USA 1970 911T - the Tangerine Dream

[RobFrost]

My fingers are black and blue after reassembling the Bilstein jack, but it has come up nice and seems to work perfectly now whereas it was sticking before. I cleaned off all the corrosion with fine sandpaper, degreased, disassembled, ran all the parts through the ultrasonic cleaner. I waxed all the nickel-plated parts, stripped and repainted the painted parts, before reassembling. The top o-ring was a particular game. Apparently the VW logo is correct for the 1970 911T.







All it needs now is the correct wheel brace with the slim handle end for cranking it.

[RobFrost]

Finally got back onto this project after lots of distractions. Mostly stripping back the dash, column, wheel and knee rests to prevent burn damage while welding the dash.

I'm mindful the petrol expansion vessel is in this corner so fingers crossed for no explosions.



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[RobFrost]

This is a tricky little spot to get the grinder in. I guess we've all saved the last remnants of a disk for this kind of job.



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[RobFrost]

Water from the failed windscreen rubber appears to have been collecting under the dashboard top. I decided to cut away the top lip and re-form that along with this little area of the dashboard front.



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[RobFrost]

I did my best not to grind or sand the lead in the bottom of the A post.



This was a tricky little spot to form. It's right in front of the driver so it should probably be as tidy as possible. And very difficult to get the grinder in.



Having finished that patch, it looks like I need to extend down the door frame a few inches.

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[RobFrost]

Strong fingers needed to pry this away today without any damage.

Just in time, it seems. There was the tiniest touch of damp under here from the hole above but no rust on the underside.



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[RobFrost]

Failed rear windscreen seal - 50 years in the New Mexico sun.



Rust damage to the parcel shelf from the dripping water.



The windscreen corners are in great shape. I presume the water came between the glass and the rubber.



Not sure if I'll use this but I'll have a go at fabricating a repair patch. This isn't the finished shape, I'll make it in parts.



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[RobFrost]

Two floors for the price of one in the rear left corner.



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[RobFrost]

Not looking any better from underneath. It looks like the car has stood with the front elevated because the water has collected at the back.



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[RobFrost]

The seams look solid, to weld to though.

I'm using a new method, which seems promising. 3mm drill through the centre of the weld, then use the spot weld bit to cut the side that's being removed. That will leave a little disc of steel weld to grind off but a nice clean seam to weld to.



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[RobFrost]

Some idiots never learn. Gashed the pad of my thumb by 9:15 on a sharpe edge, that'll be annoying for the day ahead.



Having done one of these before I know how to cut the floor and leave everything else intact now.



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[RobFrost]

The new method got the seam separated without any damage, after this I ground off the little discs of spot weld remnants.



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[RobFrost]

I made a new bottom lip for the inner sill, marked up the inner sill for cutting before I removed the floor, a bit of fettling left to do once the floor was out.

Making this would have been easier if I had a shrinker stretcher.



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[RobFrost]

I managed to get it pinned in place before it was time to pack up. The job's a lot easier since I switched to 0.8mm mig wire. Worth putting up with the occasional bird's nest.



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[RobFrost]

An hour to pack up, get the seat back in and drive it back into the garage. 10pm finish with no dinner





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