So on with the LH door, same as RH. Fit to rear wing and outer sill again REALLY good, with very little faffing required.
So in with the window winder and frame
Before fitting the wing I had to fit the two-tone fanfare horns. I saw in another thread the brackets were NLA, and that the best (only?) source was a bloke in Australia! Sod that - they are only bent 2mm mild steel plate after all. So after 30min of fabrication and some primer and paint ...
To do this you need some of the 25mm wide, 2mm bar you can see in the photo, and the tools shown (plus a hacksaw and a vice)
and fitted...
Might need a bit of adjustment to clear the wing and bumper as I had to guess the measurements... So on with the LH wing. Bit of fiddling to get the petrol filler cap release tube in place as you fit the wing. One trial fit and then on she goes. This one needed quite a bit of 'easing' to fit the profile of the door, but with a little help we got there in the end. The gap a the top near the scuttle is not good enough though and for some reason the wing edge is a bit 'raggy'. Not sure why, or what in the painting process could result in this (hi-build primer?). Anyway as you can also see some idiot forgot to fill the holes where the PO had fitted at least one wing mirror
(this door was off a LHD donor, so this was the drivers door) ... so this door will need rework and repaint anyway. My plan is to refit the unmodified engine, do some testing and hopefully get a MoT, then take the engine back out and either rebuild or just tart it up a bit. I'll get this sorted and repainted then. Have sacked the fool who forgot to fill the holes in door...
One learning to pass on...... how to fit the inner of the two M6 bolts that attach the wing to the scuttle inside the door opening. The outer one can be started with your fingers, but unless you have a tame 5 year old who can (and will!) get his/her hand in there, getting the inner one started can be a right pain. I faffed about for ages on the swb with the trusty bit of fuel pipe trick, but if the pipe is big enough to fit the M6 bolt in the end, then it's too big to go straight towards the hole though the small gap between door and wing. The answer IS......
Wrap some tape around a long thin screwdriver so the hose will hold on the end. Fit bolt and washers into the other end. Fit through the gap ... and it's easy.
So then back to the bonnet. Despite the fact it's a new Porsche bonnet fitted to two new Porsche wings, I couldn't get it to sit flat and even to the scuttle (too close even at max adjustment) and both wing profiles were low to the bonnet by about 4mm in the middle on the RH and 2 mm on the LH when the top and bottom edges were flat. First step - take the hinges off and lay the bonnet flat on the seal. Fit much, much better, and obvious that the hinges had been much modified with lots of filing out of holes in the brackets. LH wing profile now spot on, and the 'bow' up of the bonnet max 2mm in the middle on the RH when flat to the wing at top and bottom. Now I'm holding Charles' gulf blue bonnet in storage until he can collect, so we laid that on next
Thanks Charles .... anyway same result. Also tried the old original bonnet - same result. So a bit a gentle leverage was applied and to my surprise it was relatively easy to get the wing to flex by the required amount. I left the bolt in the very bottom edge and the next screw tight in place and the top screw and the two screws in the scuttle, and just eased up the lower edge of the wing flange (not the wing itself) with a pry bar. My assistant tightened the wing attachment screws as we went. Relaid bonnet - fits really well. Now I just need to get a spare set of hinges out and see if they are better, before fettling the ones I have.
Lastly the rear lid went on and the blower gubbins and its Weltmeister strut brace went back in. Under bonnet now finished apart from the 'trim'
Carpet in, rear seat squabs just laid in place.
In fact they are a bit big despite the fact I've used an original rear seat soundproof rubber moulding, so I might need to 'rework' them a bit!
Just need front bumper, seats, seat belts and an engine......
). Anyway it, and the associated wiring, went in really well. I had researched as much as I could here, on Early911S and Pelican. See here for more details if you face the same task....
