Bringing out the dead Options

[sean_v8_914]

could you send me a close up of your butt weld? ...or the high res version of that photo

[type11969]

Jeff-

I think you should take an extended vacation in Philadelphia. Bring your tools.

(IMG:style_emoticons/default/biggrin.gif)

-Chris

[Wes V]

Dang Jeff, I'm confused about the sequence on how you are doing this!!

In your last entry, you are welding the fender back in place.

And yet it doesn't look like you have welded the outer suspension bracket back on!!!

I know (from reading this string a lot) that you are planning on installing the Tangerine Racing (CFR) suspension relocation set-up, but from what I've been able to figure out, you will need that fender partially removed to weld everything in place! (the gusset plates in particular)

So, did you already install that and didn't say anything or what?

Are you planning on installing metal flares and feel confident that the opening for the flare (prior to welding in place) will allow you to weld in the suspension?

Wes V

[Jeff Hail]

could you send me a close up of your butt weld? ...or the high res version of that photo

Lets see how large a file the site will let me post. I always reduce them out of courtesy to the site owner. Someone is paying for web space.

[Jeff Hail]

I started blocking the primer today and ran into 2 prior repairs above the weld line.
Pink filler and yellow filler. Get out the "Mud Hog". Oh well it's only a little primer wasted.

The pink filler is below the color coat (copper) and yellow on top of old color where it shouldnt be. Hard to featheredge when it is like that. 6 coats of paint and primer I counted not including filler. The old filler is very thin and doesnt cause any concern. The red does as it is acrylic enamel or possibly Nason synthetic enamel and it has to go away because past experience dictates it will lift or react with solvent. It will get stripped even know the substrates are in suprisingly good condition.

As far as the butt weld line there are 2 small low spots (below the pink filler) and 1 more at the lock pillar that can be bumped out with a hammer and dolly or skim coated.

I have a set of steel flares and most likely will go that route although I have been talking to a fiberglass supplier that is willing to do a wide street weight version of belt line qtr panels with a reinforcement in the debris impact area. We will see?

Wes,
Lots of room under the wheelwell to install the pickups. All I need is a 3 inch cutoff wheel, an airsaw and a angle grinder.

[Jeff Hail]

As close up as I can get of the butt weld line blended in

[1970 Neun vierzehn]

The title of this thread should read......

Carrozzeria Hail

High accolades are in order here, not only for your craftsmanship, but also for selecting a 914 to be on the receiving end of your obvious skill and talent. (IMG:style_emoticons/default/clap56.gif) (IMG:style_emoticons/default/pray.gif)

Paul

[Jeff Hail]

Few days off from "work"........time for play

Fitted the heater tubes. I repaired the passenger side muffler. Was a bit chewed up and falling apart on the rear end of the can . Some resin and mat should keep it together. Sprayed with high temp paint. Never to be seen again. Have not decided if I am going to run heat or not....better safe than sorry.

Welded in the Heater-J tube. Cannot install this later with the firewall on. I tried everyway possible but I really want to get the rocker done and closed up. Decided in the end it would be easier to cut a slit on the firewall and bend it back around the tube.

One important thing. The heater tube exit hole on the replacement inner long does not come flared. This is a load bearing member and flaring the hole is vital to safety. The hole needs to be radiused and the edges flared. I do not have a 2-1/2 inch punch flare so I had to get creative. Ever wonder why aircraft windows are not perfect squares? If they had squared corners they will fatigue and crack. If you round them and flare (chamfer) the opening they will simply flex. Besides the flare adds strength where the metal has been removed.

[Jeff Hail]

Mocked up the firewall and lower reinforcements again (actually before I welded the heater -J tube in). Pays to recheck fit as you go. Small adjustments are easier then big ones that aren't expected.

Clutch and throttle cable conduits lined up perfect. These will be cut to proper length when the time comes.

[Jeff Hail]

Cut and trimmed the new outer rocker panel to fit (I call the outer bolt on part a rocker molding).

At the rear where it fits the wheelhouse was tight so I had to bust a few welds top and bottom to get it to slide in all the way. It was hitting the inner reinforcement. Tried shoehorning it with a body spoon to persuade it but it wasn't moving back where it needed to be.

Added a backer plate at the front which will provide a clean butt weld and something to burn into. The backer is a piece of the new part that was trimmed off.

Final fit and trim..........and ran out of daylight.

Tomorrow I will punch all the holes and get this piece welded up.....

[craig downs]

Its just incredible what you have done to save this car. Anybody else would have just cut it up.

[Jeff Hail]

Its just incredible what you have done to save this car. Anybody else would have just cut it up.

All this because an Exige S pissed me off and a friend said take the 914, its free!

[tdgray]

Great Job Jeff.... keep it up.

[KELTY360]

Its just incredible what you have done to save this car. Anybody else would have just cut it up.

Well actually, he has cut it up......and now he's putting it back together.

(IMG:style_emoticons/default/sawzall-smiley.gif) (IMG:style_emoticons/default/welder.gif) (IMG:style_emoticons/default/beer.gif)

Amazing work Jeff.

[Jeff Hail]

Great Job Jeff.... keep it up.

Todd,
You made me laugh my ass off with:
"ass-hat (adj)- One whose head is so far up their rear end it could pass for a hat; used to describe a person who is stubborn, cruel, or otherwise unpleasant to be around".

Thats a great one!
Thanks

[Jeff Hail]

Welded up the right rocker. I plug welded the top from inside the car. No holes were punched on the new outer panel....the lower was done from underneath the car.

First -it's easier welding thru old steel into new metal
Second- no grinding a gazillion plugs on the exterior. No pin holes on the outside to leak.

Butt weld with a backer at the front and seam welded the rear outer wheelhouse (another area that is prone to water because the outer panel faces towards the front of the car)

[Jeff Hail]

Can someone clarify if this is what a 914 rocker is supposed to look like?
I am kind of new at this and mine originally came with the translucent iron oxide version! (sick 914 humor) (IMG:style_emoticons/default/av-943.gif)

I also misplaced some measurements I noted somewhere. Now where the hell did I put them? Body panels make great sticky notes! (IMG:style_emoticons/default/dry.gif)

Day is done for now. A quick squirt of primer and its time for a (IMG:style_emoticons/default/beer.gif)

[Jeff Hail]

Passenger side sill plate is in.

Ran out of C02/Argon so I couldn't weld the sill triangles in.

Good tip....do not throw out those old weatherstrips. They are still important
when fitting parts such as the sill to make sure you get a proper seal on the door shell.

[Jeff Hail]

Lite duty this week. Carpal Tunnel sucks.
Welded in the sill triangles I fabricated and prepped the threshold area.

[Jeff Hail]

Tomorrow I will coat the gap where the rocker and sill plate meet with Wurth Seal Fix. WSF is closed cell sealer and semi rigid. Water and moisture will not get past it like the factory sealer.

Notice I installed the triangles flat side forward. The factory should have done this so as not to be a catchers mitt for road debris.