Bringing out the dead Options

[Jeff Hail]

Made a backer to go behind and underneath the cowl. Three reasons: First to set the cowl height to the hood. Second with all the heat it will minimize distortion during welding. Third I can get some heat in this area without burn through (cowl top is thin).

Getting dark. Til next time!

[Jeff Hail]

A good friend who happens to be a full time welder asked me to design a new business card and logo for him. He's having a mid life crisis as he just turned 50 years old.

His request went something like this "it has to have fire and a skull since that's been my trademark for twenty five years. It needs to make a bold statement when I am on site and EVERYONE needs to know it's me. The rest I will leave to your imagination Jeff"


Hum? My imagination? A big burly guy who's into fire and skulls, Harleys, huge BBQ's and tat's wants to make a statement because you are having a mid-life crisis. This is you pal!

[heavydriver]

If you were to replace the firewalls as well as the floor what would you do first ?

Specifically structural or ease of work considerations. Any helpful advise would be appreciated
(IMG:style_emoticons/default/driving.gif)

[Jeff Hail]

If you were to replace the firewalls as well as the floor what would you do first ?

Specifically structural or ease of work considerations. Any helpful advise would be appreciated
(IMG:style_emoticons/default/driving.gif)

Good question. It all depends on how the car (any car) is constructed. If I was just replacing a floor pan and a lower firewall it would be fairly simple on a 914. Remove damaged/ rusted panels and then one critical issue comes up.....The floor has to be correctly aligned to the lower firewall at welding time. Even more critical if you are installing a six mount. I would tack the lower firewall to the upper firewall and let it just swing (leaving the sides and lower loose). I would then fit the floor pan/ cut to length/ tack at the forward floor seam (lap/ few plug welds to secure). Add a few plug welds to the sides for position only. Check everything for fit and then plug the lower firewall to the floor. I would then chase the perimeter with the remaining plug welds. Finally returning to the floor seam section. I would plug and fillet weld the seam overlap completely (both sides).

One hint that a few people forget when sectioning any lower panels (floor's especially), trunks etc ALWAYS postion the forward panel below the rear panel section. The reason for this is two fold. You dont want a leading edge facing forward ever. This will allow road splash/ debris to to stream past the bottom edge of the joint and not strike the joint head on. If you don't follow this rule the joint will rust/ corode due to being blasted by what ever impacts it.

Second just picture in you mind a leading edge hitting something (example:high centering a low car in a driveway or running over an object at speed). The joint can be easily torn wide open.

I recall years ago IMSA would not pass a car in tech inspection if they saw a floor that had been sectioned with the rear panel leading edge exposed underneath. In the collision repair industry its called blaphemous butchery.

On with the fun!

[heavydriver]

Thanks for the response. Based on what I have seen being done by those with more skills I will do the following......
Put her up on a jig (I will build one like yours) and fix the hell hole first then the firewalls followed by the floor. Whew, is that a good plan or should I punt ?

[Cairo94507]

I am absolutely in awe of your skills; you are the Holy Grail of metal work. As I was reading your thread and watching the progress all I could think of was how lucky is that 914 to have this kind of skillful repair work. Love the thread; can't wait to see more. (IMG:style_emoticons/default/popcorn[1].gif)

[Jeff Hail]

The tub is off the front jig. Prepped, primed and a thin coat of SKS in the crossmember tunnel and left front wheelhouse. It will get primed again later.

[Jeff Hail]

Back to the driver side cowl. Fabbed all the little pieces. Only 2 actually.....and burned them in (the gutter and the side piece) Rough metal work done.

[Jeff Hail]

I removed what was left of the fender gutter at the apron.

Folded down the tab on the cowl gutter to make a smooth transition and set the hieght.

Fabbed piece #3 to close the apron to the cowl gutter. More burning.

[Jeff Hail]

Lots of grinding and shaping

and more grinding and shaping........

[914Mike]

Lots of grinding and shaping

and more grinding and shaping........

I did a similar repair to my '74, and word to the wise, now is the time to check the fit of the hood.

The side view looks a little bit forward on the corner of the cowl, like the corner of the hood may have a bit less gap than the center, which is exactly what happened to me... (IMG:style_emoticons/default/headbang.gif)

Nice work! (IMG:style_emoticons/default/welder.gif)

[Jeff Hail]

I've been quiet and for good reason.

#1: I am moving and have been packing up the home & shop which has been quite daunting. Home easy, shop not so easy. My garage is full of equipment and attic is a time capsule of rat holed Porsche and racing parts for some 23 years. I have been packing things I didn't even know I had. Some of these will go into the 914 which will be unveiled later. Surprise, surprise AND no none of it is for sale! Once I had everything out in the open I realized its a damn 401k in the making.

My escrow closes 3-26-2009 so lots to do between now and then. It's a good thing for me. Bigger, better and about the same price which in todays economic times and market is a blessing. Change is good.

#2: I am a multi-tasker (aka A.D.D (IMG:style_emoticons/default/smile.gif)...always have more than one project going on simultaniously. I just completed a huge undertaking that started in November 2008 that exceeded all expectations. It was a rush request and I couldn't say no to it. I cannot elaborate at this time but it was worth it.

#3: New home will need to have shop organized and outfitted. So this means I will be OFFLINE for a bit. Once I am back on line the 914 becomes #1 priority from here on out.

Later for now....

[type11969]

Good luck with everything Jeff, looking forward to updates once you get back into it

[flippa]

ADD is a blessing; I would be out of buisness without it. i don't understand why they surpress it with drugs!

Congrats & good Luck with the move. Looking forward to see the next installment

[Jeff Hail]

Don't count me out until you see the box going into the ground!!!!!

Move completed. Dealing with house things now. Garage is secondary at the moment.

[strawman]

Don't count me out until you see the box going into the ground!!!!!

Move completed. Dealing with house things now. Garage is secondary at the moment.

Good to see you haven't given up on your incredible project. I've been having withdrawals these past few months waiting for an update. Hope you can back to the project soon!

Geoff

[Jeff Hail]

The house stuff is close enough. Shop has been fitted. Now its time to get back to work. Winter is coming and no time like the better to.......GET THIS BITCH DONE![size=7]

[veltror]

First class, I hope to have some news on my project soon also...

[Jeff Hail]

Where was I? Oh yeah....rust

I pulled the tack welded ft tube structure from under the hood to access the lower control arm bracket, floor and corner reinforcement. Wasnt as bad as anticipated. Always new it was there under the reinforcement.

Remove the corner reinforcement

Hello floor

Wire wheel the area. Floor repair will follow later as I have to make a template
and didnt have the correct guage sheetmetal.

[Jeff Hail]

Made a template of the reinforcement using the old one.

Salvaged the inboard portion and fabricated the new section. Lots of weird contours on this piece to duplicate. You can see the holes where the spot welds were on the old section that remains.

Presto!