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> 914 2.0 > 3.0 GT Conversion, On the road!
Larmo63
post Apr 4 2018, 05:48 PM
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Is this car originally Light Ivory?

That's a solid 914 color.........

just saying
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Eric_Shea
post Apr 5 2018, 10:57 AM
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Great Job Stephen. A true talent. (IMG:style_emoticons/default/smilie_pokal.gif)
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914forme
post Apr 5 2018, 11:20 AM
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Times a wastin', get wrenchin'!
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Glad to see you fixed your dolly issue.
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Casanoroc
post Apr 23 2018, 01:50 PM
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Great work, good to hear I'm not alone in Essex.
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defianty
post Apr 23 2018, 01:54 PM
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QUOTE(Casanoroc @ Apr 23 2018, 08:50 PM) *

Great work, good to hear I'm not alone in Essex.


Well there was me thinking I was all alone in Essex!
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defianty
post May 9 2018, 09:55 AM
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Right let's get back on track, it’s been a while.

Rewinding back a few months you saw that I replaced the lefthand sail panel but didn't finish off that rear quarter. This was supposed to be the easy side, but it turned out to be a bit of a nightmare.

Here's where we were.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881303.1.jpg)

I took my door to a local metal fabricator and asked them if they could bend me a sheet of metal to the same profile. I would then be able to use that to fill in the hole on the rear quarter. Here's what they made for me.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881304.2.jpg)

It fitted perfectly.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881305.3.jpg)

Welded in and very happy with it.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881305.4.jpg)

I just had to weld on the flare and I'd be done with the last corner of the car. But when I stood back to look over my work I realised I'd made a big mistake.
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defianty
post May 9 2018, 09:55 AM
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If you saw my post a few months back you'll remember this.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881317.1.jpg)

I remember the bottom of the rear quarter got caught and bent on the axle stand. I thought I'd straightened it, but I obviously didn't do a very good job.

Here's a straight edge up against the bottom of the rear quarter. :shock: Yeah, that won't do.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881318.2.jpg)

Try as I might I just couldn't fix this, I made a section to replace the bent edge but then went and proceeded to totally mess it up welding it in place.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881318.3.jpg)

Frustrated I closed the garage door and left it for a while. Actually that while turned into a few weeks, but during that time I managed to source a used half rear quarter to replace what I'd messed up and I went on holiday.
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defianty
post May 9 2018, 09:55 AM
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On my return I felt relaxed, motivated and full of enthusiasm. That didn't last long though.

The replacement rear quarter panel had arrived and I intercepted it at the sorting office. Getting home I ripped the box open and lifted out the panel. (IMG:style_emoticons/default/sad.gif) I instantly knew something was wrong. An eighteen inch square piece of metal should not weigh anything near what this piece weighed.

I sprayed it liberally with paint stripper...
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881333.1.jpg)

That's not metal (IMG:style_emoticons/default/sad.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881334.2.jpg)

That's metal (IMG:style_emoticons/default/sad.gif)
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881335.3.jpg)

Once all that s*&t was removed I ended up with this.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881336.4.jpg)

Not the prettiest of panels but most importantly rust free. All that filler was hiding just that dent on the bottom right and most of that I'd be cutting off to install the flare. For the first time since opening the box I was starting to think this may just work.
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defianty
post May 9 2018, 09:55 AM
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It was only now that I noticed something with my new sail panel I’d installed. The indentation for the door handle wasn’t quite the right shape. The more I looked at it the worse it got.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881353.1.jpg)

Here it is compared to the original on the replacement piece I got.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881354.2.jpg)

Now I know it’s not a million miles off but it’s off enough to warrant replacement. So I cut it out and used all of the used panel I could.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881354.3.jpg)

Already looking better
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881355.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881355.5.jpg)

New support fabricated and welded in. Getting this the right shape and size was a little tricky but after measuring multiple times welding in this support made everything measure true to the other side.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881356.6.jpg)
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defianty
post May 9 2018, 09:56 AM
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And then finally time to install the last flare.
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881370.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881371.2.jpg)

The arrow drawn on is a reminder to adjust the door gap slightly.

