912 outlaw project
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912 outlaw project
Hi there, thought it was about time I posted my project.
Here we go...
I picked up the rolling shell last year but 2weeks later went under the knife for a second major knee surgery so progress has been slow so far, not fun, on both levels!
The shell is a '68 and on the face of it looked like it was in ok condition. However the obvious stuff would need replacing, floors and front pan etc but I wanted to learn to weld and do bodywork etc so it looks like the perfect candidate.
The basic idea is to create a road legal lightweight special, similar in vein to the Emory 356's...we'll see
Picked it up from a guy who had a trailer and offered to bring it to my house for no extra charge, bonus!
Got it home and started to strip it down, it took longer than I thought as I tried to take a picture at every stage.
Paint stripper
Started to cut out floor and added some budget bracing between a and b pillars
The rear seat section and parcel shelf were pretty gone, so removed it...
I got hold of an entire rear interior section but I found this solution from Rennline, I think it is from a 935 track car? The plan is to brace across the back section then fabricate the removable panels. I know its not stock and will probably be pretty loud but I think it could look pretty cool and go with the 'lightweight special' idea I have for the car.
After all the cutting and grinding, the first power wash
I managed to get hold of a rotisserie. After fabricating some brackets and with the help of 3 friends, we managed to lift it on
After removing the floors I found that the heater tubes were gone, so decided to remove the whole pipe and do with out, afew extra pounds saved! but, the double 'S' curve of the rear part proved a problem, so after much debate I decided to cut out the inner arch panel and then weld it back in.
After cleaning up the floor areas there was not much flange left to weld the new floor in, so I decided to make a basic metal break and make some new flanges then tack in place, this should give a better bonding surface
At some point a jack had been placed and crushed the rear sill area, so more fabrication was needed on both sides
Suspension pan arrived and aligns with everything pretty well but after cutting out the petrol tank supports the battery area was rotten. So more pattern making and sheet metal bending.
Another powerwash, it was a good passer-by talking point on sunday afternoon
First rust coat this evening, under the centre tunnel and in the sills
I hope to get the floors and suspension pan in this weekend.
Its by no way a big budget project and I am realistic about time frames etc. There is plenty to do but its good fun. So far so so...
Here we go...
I picked up the rolling shell last year but 2weeks later went under the knife for a second major knee surgery so progress has been slow so far, not fun, on both levels!
The shell is a '68 and on the face of it looked like it was in ok condition. However the obvious stuff would need replacing, floors and front pan etc but I wanted to learn to weld and do bodywork etc so it looks like the perfect candidate.
The basic idea is to create a road legal lightweight special, similar in vein to the Emory 356's...we'll see
Picked it up from a guy who had a trailer and offered to bring it to my house for no extra charge, bonus!
Got it home and started to strip it down, it took longer than I thought as I tried to take a picture at every stage.
Paint stripper
Started to cut out floor and added some budget bracing between a and b pillars
The rear seat section and parcel shelf were pretty gone, so removed it...
I got hold of an entire rear interior section but I found this solution from Rennline, I think it is from a 935 track car? The plan is to brace across the back section then fabricate the removable panels. I know its not stock and will probably be pretty loud but I think it could look pretty cool and go with the 'lightweight special' idea I have for the car.
After all the cutting and grinding, the first power wash
I managed to get hold of a rotisserie. After fabricating some brackets and with the help of 3 friends, we managed to lift it on
After removing the floors I found that the heater tubes were gone, so decided to remove the whole pipe and do with out, afew extra pounds saved! but, the double 'S' curve of the rear part proved a problem, so after much debate I decided to cut out the inner arch panel and then weld it back in.
After cleaning up the floor areas there was not much flange left to weld the new floor in, so I decided to make a basic metal break and make some new flanges then tack in place, this should give a better bonding surface
At some point a jack had been placed and crushed the rear sill area, so more fabrication was needed on both sides
Suspension pan arrived and aligns with everything pretty well but after cutting out the petrol tank supports the battery area was rotten. So more pattern making and sheet metal bending.
Another powerwash, it was a good passer-by talking point on sunday afternoon
First rust coat this evening, under the centre tunnel and in the sills
I hope to get the floors and suspension pan in this weekend.
Its by no way a big budget project and I am realistic about time frames etc. There is plenty to do but its good fun. So far so so...
# 465
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
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Great thread! Good fortune to you with the project.
