DDK - Die Deutschen Klassiker

A great project and very nice work. I must be getting old, I still think of these as nearly new

Welding looks pretty straightforward compared to the T!

Thanks Barry, after today I can 100% agree the welding is easier than the T!

The sill panel is 1.6mm thick and possibly one step up from straight mild steel judging by how it bends.

I’ve used 1.8mm for the repair to compensate as I only have straight mild.

The welding maybe easy, but oh the fabrication isn’t! This panel looks simple at first glance but has loads of form to follow the different layers of the sill.

I made the most basic of hammer forms layered up with off cuts to knock the edge over.



Some time later:


You can never have too many clamps:



Welded the little triangle in first and ground it back so the main panel can overlap:


Then onto the main event: Tacked in and started on the spots:


Fully welded:


And ground back:


Just need to tidy the edge of that oval grommet hole tomorrow and I’m calling that done. I’m leaving the welds for the plug welds as they look ok for once!

Oh, very nice: that looks very good indeed. Particularly fine plug welds Sir.

Somewhat more impressive than the work I'm stripping off the current 911 from one of the country's biggest names ...

BTW just bought something made in the same plant as the S2000, also in 2001 and it's not an NSX.

Thanks Barry, Ooo do share, I’m pretty sure I have some insight into the answer to the other question!

bingo!

Don’t know Barry. Maybe you could give us a clue or some other insight...

I think Gary said the plant used for S2000 build was also used for the first NSX, another short production level car, so maybe it is an S800!

Some parts have turned up so time for something different from welding and grinding.

Started to swap out the suspension bushes today, which was fun…

No chance of any of them coming out without violence! Well one did, but that’s the exception.

I’ve bought some cheap and chunky metals from eBay which give a range of options for tackling this job on the bench.









Then last night the newly wrinkle powder coated rocker cover turned up:


The rest of the bay is letting it down now, but all in good time!

More bushes tomorrow!

It’s fair to say the compliance bushes in the front wishbones had too much compliance…



New Mugen bits are replacing these old OE parts, which although ‘uprated’ look absolutely the same as the OE Honda parts down to the moulding of the part numbers and machining marks…

Think someone may have bought the tooling.

All bushes now done, the pile of remains bears witness to the joy of getting them out!
The big vertical compliance bushes were the easiest, put some preload onto them, then waft a blowtorch over the outside of the wishbone and they crack free.




Now started on the front upper ball joints, one had seized so hard you could only move it in the vice with a hammer…



Got the old ones out easy enough with the eBay special ball joint removal G clamp thing.



New ones on order, should be here Tuesday.

Hopefully we can get all the remaining wishbones etc painted up by the end of the week and start reassembling the suspension.

Loving your updates Gary (yes, I do lurk more than I care to admit); your son must be very pleased with his father at the moment

Cheers Ian. It keeps me out of trouble

Did the front ball joints today and did the last batch of suspension painting last night.




I’m off to see my parents for a couple of days so hope to find my son has the complete underside cleaned back ready for paint.

Also hope to find the unicorn being carried by a flying pig, but we can dream

A good portion of the underside did get done whilst I was away, not exactly finished though…

However the subframe (finally!) returned from powder coating yesterday so we did the more interesting job of the rear suspension dry build this evening.



Currently nothing suspension bush related is torqued up and the adjusters are all set in the middle. This should hopefully allow the 5 miles to the specialist to do the geometry without it trying to kill us

Still lots to do and need to replace a ball joint gaiter we spotted a split in, but new OE brakes can go on tomorrow then we can put this assembly to one side and get back to the grind…

I'm expecting to see it in late August!

Hopefully Graham, hopefully!

Need to have a concerted effort over the next few days on the underside and get some paint on it.

The struts are back together now and the dampers are all apparently still good so progress is (slowly) being made.


Brakes are rebuilt with new rubbers on the sliders and new bolts.



I’ve got nothing planned for the next couple of days so time to put some hours in and get it moving