A sort of Barn(es) find
Moderator: Bootsy
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
Last year, around November I attended a metal shaping course here in Johannesburg.
It was run by a very interesting chap called Barry Ashmole.
He is a bit of an expert that has spent time with Ray Schelin, some Jag experts in the UK who's name escapes me and a few other gurus in strange parts of the world.
He is based in beautiful Stellenbosch (perhaps the most beautiful wine region the world....but I'm biased).
In this case we ran the workshop up her in JHB with 3 other nutters.
If you're looking for a motor themed mini break in a spectacular part of the world that is very cheap (when paying with Pounds) then look up Barry Ashmole on Facebook. His courses are about 250 Squid for 3 days.
Here are some pics.
All hand tools.
(Barry is the guy in the Welding mask)
An example of his filler-less fusion TIG welding, as used on all steelwork.
You can see from the heat pattern where he purposefully burned a hole to show us the effect of heat.
The benefit of no bead is that planishing the metal to work out stretch or shrink is much easier. Very impressive. But the accuracy needed to get two panel to sit flush, with no gap, is a skill that it seems takes years to master.
Making a buck for a fender
Hinge template he made.
Resin and wood buck for a VW Bus door handle
Handy use for old bearing races
Home made tucking fork
Various tools. The wonderful thing about Barry is that most of his tools are hand made with bits and pieces that lie around in a workshop. The little tucking tool is brilliant (the pic of flat bar with a diagonal slit in it)
Prestretching and working a pattern with 1mm mild steel and 3mm masonite
Look mom, an ashtray....a simple example of shrinking by hand using tucks, mallets, a stump and then planishing by hand.
Not bad.
And of course, I've forgotten much of what I learned but have trying to practise the principles.
A great 3 days. Even if you have no aspiration to use what you have learned, I recommend one of these course (there are many masters in the UK). Great to get your brain out of work mode and to work with your hands and steel.
It was run by a very interesting chap called Barry Ashmole.
He is a bit of an expert that has spent time with Ray Schelin, some Jag experts in the UK who's name escapes me and a few other gurus in strange parts of the world.
He is based in beautiful Stellenbosch (perhaps the most beautiful wine region the world....but I'm biased).
In this case we ran the workshop up her in JHB with 3 other nutters.
If you're looking for a motor themed mini break in a spectacular part of the world that is very cheap (when paying with Pounds) then look up Barry Ashmole on Facebook. His courses are about 250 Squid for 3 days.
Here are some pics.
All hand tools.
(Barry is the guy in the Welding mask)
An example of his filler-less fusion TIG welding, as used on all steelwork.
You can see from the heat pattern where he purposefully burned a hole to show us the effect of heat.
The benefit of no bead is that planishing the metal to work out stretch or shrink is much easier. Very impressive. But the accuracy needed to get two panel to sit flush, with no gap, is a skill that it seems takes years to master.
Making a buck for a fender
Hinge template he made.
Resin and wood buck for a VW Bus door handle
Handy use for old bearing races
Home made tucking fork
Various tools. The wonderful thing about Barry is that most of his tools are hand made with bits and pieces that lie around in a workshop. The little tucking tool is brilliant (the pic of flat bar with a diagonal slit in it)
Prestretching and working a pattern with 1mm mild steel and 3mm masonite
Look mom, an ashtray....a simple example of shrinking by hand using tucks, mallets, a stump and then planishing by hand.
Not bad.
And of course, I've forgotten much of what I learned but have trying to practise the principles.
A great 3 days. Even if you have no aspiration to use what you have learned, I recommend one of these course (there are many masters in the UK). Great to get your brain out of work mode and to work with your hands and steel.
-
- Nurse, I think I need some assistance
- Posts: 8732
- Joined: Sat Apr 23, 2005 9:08 pm
- Location: Nottingham, UK
Re: A sort of Barn(es) find
Great stuff - I do fancy a course like that
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
Do it Sladey. Complete disconnect from the pressures of modern commerce and general empire building!
-
- Nurse, I think I need some assistance
- Posts: 8732
- Joined: Sat Apr 23, 2005 9:08 pm
- Location: Nottingham, UK
Re: A sort of Barn(es) find
Currently fumbling my way around my new lathe and loving every minute of it
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
-
- Nurse, I think I need some assistance
- Posts: 18926
- Joined: Mon Mar 10, 2008 6:26 pm
- Location: West Midlands
Re: A sort of Barn(es) find
Could never be without my oldie now..