1972 911T | 1994 993 Carrera | 1999 986 Boxster | 1990 T25 Camper
Vintage Heuer, Omega, Zenith and other vintage watches - http://www.heuerheritage.co.uk
Vintage Heuer, Omega, Zenith and other vintage watches - http://www.heuerheritage.co.uk
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- I need to get out more!
- Posts: 3417
- Joined: Mon Apr 16, 2007 9:06 pm
- Location: Portland, Oregon, USA
About time for a quick update...
Floors went in, I don't know if there is a supposed to be an order front first/back first or visa verse but there was no way I could get the panels seated right with the back going in first, so long story short the front half went in first...
This might be obvious, but I couldn't work out how to clamp down the two panels together and I didn't fancy making the worlds biggest C-clamp. So I drilled through both panels using the last spot weld hole as a guide, and also drilled through the brace in the transmission tunnel (there was actually already a hole in the brace), then bolted the panels together. After some 'gentle' hammering the gap was acceptable to weld, simple but effective.
floors welded in
However I still hate grinding! the only way to get any purchase on the grinder was to climb inside the shell whilst on the rotisserie. It had abit of a lean on at one point and thought that a carpet set can't weigh that much did cross my mind! (the idea is to have a bare painted interior).
Patch panels for the battery support fitted and welded in well
Decided to seam seal all the fresh welds, that stuff has quite a kick but works great!
And first rust/sealer coat yesterday, this was a good feeling!
after that the wheels have been relativly straight forward...
Next steps are to finish the underside paint and wait for the A-arm/swing arms to come back from the powdercoaters, then off the rotisserie and make a start on the rear seat section...but... as of this coming Monday 14th I am looking forward to joining the parenthood group! My wife is expecting our first children (twins!!) priorites may have to switch for awhile...
Floors went in, I don't know if there is a supposed to be an order front first/back first or visa verse but there was no way I could get the panels seated right with the back going in first, so long story short the front half went in first...
This might be obvious, but I couldn't work out how to clamp down the two panels together and I didn't fancy making the worlds biggest C-clamp. So I drilled through both panels using the last spot weld hole as a guide, and also drilled through the brace in the transmission tunnel (there was actually already a hole in the brace), then bolted the panels together. After some 'gentle' hammering the gap was acceptable to weld, simple but effective.
floors welded in
However I still hate grinding! the only way to get any purchase on the grinder was to climb inside the shell whilst on the rotisserie. It had abit of a lean on at one point and thought that a carpet set can't weigh that much did cross my mind! (the idea is to have a bare painted interior).
Patch panels for the battery support fitted and welded in well
Decided to seam seal all the fresh welds, that stuff has quite a kick but works great!
And first rust/sealer coat yesterday, this was a good feeling!
after that the wheels have been relativly straight forward...
Next steps are to finish the underside paint and wait for the A-arm/swing arms to come back from the powdercoaters, then off the rotisserie and make a start on the rear seat section...but... as of this coming Monday 14th I am looking forward to joining the parenthood group! My wife is expecting our first children (twins!!) priorites may have to switch for awhile...
# 465
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
Bloody hell you are going though it ... OK I have booked you a flight to my garage here in the UK... I have all the panels there and I will pass though tea and toast on the hr till you get all the work done on my car..
Great thread..
Tell us more about that eastwood product you used.. on the floors.. ( black coating )
Great thread..
Tell us more about that eastwood product you used.. on the floors.. ( black coating )
-
- I need to get out more!
- Posts: 3417
- Joined: Mon Apr 16, 2007 9:06 pm
- Location: Portland, Oregon, USA
PG tips with a direct flight to Manchester Business class...I could be tempted
The Eastwood rust encapsulator (black coating) is from...
http://www.eastwoodco.com/
...its a US classic car restoration company focused at body off muscle car builds. Basically its a comparable product to POR-15, however their marketing blurb says that is performs better and is easier to use. I have used other products from them, wheel paint, engine paint, sealers etc with great results. With one coat its pretty bullet proof, I first used the their rust stabiliser and I'll probably use 2 coats of the rust encapsulator followed by eastwoods rubber coating then at least 3-coats of colour.
The Eastwood rust encapsulator (black coating) is from...
http://www.eastwoodco.com/
...its a US classic car restoration company focused at body off muscle car builds. Basically its a comparable product to POR-15, however their marketing blurb says that is performs better and is easier to use. I have used other products from them, wheel paint, engine paint, sealers etc with great results. With one coat its pretty bullet proof, I first used the their rust stabiliser and I'll probably use 2 coats of the rust encapsulator followed by eastwoods rubber coating then at least 3-coats of colour.
# 465
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”