'65

[Lightweight_911]

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Agree - the floors look to be in excellent condition but I'm guessing from your comment above that this is going to prove to be something of a 'red herring' ...

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[inaglasshouse]

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Agree - the floors look to be in excellent condition but I'm guessing from your comment above that this is going to prove to be something of a 'red herring' ...

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Not really Andy. It’s a fantastic shell overall. As it should be, for the price I (over) paid!

But the fiddly bits add up.

I reckon in the end, by the time Barry has fabricated a fair number of small local repairs, the shell will have a very high proportion of original metal (good!) but will still have consumed quite a lot of time, hence money.

I need to get out of the mindset of breaking even on it, I think. Even though I am going to have to sell some cars and this one is unlikely to make the cut as a keeper. For now just enjoy the process and the result.

[Gary71]

That’s a lovely looking shell

[inaglasshouse]

The RH rear seat pan was pretty rusty.
Here Barry fabricates a new one:

[inaglasshouse]

Rear Inner Wing Repair

Note the dummy spot welds carefully formed to be just as nasty looking as the originals. There’s no way of actually getting a spot welder into this area because the rear outer wings are there, but these welds are quite visible normally.

So the hand-held welder is used, with a good wobble on each weld to really bring the metal up.

[inaglasshouse]

Rear Bulkhead (end) Repair

Not obvious, but I also had to restore the little bracket as the entire base had been peppered with spot-welds. Therefore I had to cut the base away, weld In new metal than spot-weld it in place in advance of welding the repair in.

[Gary71]

Love a bit of Barry’s work in the morning

[911hillclimber]

Indeed!
What a repair that seat back/corner is. Does he grind both sides as you could see the area readily from the engine side?

[inaglasshouse]

Does he grind both sides as you could see the area readily from the engine side?

Of course! Barry is Mr "Are you sure that's a new bit? Where's the join?"
The repairs are quite hard to spot while in bare metal, and once in paint you'd really never know (based on my previous experience with the orange car).

[arminius]

Looking at the surface of some of those formed parts looks like Barry has got himself a power hammer? Nice!

[inaglasshouse]

Seat Pan and Bulkhead - all done for now:

[inaglasshouse]

A little before and after:

[Rustytubs]

Fantastic work, your fabrication and metal bashing skills are awesome

[inaglasshouse]

Fantastic work, your fabrication and metal bashing skills are awesome

Sadly not my skills. But yes, Barry does know what he's doing!

[inaglasshouse]

Side note. I was chatting with Jamie about his 912 which (per other thread) he sold quite recently. Sold via one of the high-end California Porsche places.
When presented with the usual set of photos of Barry's work, they said it's uncommon in the US (even for very valuable cars), to see this kind of fabrication to preserve as much original metal as possible. Seems they were impressed.
Cheers, Richard.