're all gone.

And remember: It's only metal!

Keep up the great work.

(IMG:style_emoticons/default/agree.gif)

[Dion]

Polished

[mb911]

Looks nice way better then what I had ..

[tygaboy]

Looking good, Dion! (IMG:style_emoticons/default/smilie_pokal.gif)

And slightly hijacking but: I'm with you on "driver quality". I plan to drive my car, do an occasional track day, park it near other vehicles, even leave it outside sometimes.
I look at some of the fantastically wonderful work being done by folks like 914dave (and his helpers!) and wonder if I'd ever really want something that nice. I'd be worried sick about every little thing. Heck, just working on my car with the new seat in it is nerve wracking.
It's also a convenient excuse for not spending a ton on paint!

Sorry to distract but this is just my way of supporting you in not obsessing about a bumper that isn't perfect!

Keep on posting - you're helping keep me motivated.

[Dion]

Chris your too funny man! I have to agree. Mine is a driver for sure.
I'll never have the level of finish some of these builds have because....
Yes I'd prolly be paranoid! I told Dave that first rock chip is gonna hurt
real bad. Heheheh Hell I get nervous about of his tools in the garage near
his ride.
I'll be getting back to welding shortly. Like melting the metal.
Thanks guys!