DDK - Die Deutschen Klassiker

Well, I've started to fix up the 912 for its MOT, the engine now runs well, the brakes are all stripped and awaiting rebuild and the small amount of rust in the floor has been done, I made a press tool and was able to make the section I needed.

The pedal assembly has been rebushed, I went for bronze bushes that should last for ages, the pedals now feel great !








New floor panel. lightly blasted for a good key.

Nick I am about to repair an area just like that on the 65 car? are you able to make another panel ? saves me hrs of bashing metal todeath..

Hi Mark, that shouldn't be a problem, I'll pm you soon, Nick.

arr nice one I will take a shot of the area I am looking to graft in.. last bit on the car to do I HOPE better not get too heavy with the screw driver any more

if you don t mind asking how did you make this repair panel , it s excelllent owen nw

sorry Nick no picture yet will venture out tomorrow terrible case of man flu for the last 6 days

Hi Owen,
I made a simple press tool, the top (male) tool is just a piece of 30 x 6 flat steel with the correct shape at the ends, the bottom tool ( female ) is a rectangle shape from the same material, 3 mm bigger all round so the male fits into the female, ooer.
I used a hydraulic press, put the female tool down flat, sheet metal on top, in the correct position, then the male tool on the sheet and press them together.
each pressing was done individually.
Hope this is clear !
Nick.

here you go Nick

Hi
if the rusted area is as big as it appears why not go for a half pan from Euro's or similar , I think they are under two hundred quid and fairly straight forward to fit if the sills arn't too bad , I have done quite a few and its a very satisfying job.
yours Bill.

currently on a Huge budget tightening I have replaced an area like this on the other side and again I made the panel but if Nick has the press tool it will be an easy press and neater than me beating the ribs in place by hand..

the panel is not that rusty it's me and my screwdriver I just like to make sure.. the panel is painted in some rust coloured paint by the PO and it looks pants.. it makes it look like the whole panel is knackered and it's not..

Hi
Bonda primer is the way to go, you slap it on, it always dries with a good finish and holds rust at bay . I have used a similar process to the one described to make up all sorts of sections and panels , I buy thick wall box section and weld it together to make the outer of the rib , the radius on the end is made up with weld and a grinder , the male section is is more box section with the ends radiused and closed off the, steel has to be accurately marked both sides and then since I don't have a fly press I tack the female outer to the steel then turn it over, line up the male part and whack it one with a large copper mallet. Ok sounds crude but its surprisingly effective and the tools survive this process more than once so you just grind through the tacks reposition and go again, the round dimples can be formed using large round tube, again one section tacked on with a large old socket being employed as the female, I even made a large and rather complicated female tool to bash out a rear shelf and then made up a little tool to stamp in the little ribs that run fore to aft such is my level of perversion when it come to old cars .
best wishes Bill.

oh yes I know what you mean with a skill I wanted to learn more mixed with Barries metal work day and constant guidance on the forum I am oftern in the garage tapping away at new metal going you will bend to this shape for hrs on end all with my ear plugs in not knowing how much I am pis**g off the neighbours with the constant banging ops

all done now will post picture tomorrow

I made a new panel with 1mm sheet steel and a trick Mr Barry showed me with a chisel and abit of scrap metal..with my dad's help to hold in place with in 20 mins we have all 4 ribs made and not a bad job I have to say.. very pleased.. will post up pictures but the floor is nice and VERY firm now and the rest looks ok.. the picture shows this horrid rust coloured paint the PO used it's RUBBISH!!!

2pk chassis paint going down once I have cleaned up the rest.. then it should be good for another 15-20 years..very pleased another job done heading for the MOT date now... home stretch...... will hold off the respray till next year me thinks..

Hi Nick out of interest to all others perhaps show a few step by step photos of you using the tooling you made?? The idea is simple and effective but a picture can say a thousand words....cheers Michel

I have asked my self but I know Nickt gets very busy. I worked out from before about hitting the metal with a chesil but Barry showed me a trick using a blunt chesil and a vice, it made for very nice edges so I took it further and clamped the metal down with G clamps and used box section underneath and clamp that also.. then hit ( not very hard but to start to form the shape ) the edges of the rib and in no time I had nice formed ribs to match the orginal, it's not 100% the same width but with some hunting about I could find the right width metal to use as a former but for me it's a perfect job for the small area's I did..try using some metal and chesil, trick is to clamp it well ..