A sort of Barn(es) find

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

911hillclimber wrote:Well, until just I couldn't work out where those pieces with all the holes went!
Lot of work but so much better.
Looking forward to the next 'holes'! :wink:
Cheers.
A very satisfying piece.
A lovely detail from the form follows function dedication at the heart of these flat beetles.

It is one of those jobs that sits in the back of my mind.
I really should replace the whole shelf and the support rail.
Probably can't see it in the photos but the lovely ribbed deck has been bashed about and warped.

Worry not, there will be lots more holes!
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

sladey wrote:Nice thread - good to see someone getting stuck in. From the pictures you can see how your fabricating skills improve the more you do it. Ive got to re-do the rear roof seam so interested in how you achieved that

For metal shaping I'd recommend this DVD. I appreciate you've come to the end of your metal work but you can never learn too much
https://www.stakesys.co.uk/david-gardin ... torial-dvd

Thanks Sladey.
Reconstructing this thread (still about a year behind) I am struck by the same thing.
Patience and practice are the secrets. A little skills helps but not essential.

The rear rain channel is a tasty bit.
Not sure the way I have done it is right, but I do now understand how the whole thing comes together.

General learning for me is that you have to think a little bigger when patching. My tendency was to try and limit the size of the new steel. Whilst I think its a great idea to save as much of the original steel as possible, repairing rot properly requires thinking beyond just the rot. The best example would be unpicking the whole rear fender to properly patch the window frame corners...like Mr Carter does. Far more time consuming in the short term, but essential to do a proper job in the long term. \

Thanks for the metalwork lead. Brilliant.
Can never get enough learning material.
Do you follow The Rust Killing Blog?
Bengt Blad.
https://www.bladsforlag.com/en

I spent last week on a 3 day metal shaping course with a local master.
He came up to Johannesburg and ran a few courses.
All hand tools; stumps, bucks, form work, shrinking and stretching.
Chap is called Barry Ashmore.
First name is a good start!
He is normally based in glorious Stellenbosch in the heart of the Cape winelands.
Does custom American hot-rod work and European classic repairs.
Fusion welds body panels with a TIG. No filler. Bloody impressive.
If anyone is interested in the courses give me a shout. Thanks to the exchange it'll cost you 250 Squid for 3 days!
For a grand or so more you can spend a week in Cape Town and the winelands!
jjeffries
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Re: A sort of Barn(es) find

Post by jjeffries »

Great job. That's a complicated bit of real estate to trim back then repair properly. John
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

jjeffries wrote:Great job. That's a complicated bit of real estate to trim back then repair properly. John
Thanks very much. Not sure I can use the word 'properly' :wink:
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

Next: the LHD sill

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Pretty much as I expected.
The lower parts of the sill were shot. As were the front and rear corners.
The heater tube was in remarkably good condition.
Nice result.
BUT, the outer floor pan and seat rail supports....not so much.

So, after procrastinating, I decided the only way forward was to cut out the outer edge of the floor pan.
It helped that RD started offering the outer floor pan patch....the thought of having to fabricate my own helped with the procrastinating.

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Not so healthy.

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Seat rails shot.

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Front corner also toast.

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Despite all the rot, after a good clean things didn't look too bad.
Until my little MIG packed up.
Cue a 4 month delay....
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

With the MIG in the sick bay (awaiting a spares) the only way forward to make a whole bunch of patches.
To be honest, I should have gone out and bought a decent replacement MIG...I'll blame being so tight on my ancestry.

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Seat rail support

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Rear patch. Start with cardboard.

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Switch to steel

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Lower wheel house patch.
This was pre-shrinker/stretcher so pie cuts seemed the only way to make it work.

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Had to make it in two parts.

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The heater tube cleaned up nicely

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With the help of one of these highly sophisticated piece of equipment, I managed to create a compound curve for the patch (the other side benefited from a shrinker / stretcher so took 1/4 of the time and 4x less swearing.

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

Delivery from Canada.

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Nice pieces.
Cost a bloody arm and a leg though.
The shipping ex the US is larcenous.

And while I was waiting for this lot (and figuring out what to do about the welder, I attacked the front.
Bad repairs and lots of extra rot.

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Take lots of measurements and photos of the measurements.
BUT I had no idea if what I was measuring was straight.
No sign of creases or stress bends, so that was a good sign.
So with the aid of factory dimensions I was pretty sure I could get everything reasonably lined up later on.

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Not pretty.

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I cut back as far as I could to get rid of the rot.
A brace welded in helped keep everything from moving....too much.
And on to the repair.
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

A rather different approach to forming the lower piece of the front.

I drew up all the fold and cut lines onto a piece of 1mm, welded it to the contour of the inner fender and then went to work.
Th told piece was so rotten and badly repaired, getting the depth and shape of the curves was tricky. The new suspension pan helped as a guide.

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The inside

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Some interesting folds...

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Welded up and cleaned. Not bad.
I ran a bead on the inside and the outside to ensure it was strong.

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Always looks better when hit with some etch primer.
(Top tip, it comes straight off again if you wipe it down with thinners...even if it has been on there for a year or more)

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My alignment wasn't perfect along the flanges, so I had to cut a piece out and weld another piece in to get the flanges to mate nicely.

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Much better

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Tight fit all along the flange

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The other side also needed some work.
Pie cuts make me cringe now, but 2 years ago I didn't know any better. At least it's strong.

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And once in, the suspension pan got welded in.

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After finishing this part, and taking a proper look at the rotten front slam panel I wisely decided to abandon my plan of patching it and putting it back in. The steel was so marginal and badly repaired in so many places....the smarter plan seemed to be to bite the bullet and order a new one. In the meantime, there were lots of other jobs to be tackled...