Use it so much just making things or making them better.
Use it so much just making things or making them better.
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
I am fascinated by the old lathe. Seems like a proper grown-ups piece of kit.sladey wrote:Currently fumbling my way around my new lathe and loving every minute of it
I seem to have a slight problem with machines and high rpm.
In my younger years, two fingers and a belt-sander, more recently, this...
14 stitches.
Mini grinder with a flap disk...literally the last weld of the body work....
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
That's a rather nice workshop Climber.911hillclimber wrote:Could never be without my oldie now..
Use it so much just making things or making them better.
You have clearly moved well beyond 'standard' Porsche resto's.
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
Previous to the injury, I've been charging ahead trying to get everything done so I can get the tub back on its wheels and start with the next chapter. Lots of sanding, painting and sealing - with a few of those final welding jobs to be done.
I've done all the spraying so far in my garage. An old fan from a jumping castle helps as an extractor.
I've done all the spraying so far in my garage. An old fan from a jumping castle helps as an extractor.
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
One coat then sand then seam sealer.
Have been on two minds about what to do with this lovely detail.
Since I am considering not having a dash pad, the only option seemed to be to cover it up again, with satin black.
Considering my dusty garage, the result was almost flawless.
Masked for final coat. Aside from having a new puppy, or a budgie, I have found a reason to buy newspapers again.
The octagon is your best friend.
Putting some bits back in to get an idea of colour scheme.
Floorboards from Boysowngarage and 356 wooden gear knob courtesy of someone in SOCAL.
Looks good.
Later impact bumper oil cooler for the front wing.
Amazingly, still has the factory sticker...
Will have to weld up a bracket to support it in the wing.
Last job on the underside was to prime and rubberise the rear wings.
This retaining plate was the last rotten piece on the RHD side - understandable considering how rotten the door lock post was.
The retaining nuts were okay but the rest was rubbish.
Cheap fix.
Welded in and primed. Seam sealed.
Lovely to have it all in one colour again.
Next rubberising and satin black topcoat.
The rubberising is a messy business.
I found it helped to have a can of brushable rubberiser on hand to ensure the hard to reach places were covered. Bloody hell, it makes a mess.
The entire underside has received two coats of rubberiser and two coats of satin black topcoat.
Just the engine bay is left. Weld in the brand new engine mounts and spray.
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
A few other jobs while the undercoat was drying / being sanded.
My doors have been the bain of my existence: the skins warped by my own stupidity, or the various seemingly endless patches to get them solid and rust free. In truth I should have removed the skins and had fibreglass skins bonded to the steel frames. But I am stubborn and nostalgic, so trying to save the original skins seems like the best idea.
Some repairs on the LHD door.
Top of the door was rotten.
Bottom corner was rotten (and I had tried to repair it previously - only to warp the skin.
Front corner was rotten
...been here before
And a bit of upper body workout...
In primer.
Ready for another few days of sanding and finishing....
With an injured hand I have spent my time spending money...
Money I need to spend to get the bucket back on its wheels.
Staggering that you can walk into PC Johannesburg, hand over a whack of cash and order parts for 1967 car, delivered from Germany 10 days later. Try that with a British or Italian car.
And to be fair, the parts are not the expensive in dollars or euros. It's our pathetic exchange rate that messes things up.
Sans welding in the engine mounts and spraying the engine bay, the body is done!
4.5 years and 14 stitches later.
Not bad for an amateur...hopefully nothing falls off when I eventually drive the thing!
The downside is that I now have to start spending money:
- electro plating
- bushes, rubbers, etc
- engine bits
- clutch
I have now exhausted my ability to do the heavy work myself.
Still, quite an achievement.
Next on the shopping list are the following:
- 1973 RS alu calipers (kind of have to really)
- Seats (importing is bloody expensive and Historika have not responded to my mails about buying shells for 3 years)
- That missing 5.5 x 15 Fuch or a set of Group 4 7R replicas
- Clutch
- Headers (will get these made up locally by a racing pro)
- Tyres
Still, nice problem to have.
My doors have been the bain of my existence: the skins warped by my own stupidity, or the various seemingly endless patches to get them solid and rust free. In truth I should have removed the skins and had fibreglass skins bonded to the steel frames. But I am stubborn and nostalgic, so trying to save the original skins seems like the best idea.
Some repairs on the LHD door.
