1960 356B Restoration

[DustyM]

So last summer we took delivery of this 356B, Its LHD but has been in Ireland a long time and has sentimental value to the owner.

It came in drivable (just about) but it became evident on close inspection that it was going to need a lot of work, with plenty of filler evident and poor previous repairs.



So strip down began.





Back to a completely bare shell





And a cage welded in to keep the integrity of the shell.

[DustyM]

The shell was sent away to be stripped and at first glance seems solid enough but unfortunately it has been restored in the past and has an awful lot of patchwork repairs that are well below todays standard. It has also suffered from accident damage to the righthand rear wing, bumper and chassis rail as well as the lefthand front. Not surprising as it was used as a race car for some of it's life.













Some repairs aren't even welded but op riveted!



A similar story underneath on the floorpan, poorly welded repairs roughly hammered into place.









Even the roof has suffered with a repair to the outer skin and inner rails

[DustyM]

So it was time to order some panels!

[DustyM]

Next step was to get the shell on the rotisserie to access the underneath



And cut the floor out



Work starts on properly repairing the perimeter of the floor pan starting with the lower bulkhead for which a section is fabricated.





Repairs to the front chassis rails





All closed sections are zinc primed inside



Spot welded where possible





Diagonal cross member trial fitted



Damaged tunnel sections straightened out



Inside tunnel protected whilst accessible



Rusty and poorly repaired Fuel tank floor removed



Guides and brackets are removed from the old section and spot welded onto the new panel





New panel not quiet correct so edges are modified to match the original



And welded into place



Complete with drain holes as original



Underside and under dash protected whilst access is easy without the floor in place.



Scrap Pile is growing!

[stretch]

Nice work as usual Jon.

[DustyM]

Nice work as usual Jon.

Thanks Dave, though I can't take all the credit for this one, I have a fabricator/welder working with me now.

[DustyM]

Trial fit of the floor pans





Welding into place along the centre tunnel only for now







Floor perimeter will be attended to later on.







Rear of the engine bay



Sections removed





And a new rear crossmember fabricated





New sections welded in place



With the joining piece exactly as original, even though it will never be seen



And zinc primed





New heatshield spot welded in place

[DustyM]

Next we decided to get the areas of the shell which would require little or no further welding into etch primer

Areas of shell etch primed









Shell removed from rotessairy to allow nose sections to be removed.







Hundreds of spotwelds drilled out...



More corroded internal panels which will need repair





The ever increasing scrap pile!

[jtparr]

Phew....read that in one go.....!...enjoying the detail John....

[Lightweight_911]

That's going to be a lovely car when finished - great detail shots to have as part of the car's documented restoration.

The workshop's looking very tidy Jon !

I particularly like this shot




- potential 2018 DDK Calendar entry ?


.

[DustyM]

Jig brackets fabricated to enable the shell to be bolted to the jig bed to keep it flat and square whilst the floor and sills are welded in place.







Remaining front end panels removed





Inner sill sections fabricated and welded in.





Original style of fabrication joins re-instated



And still it grows..



Trial fit of front end panels









Trial fit of outer panels (First of many!)

[911hillclimber]

really interesting thread, keep it all coming please.

[jjeffries]

Amazingly hideous prior repairs...almost vandalism. Superb work being done now. Difficult cars to get right. Great to see Classic Carreras growing and sharing all these photos; helps us amateurs no end.
John in CT/USA.

[DustyM]

After removing the outer panels again, the inner panels are fianlly welded in place









Spotwelded as original where possible





The metal is then etch primed to protect it whilst work moves to another area of the shell

[DustyM]

Before the sills (longtidudinals) can be fitted more areas of rust need to be cut out and repaired.







Also the heater channels need repairs, with new sections fabricated for the ends of the pipes



New heater tubing made up



Inside of sills coated with epoxy before fitting





Repair sections fabricated to panels adjoining the new sill















Jacking point welded in place



Similar repairs needed for the other side



That's better!





Smaller closing panel spotwelded in place