Finally back in one piece!
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881371.3.jpg)

I’m so pleased to be at this stage now. It’s been way more of a job that I ever imagined. The ‘to do’ list before paint is now finally just a few small things.
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mepstein
post May 9 2018, 10:00 AM
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(IMG:style_emoticons/default/beerchug.gif)
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bbrock
post May 9 2018, 10:10 AM
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I am truly jealous of your skills. I just can't seem to make those welds vanish the way you can. You made the right call on replacing that door pocket. Strange that it was off like that. I've said it before but... (IMG:style_emoticons/default/pray.gif) (IMG:style_emoticons/default/pray.gif)
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tygaboy
post May 9 2018, 10:11 AM
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I hear you on the "not good enough so I redid it..."

I tell you, though, I'm of the mind that when there are little things that are off, even if you don't consciously notice them, it has an impact on the overall "feel" you get when looking at the finished product.

Contrast that to what I'll call a "calm, integrated feel" that comes from all the little things that add up.

That's a long way around to "Awesome job!" (IMG:style_emoticons/default/aktion035.gif) (IMG:style_emoticons/default/pray.gif) (IMG:style_emoticons/default/wub.gif)

You're surely going to have one of the nicest GTs on the planet.
Continued great results with all your work!
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autopro
post May 9 2018, 10:15 AM
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Very nice work, I love seeing the car all put back together. It looks so good.
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Dion
post May 9 2018, 10:58 AM
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Wow what a journey so far. Epic, just epic. (IMG:style_emoticons/default/pray.gif) metalwork
(IMG:style_emoticons/default/beerchug.gif)
BTW thanks for the info on your tach
I sent mine over, returned in beautiful condition .

Cheers,Dion
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defianty
post May 9 2018, 11:30 AM
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Thanks again for all the positive comments guys. The hard work is finally paying off.


QUOTE(Dion @ May 9 2018, 05:58 PM) *

BTW thanks for the info on your tach
I sent mine over, returned in beautiful condition .


Good to hear Dion, he does a great job doesn't he!
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Lucky9146
post May 10 2018, 06:53 PM
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QUOTE(defianty @ May 9 2018, 08:56 AM) *


Finally back in one piece!
(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1525881371.3.jpg)

I’m so pleased to be at this stage now. It’s been way more of a job that I ever imagined. The ‘to do’ list before paint is now finally just a few small things.


The effort was worth the result. You should be pleased, Looks Great! (IMG:style_emoticons/default/beerchug.gif)
Paint is on the horizon!
(IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/white914.jpg)
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defianty
post May 17 2018, 10:59 AM
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The next stage has been fitting the rocker panels. It was obvious on purchase these would need a fair amount of fettling to fit correctly. I've never fibreglassed anything before so once again I hit up YouTube and sought out a few tutorials. Armed with just about enough knowledge I ordered up the relevant supplies and set to the job.

Whilst the lefthand one fitted well enough to the car the righthand one didn't - the top edge was at the wrong angle and pushed it up into the door. You can see in the pic below, there was no gap at all and bottom of the door scraped on it when opened.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576375.1.jpg)

It's difficult to capture but you can just make out that top part slopes down too much.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576376.2.jpg)

In the end I decided to cut off the top section and then reattach it at the correct angle. I took several measurements along the length before cutting and decided the edge needed to be 5mm higher to be at the correct angle. These struts held everything in place so I could fibreglass under the lip. Once set I then had both sills ready to fit too the arches.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576377.3.jpg)
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defianty
post May 17 2018, 11:00 AM
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So here’s the fit out of box… I guess you could say, not even close!

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576397.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576398.2.jpg)

I scratched my head for a while went to work cutting it up. Then with thin aluminium strips for support I could bend everything to the correct shape.

You can see just how far I needed to move them to fit correctly.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576398.3.jpg)

I learnt that fibreglass doesn’t stick to aluminium foil so I used that as a backing in the first instance. I later found using duct tape a stronger method.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576399.4.jpg)

Resin starting to harden

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576399.5.jpg)

Foil removed and offered up to the car for a test fit.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576400.6.jpg)

Next stage was bridging filler

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576400.7.jpg)

Getting closer

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576401.8.jpg)

After sanding to shape and some body filler I was really pleased with the result.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576401.9.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576402.10.jpg)
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defianty
post May 17 2018, 11:00 AM
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The front didn’t need as much work as the rears. This time though they were both a bit big and the profile wasn’t quite right.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576419.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576420.2.jpg)

Last was to cut the hole for the jack point and test fit the cover.

(IMG:http://www.914world.com/bbs2/uploads_offsite/s6.postimg.cc-6621-1526576420.3.jpg)


Next job is the front and rear valance, they both need an equal amount of work to fit perfectly.
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