Grabbed a few more hours on the 911 today.
I wanted to trial fit the Dansk wings to see how much work they would need.
The doors I re-skinned in '89, and the sills are also Dansk, so 3 sets of Dansk panels to match together...
Started on the driver's side with the car outside to allow a lot of standing back. I trust my eye and hands more than measurements.
It bolted straight on and was even a reasonable fit but the wing/door gap was poor. It was with the old Porsche wings too so no surprise. Some careful lead loading of the door will soon fix that.
I will make all adjustments on the doors as there is much work to be done on them. They were well rotton in '89 and I welded them to death then.
Encouraged by this instant success, the off side was similarly trial fitted.
Well, no so fast!
The wing would not move back close to the door leading edge, and it was fighting me. Found out the reason, the tube brazed to the inner section of the fuel bowl/A post flitch fully interfered with the A post flitch, it was 45 deg out compared to the old factory wing.
Simple fix, I cut the offending 10 mm of tube off and will use some longer pvc tube to allow passage of the fuel filler flap release wire.
Also, and maybe of some consequence is the base of the fuel bowl where the large rubber funnel locates is far bigger on the new wing than the original Porsche, 5.5" dia v 5" dia. I presume there is a latter model year fitted?
So, it was trial fitted and to a much better position.
The gap of the wing to door is really nasty so that will need leading too to get the right gap consistency I want.
Unfortunately, I keep on imagining Barry is looking over my shoulder crying at my efforts. He has a lot to answer for raising the bar so very high for us DIY guys.
The fit by the front panel was a bit gappy on both wings, so fitted the bolts that go through the headlamp bowl to the mounting bracket on the battery boxes.
There was a good 10mm gap so I slowly bolted each side watching to see what might happen or crack.
It is startling what effect this bolt tension has to the fit of the rear wing to the door/sill and the improvement is huge.
There is a gap of 3mm there now to the bowl/bracket, so that will be shimmed to suit after paint.
Hope to get another few hours tomorrow to fit the steel bonnet and the 'new' front valance.
It takes up a lot of time and so far I have 'worked' for 8 hours to do what you have seen.
Times £50/hour = £400 saved. It will be £600 by the end of tomorrow.