DDK - Die Deutschen Klassiker

What a cracking job you're doing Stephen, can't believe how much filler is on the car.

Superb work! Well done. Very inspiring.

johnM wrote:What a cracking job you're doing Stephen, can't believe how much filler is on the car.

Was on the car John!

Thanks, indeed there was a lot, fortunately it's all gone now. I've got a few offcuts from the car I've saved that have about 0.5-1cm of filler on, the weight of them is unbelievable!

Top class Stephen. What great skill and care in your work.

Regards
Mike

Nice work Stephen

Well I have to say, more fantastic welding work there Stephen!
I feel a bit of a fraud posting on Project Blue Book as it's in such good order. Really enjoying seeing your progress and how you are tackling each hurdle. I say a bloomin good effort sir!

chief wrote:Well I have to say, more fantastic welding work there Stephen!
I feel a bit of a fraud posting on Project Blue Book as it's in such good order. Really enjoying seeing your progress and how you are tackling each hurdle. I say a bloomin good effort sir!

Cheers, Chief. About time we had an update on that easy project of yours eh?

Stephen

To echo Chief's comments, I sit and write an update, but then read yours and realise my project is a walk in the park!!

Keep going and keep us updated

In this weeks episode of the Rust Explorer we take a look at the sail panels.

There's no easy way of doing this without removing a lot of metal. This part of the rear quarter had been beaten to hell in a previous life and was covered in filler. It didn't take long to decide to cut that off and bin it.



Originally I'd hoped I'd be able to repair the rust that was bubbling through above the door handle but on closer inspection the copious amount seam sealer that was stuffed there had failed. This resulted in a fair bit of corrosion and metal thinned beyond repair.

This is where I had a couple of bubbles peeping through.


It didn't get any better.


So... off with the sail panel. I've not mentioned my hatred for drilling spot welds have I. I've tried multiple tools and have just decided it's a bugger of a job. Every tool seems to blunt so quickly.



I've discovered opening up panels on a 914 is not like opening up presents on Christmas morning. Much too much disappointment in my opinion. Unless it was a present from an elderly distant great Aunt





That stuff hanging down is sponge - the water absorbing, rust inducing kind

Here's the underside of the removed sail panel, I think you can see just how thin the metal is here. Not savable.


Fortunately after removing all the seam sealer and underseal the damage was only on the surface, again I got there in the knick of time.

Before the car gets painted the remaining painted areas are going to be media blasted. This area under the sail panel will be almost inaccessible so I'll be treating it now before putting it all back together.

A good coating if epoxy primer later and things are starting to look a lot tidier. The areas where the seams will be welded are coated in weld thru primer.



Roger Bray did me a good deal on a pair of sail panels, now was the time to try them out. Getting everything lined up wasn't easy, well for me it wasn't.



I refitting the door latch mechanism so I could get everything lined up, at this stage I wanted to make sure I was heading in the right direction so the door gaps were perfect.

Looking good, and measuring within 0.5mm all down the door.

You can't just do one side can you...

So the otherside received the same treatment. Tougher this side though as I need to replace the door jam too as that suffered in the accident.









The sail panel obviously came from a different supplier originally and abielt a slightly thinner gauge steel it did fit slightly better.

Whilst I was in the area I need to attend to this jacking point too. Luckily the inner skin was unaffected so it was a simple case of cutting off and replacing. Nice simple job.



Ready to weld.


Done.

I finally found a decent early passenger door. These are starting to get rare now in good condition and not easy to find in the UK. I was very close to buying one and shipping it from the US. Thanks to Retro Restorer in Oxfordshire for this.




And this is where we are now, all ready for lots of welding but close to finishing the body.



Hopefully the next installment will see the body back in one piece Well almost.

And if I ever decide what colour to paint the thing it'll go off to paint.

Mega work!

Great work again Stephen. It looks Monster with those arches on. I remember chasing Andy Amallagh’s wide arch one in Wales and how cool it looked. This car is going to be great