1987 3.2 Carrera Backdate project - Sladeys hotrod

[Lightweight_911]

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Must have felt like a satisfying couple of days' work Mark ... well done


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[DustyM]

Order yourself some epoxy mastic if you don't have it and give everything a good coating before putting the rear wing section back on.

[jjeffries]

Gents, I need some cross-Atlantic translation, please: epoxy mastic...two-part epoxy primer, but brushed on? For better or worse, we don't use the word mastic here, but from my days as a lad in Brissle, I associate it with something more gummy or at least thicker and more viscous. Any clarifications appreciated. Thanks, John

[sladey]

You’re right Andy - it was great

Good call Jon.


No problem John

This is the stuff

https://www.rust.co.uk/product/cat/em-1 ... is-paint-7

[jevvy]

Made up a repair patch



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Nice work fella, I hope you managed to get the curtains back up before the Mrs got home though?

[Sam McMahon]

Glad to see the panel turned up in good time and that it’s been of use to you, great looking project you’ve got there.

[sladey]

No problem jevvy - she’ll never notice they’ve gone

Thanks Sam - the part is just what I needed. Seemed a shame to be cutting off the engine mount to get at the bit I needed but needs must

[sladey]

OK I”ll do a bit of progress report before starting again today

I’m starting with the bit in the photo above. I cut down my repair piece to the point where I could clamp it on top



With it clamped on top I scribed all the edges in the original panel underneath.

I then cut near to them with a grinder and cutting wheel and used a sander to take it carefully to the edge


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[sladey]

This produced this



Took a bit of jigging about - the flange on the left was bent a bit so when you clamped it down it threw the rest out. I straightened it out and it sat OK


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[sladey]

Then sprayed the back of the repair piece in weld through primer



On the body I masked up and sprayed the back of where the seam weld would be in weld-through primer
Then I worked out where the plug welds would be, sanded them back to bare metal and spot sprayed them in weld-through primer

Then I sanded back the inside of the cavity and treated it with Fe123 rust converter. This converts any rusty steel to a black hard surface. I forgot to take a photo at that stage. Once that had dried I sanded it down roughly by hand

Then I epoxied the back of the repair piece and all the inside of the cavity - staying clear of the bits with weld-through primer on them


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[sladey]

Then it’s welding time. This is part way through the process




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[sladey]

and this is with it mostly smoothed down



Back onto it today


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[Gary71]

Good stuff Mark,
I've taken to removing tiny patch of 'weld through' primer from behind the the plug weld. Splatter central otherwise!

[sladey]

More progress today

Marking out




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[sladey]

Then cutting out - brave pills required



After cutting I was relieved to see how thick the steel was - even though it was pitted


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