'89 3.2 Carrera restoration

[DustyM]

Well we don't seem to have many restoration threads running at the moment and since I'm making zero progress on my 930 Hotrod I thought I'd run a thread on my 3.2 Carrera which at least is progressing nicely (probably because I'll be selling it when finished so there is some incentive to get it done!)

Those of you on the Stuttgart trip last year will know the car and whilst it looked OK from a few feet away



It was in need of some TLC, and was starting to show the usual signs of rot.







So into the workshop for strip down

[DustyM]

The left hand rear wing was hiding some rot so was removed.



Nice!



Also the sill and kidney bowl as is par for the course on these cars





Decided to repair the inner wing first, no repair panels are available for that area so it has to be made from scratch.









Jumping ahead a bit but eventually it looked like this

[sladey]

Awesome stuff Jon - good to see this. That was really bad on that inner wing

[Mike]

Great thread Jon, and one that others here talking up average 3.2 Carrera's for big money should have a look at!

[impmad2000]

I remember my Targa looking something like that. The engine lid release tube had acted as a shelf for the crud to sit on ! Other side was similar behind the oil tank, and the front inner wings behind the oil cooler lines. But for the sake of wheel arch liners eh !

[jury]

Nice Jon, look forward to seeing more progress.

3.2 Carrera's.....now there's a thought


Cheers
Chris

[DustyM]

Other side was similar behind the oil tank,

And this car was no different.



Rotten area cut away and a section fabricated and welded in





Once coated with a textured coating to match the factory original the repair is invisible.



and back in paint

[911hillclimber]

Nice work and very practical approach to me.
What do you use for the textured effect, just stone chip resistant spray?

I hope to strip my shell (73T) that i rebuilt in '88 and I'm expecting to do such 'nip-n-tuc' corners when I dig deep, so this is great.

[DustyM]

What do you use for the textured effect, just stone chip resistant spray?

Yes, Wurth overpaintable stone chip coating.

[911hillclimber]

Thank you indeed, i even have some but about 20 years old now..

iirc the stipple density was not like the car repair above. Is there a smooth type/rough type?
Sorry for the small hi-jack.

[stretch]

Nice hammer work Jon. Look forward to the rest of the metalwork.

Dave

[DustyM]

Thank you indeed, i even have some but about 20 years old now..

iirc the stipple density was not like the car repair above. Is there a smooth type/rough type?
Sorry for the small hi-jack.

You can vary the texture by changing the air pressure / distance / coverage when applying the coating.

[911hillclimber]

Thank you!

[DustyM]

Nice hammer work Jon. Look forward to the rest of the metalwork.

Dave

Thanks Dave, though fortunately there wasn't much fabrication needed on this shell, the main work was the usual sills, kidney bowls and B-posts.

After cutting away the outer sill and cleaning up inside, a zinc paint is applied



and the "Kidney bowl" fitted (this is the later type)



The new rear quarter and outer sill are trial fitted



The inner rear wing repair (which up to this point had been only screwed in place until correct alignment with the rear quarter could be confirmed) was welded in place along with a new cable guide tube



and the whole area coated whilst access was easy.



Welding the new quarter in place.



And dressing the welds



Spot welding where possible such as around the window frame



And in the gutter as these welds are visible after painting so need to look factory.



Some filler primer sanded back and voila!

[911hillclimber]

Interesting!

Always wondered:

The end of the guttering of the rear wing to the boot lid corner; do you braze/weld that tight? I brazed both corners in my car a long time ago and all is well but the water run-off irritatingly runs over the rear wing and can mark the wing rather than run into the boot lid channel and off over the rear shroud area.
I used real Porsche rear wings but they were about 2mm short at the gutter end.(1973T Coup)