DDK - Die Deutschen Klassiker

There is damage of some sort absolutely everywhere! Makes my shell look pristine.....

Great up-dates and seeing some less common damage spots dealt with is very interesting.
Thanks for posting all these reports.

Yep damage in lots of places and no doubt caused when it was used for rallying.

I'm sure mine will be pristine when it leaves Barry.

Glad you're enjoying the updates..

Wow! amazing skill, its like art. Keep the detailed pictures coming!

A lovely thread and some great pictures.

Unbelievable what Barry can fabricate! Looks like a lot of Restoration Design panels are being used?

All the best with the next stages...

Matt

Hi Matt... glad you're enjoying the thread updates.

Almost exclusively Porsche panels other than the floor halves which are Restoration Design.

Magic!

Love this stuff

Hi Kieron,
Many thanks for posting these pics. Very interesting to me, not least because my 70S is on Barry's list.
I'm greatly enjoying this taste of things to come.
Cheers, Richard

Hi Richard... I can definitely recommend the 'Barry Carter' experience. Have you got all your panels bought yet ?

aston wrote:Hi Richard... I can definitely recommend the 'Barry Carter' experience. Have you got all your panels bought yet ?

Not yet. I don't think I'm nearing the top of the list any time soon, so Barry hasn't yet been round to see the car. In fact that visit is planned for this coming weekend. I guess at that point I'll have expert guidance about the panel shopping list, and some idea of the first of the large bills!
If you have any recommendations / advice I'm all ears.
Cheers, Richard.

28. Front end clean up.

The final part of the front end clear-out, as far as the remove and replace areas are concerned anyway, was to lose the remains of the front inner wing, A-post, scuttle end and the very base of the A pillar. This revealed that the sunroof drain had rotted away so just as well Barry ended up in there. He'll make up a sleeved section and join it in further up once he can find something solid to marry it to.

He says he's always very wary of leaving himself with either metal hanging in space, or having no reference points, so the end of the dash and scuttle were well supported before the last of the metal was removed.

His starting point on the actual repairs was to sort out the offside front bulkhead as this whole panel was badly buckled all the way across. With the inner wing removed though, the O/S at least did want to return to the flat, so took very little work to get it looking right. After that he made up the area just outboard of the bonnet strut support, and welded it in. Incredibly it's his worst place to make on a 911, it looks so innocuous and yet is a real teaser. I think he'll be creating a hammer-form tool shortly to make it easier.

A bit of light relief after that was to do some repairs to the flanges lower down on the car, and have a general tidy up of flaking paint / sealant / gunge whilst access was so good inside the car.


Offside bulkhead - before and after...





















Results of blocked sunroof drain.

That man Carter...he's not half bad is he....was just having a chat with him this evening and he mentioned this thread...read all 4 pages just now....lovely work isn't it....
Kieron, you are absolutely in safe hands with Barry...a real craftsman....
Jonathan

29. N/S/F inner wing base.


The base of the inner wing was quite badly corroded underneath the old chassis leg / side tank support, plus the flange joining the wing to the front pan had been through the mill before and was beyond help. Therefore, Barry removed the rearmost section first, whilst retaining the front. He explained that he tries to have a handshake of some sort between known good references and new metal. Obviously it would be the easiest thing in the world simply to run the cutter right around the whole lot and drop it out, only later would you realise you have no way of judging what the width should be at the inner wing base. You'll notice that even later on there's a tiny fragment of original (cleaned up) flange, just to guide him to the correct positioning of everything. Takes longer, but really pays off later.
Anyway, lots of new metal with fresh, tight fitting and full thickness flanges.




Reminder of hidden corrosion in this area.















]
























30. Front inner wing.

The area ahead of both battery boxes was very rusty, mainly due to the two layers of inner wing and bumper reinforcement trapping moisture for the last forty years or so.

In the past Barry has tried to rescue this area, but nowadays he generally just replaces with new. As can be appreciated they do take a bit of time to make, but fit very well and make for an effective repair. It will be one of the last parts of the front end to go in as he has an order of welding that allows the big spot welder the most access - think along the lines of painting yourself back to a doorway and out ....


















31. N/S front bulkhead repairs.

Barry says that this area incorporates his nightmare area - outboard of bonnet strut - loads of buckles to what should be a flat panel, fabricated 'pressings' with adjacent curved flange, welding right through the centre of a very thin flat area, and then tapping up / shrinking with poor access. The metal to the nearside was very thin and badly pitted although it doesn't really show in the pictures.
Anyway, for all of the challenges, it's come out quite nicely and has ended up being Barry's most satisfying part of the restoration so far.















































32. Engine bay crossmember - small repair.

An innocuous looking area soon turned out to have hidden secrets. Luckily it was only the top layer that had failed, so a good clean, prime and new top layer and another little job out of the way.

great up-date, please keep posting.

all be said before about Barry, still applies.
Some new areas to be done on your car, interesting.

Wow. As always, what a craftsman.