DDK - Die Deutschen Klassiker

I started the repairs of the rear lights. It went really quite well. I am using a product called Newtech which is a metal filler. It works really well.
I have used it to fill some of the pitting and managed to replace the broken piece and fill holes successfully. Once I prime and paint I am confident that the repairs will be invisible.
This part had a section of metal that was broken off. I built it up using a piece of offcut plastic held in place and the Newtech metal filler. Once it was dry the plastic just peeled away leaving the metal filler. I have since shaped it and sanded it. This will all be painted up and have the seals so will be invisible but it will be nice to know that it is sound.
Cheers, Neil

This shot is pre-sanding showing the metal filler dried. It is easy to sand and shape.
This is another area where metal was missing. I know that the car was in a rear end shunt and had some extensive repairs back in the day. It might well be that the light fittings were damaged but not replaced and what I am dealing with is the aftermath of that. Certainly the assembly on the RHS was buckled and cracked.
Cheers, Neil

I undertook further repairs on my lights. The holes are pitting are all filled and they are re-shaped and are IMHO looking really good.
The brake/sidelight circuit board has been previously repaired/bodged and needs some attention.
I have built up metal filler to fill the gaps where metal used to be....
I will repair the circuit board and then finish the metal tab repair which folds over to hold the circuit board in place.

Then it will be primer and paint with silver on the outside and chrome for the reflector area (hopefully that option works ok)....

Cheers, Neil

Finalised repairs and painted the light fittings.
I had only 1 diffuser (the plastic unit that fits over the hole where American cars have side repeaters) and it was cracked so I had taken the cracked unit into work and measured it up and a colleague created a 3D printed pair of diffusers.

Here is one fitted.
Cheers, Neil

In other news I finished painting and stone-chipping the petrol tank. It looks quite good overall.
I also started preparation of and painting of the shock absorbers.
There are not that many more things to prep or paint to get everything ready. I am awaiting the arrival of my H1 reflectors from being re-plated and then, with other spare parts received, I should be able to re-build them shortly.

Cheers, Neil

Those light housings look good, what chrome paint do you use? My chrome paint came out silver!

Gary it is this stuff bought from my local supplier - it has worked quite well.
I have just received pictures of my re-finished H1 headlamp reflectors - they look absolutely fantastic especially when you compare before with after
Cheers, Neil

Yum, yum, yum
Very pleased

They do look very good, so does that chrome paint!
I ended up painting mine gloss white inside as it looked 'brighter' than the can I used (way back when).

Good progress!

I moved things slowly forward. I am rewiring the headlights (the extremely short loom connecting the earth and H1s to the H4 connector. I am also cleaning up and painting the headlight cowls before rebuilding the headlight units.
I have finished painting the rear shock absorbers (although I don't have any photos).

Cheers, Neil

I have painted up the headlight cowls now and am setting up all my components so that I can assemble the headlights. I have ordered some new lenses as mine are from a later 911 with H4 lenses and one has a hole in it which I repaired some time back with clear silicone (it worked quite well and isn't particularly noticeable surprisingly enough. However having through this effort I don't want to put back the wrong lenses and one with a crack in it.
In addition to that a while ago I did a quick refresh on the headlights and found a missing component which resulted in a lack of adjustment of the headlight.

It is the circled component here (the small metal bracket/plate
I had made a copy and used that for quite some time successfully but it is much thinner gauge metal and I will create a better more faithful replica. You can see one original one and a fake here... Cheers, Neil

I have managed to move things forward a little. One headlight is rebuilt. The other is still on the to do list.

Stage 1: Stage 2: Completed: Rear Lights are completed too. I have decided that I will purchase new rear light lenses as the current ones both have been repaired following crack repairs and they don't look pretty.

Cheers, Neil

Good work

If you haven’t already, it is worth checking fitment of the headlights to the front wings. Those pesky clips are a nightmare, and if in even slightly the wrong position will prevent the unit seating nicely. Ask me how I know! The only pic I could find when doing mine was from a VW resto, that showed the exact position of all the clips

I have managed to complete the rebuild of one of my headlights. I am really pleased with the outcome. I did have to purchase some flexible shaft to replace the damaged flexis that were on the headlights. I was able to strip the original out, replace the long screws which had damaged heads but keep the original final threaded rod.
I will use some grease to lubricate each joint but it all works smoothly.
Cheers, Neil

Another good thread - thanks for sharing Neil ! I might give that metal filler a go on my rear lights. What stone chip did you use on the petrol tank?