The LHD rear quarter window sill.
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

On to the rear 1/4 window sill.
This piece is a bugger.
There are three curves to this piece:
- the consistent rounding at the top of the door slam panel / front of the 1/4 panel.
- the transition into a reverse curve that increase as it moves to the rear, toward the C pillar
- the inward curve that follow the line of the 1/4 window.
Quite a lot of movement for my little 2d brain to absorb.

In hindsight there is one thing that I would have done to make this repair and others a lot easier: make a flexible shape pattern or an old school ribbed buck to measure the shape under and around the window sill. There are so many transitions in this panel that even in primer imperfections in alignment and curve show up. Which means, for a muppet like me, hours and hours and hours of working with filler, even just as little as 1mm think, to get the curve absolutely perfect. With a buck or flexible shape pattern, I would have been able to get the steel in better shape. But that's hindsight. Maybe for the next one!

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Slowly get the crease accurate

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Almost there.

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Measure 9 times and cut 4 times. Just to be sure.
Doesn't look too bad does it....but wait.

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http://i1374.photobucket.com/albums/ag4 ... tykfin.jpg

Close-up of the rust

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

On to another repair I had been dreading: the smuggler's box.
Not in great shape.
And with a large, rather inflexible frame that I am blessed with, a real bugger to get at.

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Took me a long time to understand how I was going to repair the bloody thing.
Compound curves and straight bits....like being back at school.

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So I started make patches.
This approach has got me out of jail before: rather than stand around with a confused brow, start making patches and eventually things figure themselves out.

Quickly became obvious that I was going to have to cut out a lot more than I anticipated just to be able to get at the problem
This tentative opening was not big enough.

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The bottom of the smuggler's box didn't look very good either.
Rot had got between the two pieces of body that come together around the edge of the opening.
Not a very clever design, if I say so myself.

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Some of the rubbish that had to come out

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The new, widened scope of the trauma...

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Notice the rot along the bottom / top of the transmission tunnel.

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

Making patches.

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Trusty stove cap.

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How it all comes together

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Always the smallest patches that are the real bugger

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All of the pieces together.
Welding them in cleanly was a palava

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The tools of the trade (the biggest tool was holding the camera...)

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And weld
(make shift repairs on the MIG had worked wonders)

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Site inspection by the Minister

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Not pretty, but strong

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From inside the smuggler's box

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All done.

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Then time for the other project: the budding batsman.
If he doesn't make the Proteas he can always Captain England :lol:

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

Some cleaning up and strengthening around the underside of the suspension pan.

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And fannying about with homemade strut braces.
4 prototypes and nothing was right....

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That was 2015.
Not my most productive year.
But progress is progress.
Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

I started the year with tackling the outer floor pan.
Out with the rot.

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Drill spot welds....

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Measure the new panel

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And cut some more.

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Repair the front corner.
Not a bad patch ( i threw away a few previous attempts )

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Weld in the rear inner sill patch.

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Same for the front

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Random shot of Porsche Pointer warming his, um, delicates

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Seat rail support patch welded in.

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Cleaned and primed with etch.

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Replacement panel cleaned back to bare steal and etch primed.
I took this approach with all the patches, factory or otherwise: strip away the black stuff to bare metal, clean and etch prime.

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Drill plug weld holes for the seat rail support and check the fit.
Must have checked the fit 50 times.

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Just managed to avoid disaster in a few places...

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Start welding

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Long day behind the mask.

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In she goes.
Just to be safe, I played a bead on the inside of the join.

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

In the midst of the floorpan surgery I fixed some other bits.
Every time I opened up a channel blast medium came trickling out.
And this after I've attacked this thing with a compressor and a vacuum for days.
Amazing how much crap stays in there, everywhere.

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The LHD rain channel in the boot was a mess.
And yet the RHD side was perfect.
Maybe it was parked half under a tree?

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This pretty much sums up the state of the car.
You can see the original, rotten steel under the patch.
Whoever did the work in the past went to a lot of effort to do a crap job.
They exposed the rust, cut patches and welded them in before covering the work with bondo. They managed to do all this badly. Deserves an award of some kind.

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This bit was all original.
A soggy driver's carpet, fed by a buggered door seal and encouraged by leaks at the bottom of the windscreen corners.

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Looks like something Hester would do with Bolivian Parmesan.

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The floor clip is from a toasted Targa. Let's just say the chaps who generously gave it to me where not interested in drilling spot welds. You can see the cutting disk scars on the outer edge. Not to look a gift horse in the mouth, I was very happy to have it. Served me well.
Had to juggle a bit to get the pressings to match up...because I'm obviously such a perfectionist. Just have a look at my welds :(

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Some days my welding doesn't look half bad. Even a blind squirrel finds a nut.

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Judging by how many of these pictures are out of focus I must have been drinking for sustained periods at the time.

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All done.
Ugly, but strong.

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And slightly further aft of Hester's Parmesan dinner plate...

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You can see from the green marker circles that for a time I considered patching it. And then I came to my senses.

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Many thanks to the toasted Targa.

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Drunk again.

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Done.

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Parkview911
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Re: A sort of Barn(es) find

Post by Parkview911 »

The most recent posts (a few day's worth) add up to at least a year's work.
2015 wasn't the most productive year at Barnes Classic Porsche Resurrections.
But never mind that, we're cracking along now.
I am feeling a sense of accomplishment without really doing anything!

Forgive me if this is boring; these step by step documentaries.
To think of the quality of lots of the other work on this forum, even by amateurs like me, and then my own makes me cringe a bit.
But never mind that, we're cracking along now.

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All clean and ready to be closed up.

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Done

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And moving over to the left side of the boot...

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So much easier to weld new steel, at chest level, on a horizontal surface, with good lighting.

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Both sides, just be sure

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All together. Acceptable fit.

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