Top of the door was rotten.
Bottom corner was rotten (and I had tried to repair it previously - only to warp the skin.
Front corner was rotten
...been here before
And a bit of upper body workout...
In primer.
Ready for another few days of sanding and finishing....
With an injured hand I have spent my time spending money...
Money I need to spend to get the bucket back on its wheels.
Staggering that you can walk into PC Johannesburg, hand over a whack of cash and order parts for 1967 car, delivered from Germany 10 days later. Try that with a British or Italian car.
And to be fair, the parts are not the expensive in dollars or euros. It's our pathetic exchange rate that messes things up.
Sans welding in the engine mounts and spraying the engine bay, the body is done!
4.5 years and 14 stitches later.
Not bad for an amateur...hopefully nothing falls off when I eventually drive the thing!
The downside is that I now have to start spending money:
- electro plating
- bushes, rubbers, etc
- engine bits
- clutch
I have now exhausted my ability to do the heavy work myself.
Still, quite an achievement.
Next on the shopping list are the following:
- 1973 RS alu calipers (kind of have to really)
- Seats (importing is bloody expensive and Historika have not responded to my mails about buying shells for 3 years)
- That missing 5.5 x 15 Fuch or a set of Group 4 7R replicas
- Clutch
- Headers (will get these made up locally by a racing pro)
- Tyres
Still, nice problem to have.
-
- Nurse, I think I need some assistance
- Posts: 18926
- Joined: Mon Mar 10, 2008 6:26 pm
- Location: West Midlands
Re: A sort of Barn(es) find
Quite a gash!
Had a spate of getting fluids (ie brake cleaner) in my eye, and that is not a good thing...
As an apprentice I loped the tip of one finger off with swarf going round in a very big drill in a VERY big drill stand., but survived since then.
About to re-build my 911 I re-built in 1989, so soon back on the old girl.
Yours is a great project, very interesting and all DIY, congratulations!
Had a spate of getting fluids (ie brake cleaner) in my eye, and that is not a good thing...
As an apprentice I loped the tip of one finger off with swarf going round in a very big drill in a VERY big drill stand., but survived since then.
About to re-build my 911 I re-built in 1989, so soon back on the old girl.
Yours is a great project, very interesting and all DIY, congratulations!
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
-
- Nurse, I think I need some assistance
- Posts: 8732
- Joined: Sat Apr 23, 2005 9:08 pm
- Location: Nottingham, UK
Re: A sort of Barn(es) find
Nice work
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
Away from the steel for a while. On to the fibreglass.
A nice change.
The gaps on either side of the bonnet are between 10 and 15mm.
The bonnet has clearly had a few previous lives.
Building up the edge with a 3mm piece of dowel seemed to be the best strategy.
Never having done this kind of FBG work before I'm flying blind.
Seems to have worked out okay.
Now for a few hours of sanding and filling to get the edges perfect.
Then onto the front fenders, and the bumpers.
The steel mounts glassed into the front bumper were appalling.
Boggles the mind the shortcuts people take, even when they are selling their product.
A nice change.
The gaps on either side of the bonnet are between 10 and 15mm.
The bonnet has clearly had a few previous lives.
Building up the edge with a 3mm piece of dowel seemed to be the best strategy.
Never having done this kind of FBG work before I'm flying blind.
Seems to have worked out okay.
Now for a few hours of sanding and filling to get the edges perfect.
Then onto the front fenders, and the bumpers.
The steel mounts glassed into the front bumper were appalling.
Boggles the mind the shortcuts people take, even when they are selling their product.
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
Considering what could have happened I think I got off lightly.911hillclimber wrote:Quite a gash!
Had a spate of getting fluids (ie brake cleaner) in my eye, and that is not a good thing...
As an apprentice I loped the tip of one finger off with swarf going round in a very big drill in a VERY big drill stand., but survived since then.
About to re-build my 911 I re-built in 1989, so soon back on the old girl.
Yours is a great project, very interesting and all DIY, congratulations!
Subsequently discovered that the emergency room doctor didn't use dissolving stitches on the inside of the cut.
Have to do some remedial bodywork....
Look forward to seeing a thread on the 911 re-rebuild.
Cheers,
Matthew
-
- DDK above all
- Posts: 150
- Joined: Mon Mar 24, 2014 7:00 am
Re: A sort of Barn(es) find
Thanks Sladey.sladey wrote:Nice work