DDK - Die Deutschen Klassiker

Steady progress, managed to stick to the plan and get the body welding pretty much finished, lots of finishing off fiddly bits I'd missed or put off have now been done as well as some hole filling. Things like the fuel filler hole I considered buying a bung but it ended up only taking 10mins to weld up.

2022-02-20_09-32-31 by richard cannings, on Flickr

Still need to do the rear ARB mounts but looks like I'll need to buy the ARB to do this I'm leaving it for now. I'd still like to do the jacking point strengthening plates as I really like the look of them but holding off for now as I'd ideally like to keep standard oil lines. I do want to look more into a rear mounted cooler solution as I like the idea of the clean look without oil lines.
Also need to do the battery tray, think I'm going to got for a full size battery the same as in the 3.2.The car will have electric air conditioning, heated screen and possibly even seats this seems the most sensible option.

Was going to get straight on with the grinding but decided to do the fuel filler as it was job I was really looking forward to doing. Seems like there loads of ways to do this so on Early 911S Registry so decided that the best way forward was to come up with another.

2022-02-18_02-39-12 by richard cannings, on Flickr

2022-02-18_02-39-35 by richard cannings, on Flickr

ACME alignment tool developed.


2022-02-18_02-39-49 by richard cannings, on Flickr

Measured the bonnet angle with resect to the filler tube from under the bonnet.

2022-02-18_02-40-18 by richard cannings, on Flickr


3.5 hours in and looking promising.

2022-02-18_03-00-26 by richard cannings, on Flickr

That looks like a scary cutting job approaching if ever there was one!

Measure 20 times
Cut once

Good luck!

I think you were pretty much spot on with measure 20 times Gary.

Started with a small hole just to check all lined up from below.

2022-02-21_03-57-37 by richard cannings, on Flickr

Then a bit of woodwork to start the morning.

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Then did a test piece before destroying the bonnet forever, went much better than expected.

2022-02-21_03-58-46 by richard cannings, on Flickr

MDF former screwed to the bonnet.

2022-02-21_03-59-06 by richard cannings, on Flickr

Started hammering steadily working my way round, doesn't really need much force at all the stretch the panel.

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Trial fit of the filler and all looks good.

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Then had a tidy up, really happy with the result. Hoping to get the filler attached to the tank tomorrow

2022-02-21_04-00-11 by richard cannings, on Flickr

Awesome job Rich!


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That looks very nice .

Karl

You did that by hitting with a hammer? Wowsers!

That’s really neat, good work

Nice work - was that with a round wooden mallet?

Edit ah I can see it’s one of those plastic headed ones

Excellent work !

Great work. Seeing the details take shape always amazes and impressed me!

Very impressive.

Love the way you make this stuff look easy - fantastic

Thanks so much for the comments everyone, really nice to be sharing a job that went better than expected.
Managed to remove and weld up the original fuller tube as well as weld the new one in this morning.

2022-02-22_05-34-55 by richard cannings, on Flickr

If ever you wondered what the inside of a Dansk 110l tank looked like inside;

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Wasn't sure if would have baffles. Seems really good quality, steel must be about the same thickness as the original tank.

Really feel like its changed the look of the car.

2022-02-22_05-35-47 by richard cannings, on Flickr

Stanley getting a little concerned about the new bowl he got for Christmas as I decide on a rain catchment solution.
2022-02-22_05-51-07 by richard cannings, on Flickr

Rich,
Looks like you kept the filler tube as far back as possible in the tank. If you don't then there are clearance issues with the spare wheel/ tire. It does not look like you have clamped the tank in position ( could be wrong) which I would suggest you do and fit up the fuel outlet under the tank. There may be clearance issue with this which means you have to adjust the tank position. The knock on effect is that the filler cap is then not central to the hole you cut in the front lid. Of course all may be OK already but worth checking. Nice metal forming as usual.

Hi Kirk,
Yes I remember your advice about getting it back as far as possible, thanks for that. Your right I've seated the but haven't clamped it in, I'll make sure I clamp it down to be sure.
Thought I'd have a go at making the rain catchment bowl from an offcut of flue pipe I had, looks neat from the side and is compact but don't think I like the fact the filler cap isn't centred due to the angle of the filler tube. I think a bowl like yours would look much better. Its only tacked together so not a problem to change.

2022-03-01_09-36-04 by richard cannings, on Flickr

Working my way round the car getting any last paint off, grinding and epoxy priming as I go.

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I'm thinking I might leave this plate in place and just carefully work round it. The others plates just had pop rivets that I can easily replicate but not sure about these.
2022-03-01_10-01-04 by richard cannings, on Flickr