DDK - Die Deutschen Klassiker

Then trying the patch for size

Looks OK from this side




Sent from my iPad using Tapatalk Pro

But from this side it’s shite



That flange should sit on top of the bit underneath


Sent from my iPad using Tapatalk Pro

I knew I couldn’t work that piece any more so I cut the flange off and trimmed it down to fit

Then tacked it in place




Sent from my iPad using Tapatalk Pro

And welded it up - the whole piece fits properly now




Sent from my iPad using Tapatalk Pro

Welded it all in



I smoothed it all down a bit after this but not completely - it’s all hidden


Sent from my iPad using Tapatalk Pro

And finally a coat of epoxy mastic




Sent from my iPad using Tapatalk Pro

Before finishing I started on the lower bit - the ‘letterbox’

Initially I was planning on drilling out the spot welds. However the metal appeared to be 2-3 mm thick!! Eventually resorted to a cutting disc so I could at least make a start



This side of the chassis rail seems to be multiple layers - at least 2 and maybe 3 in places. This is where the impact bumper mounts used to go.

Any suggestions on the thickness of steel to go back in there?


Sent from my iPad using Tapatalk Pro

Gary71 wrote:Good stuff Mark,
I've taken to removing tiny patch of 'weld through' primer from behind the the plug weld. Splatter central otherwise!

I’ve been doing the same - once I’d got it clamped in place I scraped it aware with a screwdriver


Sent from my iPad using Tapatalk Pro

It may have changed on the impact bumper cars (there’s a clue there!) but nothing on my car was thicker than 1.2mm in that area.

Anything more than 2mm will be so hard to hand work it’s not worth it. As your car is now ‘early’ it maybe ok to backdate the strength as well.

Thanks Gary

OK time for another update. I’ve generally managed half a day on it each week-end. Progress is fairly slow but I’m happy that each stage is being done thoroughly.

I’m 2 months down the road now though and still haven’t got onto the small rust bleb that was going to take a week-end in early January.....

So anyway letterbox time:-

Out with the CAD




Sent from my iPad using Tapatalk Pro

Leading to this to help bend the right shape




Sent from my iPad using Tapatalk Pro

Which produced this piece




Sent from my iPad using Tapatalk Pro

Which welded in OK



I had to put the bumper back into place to work out where the mounting bolt holes were to go


Sent from my iPad using Tapatalk Pro

Once the position was established I was able to weld captive nuts in place




Sent from my iPad using Tapatalk Pro