DDK - Die Deutschen Klassiker

Here's where I regret not buying that spot welder.

The floor will be spot welded on to the centre tunnel flange and seam welded to the floor.



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It felt like this floor had been in a hundred times before I finally started welding it. Mostly a consequence of careless jacking at the front corner by previous owners.

This was the front half floor from design 911 and I'd recommend it, it's a good fit.


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It was dark by the time I started rebuilding the inner sill. Schoolboy error: I later learnt the rear parts of the butt clamps aren't magnetic. Not sure how I'm going to get those out now.



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It took a big push to get it all back together. I went without dinner and managed to get the inner sill pinned on before packing up for the evening. The car was even driveable so I was able to take her out for a Maccies drive through as a reward.


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I stripped the trim off the driver's door today to lubricate the sticking window. Amazing the condition of the bottom of the door. I've never seen a 50 year old car with the bottom of a door this good.


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I cut the rot out of the base of the wheel arch where it meets the floor.


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...and got a repair piece in. A bit of tidying up and then just the bulkhead to go, to finish this corner.


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I underestimated the work sorting out this tight little corner. The box section had a slight hole in it which I cut out and repaired. I couldn't get the grinder inside to remove the surface rust inside, so I did what I could with a wire brush and lined the inside with phosphoric acid paint. It will be waxed later with the rest of the car.


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I regretted trying out this inasa zinc weld thru primer from rust.co.uk. The spot welds I tried to weld through it spat like crazy. I thought I had penetrated but when I hammered another part of the panel into position the welds came loose. I ended up having to drill out 3 or 4 welds and do them again.

The plasticote paint I had a better experience with. It's not marketed as weld thru but a review on Amazon said it worked well and I agree.



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The bulkhead had a largish hole, I suspect from air con which had since been removed. I ended up replacing the whole area, spot welding through to the box section behind. Will try to get it all primed up while it's fresh and clean.

I've taken to not grinding welds flush. I doubt so many cars are this original, I like being able to read the car and see where the new metal is.


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On the suggestion of Gary1971 and 911hillclimber I looked into the epoxy primer from rust.co.uk with a view to brushing it out rather than committing to a whole spray can each time I do some priming. Turns out they do orange so I had no choice really. It's pretty thick, which was a good job because I brushed it out from a spray can lid, realising after I started there was an air hole in the bottom of the lid.

You can't get it as even by brush as you can with a can, but you can work it into the cracks and seams more effectively.


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The stuff we were talking about was separate pots of base and hardener that you mix up it disposable cups as you need it, but not sure they do that in orange

Battle ship grey only I think, but yes, thick though with a brush you can get it poked in everywhere.
Dries quite hard, easy to sand down for A face areas.

Gary71 wrote:The stuff we were talking about was separate pots of base and hardener that you mix up it disposable cups as you need it, but not sure they do that in orange

Yes, that's the stuff. They call it EM121 and do a whole load of colours https://www.rust.co.uk/product/cat/em-1 ... is-paint-7

Looks like the colours might be new.

Had about the 5th or 6th delivery promise on a back panel from Design 911 come and go last week, with no delivery. It's getting embarrassing now. Ordered in the summer. If it wasn't for them repeatedly promising it in a few weeks time, I'd have ordered one elsewhere by now.

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