DDK - Die Deutschen Klassiker

Thought I'd bring this thread up to date

Last summer I picked up a quaife LSD. after a bit of research I realised it wasn't a simple DIY install. I arranged for mike Bainbridge to install it and he agreed to let me help him. I removed the engine & gearbox on a Sunday, took the box up to Mike on the Monday, and spent a very enjoyably morning helping him fit the LSD. learned a bit about backlash and how to read a micrometer. Came back that afternoon and refitted everything on the tuesday. Still enjoying getting used to driving with an LSD

In November I noticed a loose grinding/knocking which appeared to be coming from the passenger side rear wheel bearing. I didn't fancy messing with the bearing so checked it into a garage. They found it was actually the drive-shaft. After they ordered 2 wrong parts I sourced the correct one from Tripe over on impact bumpers. If I'd known it was that I would have done it myself.

At Christmas the car wouldn't start. Replacing the DME relay didn't help so I called in the AA. They diagnosed a faulty flywheel sensors. I bought 2 new ones and fitted them. I couldn't help notice how close they were to the driveshaft that had just been replaced a few weeks earlier.... I'm getting cynical.
Anyway replacing the sensors sorted the problem out but it had delayed my planned Christmas project which was panel beating.

At Husborne Crawley last year I bought a couple of front wings. They were quite rotten but not nearly as bad as the ones on my car. Having these spares meant I could take my time in getting them sorted.

I started with the bottom rear of the wing. After making a cornflake packet template I transferred to metal and cut it out with my air tool



I then started to beat out the fold that is the rear bottom part of the wheel arch.


That was when I realised I'd got it wrong. Once I'd put that harsh wheelarch crease in it I wouldn't be able to put in the curve of the wing.

So I scrapped that piece and started again...
This time I put the wing curve in first



Holding it against the wing showed the shape was about right. I then started on the wheel arch lip.



And then used heat on the peaks before beating them down on a curved dolly. I found that the lip wasn't deep enough so I beat that down a bit - eventually I had too much material on the lip which I felt was stopping it from being adjusted further so I cut the excess off



Eventually I finished up with this which I was quite pleased with


I then turned to the rear of the wing which has a folded over lip - did this next


This is the result so far held against the wing


I've really enjoyed it so far. I will be cutting off the top of the piece ive made to make sure I'm joining onto a relatively flat piece on the wing. I've next got to make part of the vertical bracket that fits to the inside of the wing.

Currently I'm pondering on the welding - ideally I should be gas welding or tig welding so I can beat it further afterwards but I don't have either. I'm thinking of pushing ahead with MIG - or should I hold off the welding until I get a tig welder? Opinions welcome please.

Cheers

Mark








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Just MIG it Mark with little welds/dashes at a time.

Keep up the good work.

Thanks Nige

I think you should try and bash a new wing out in aluminium, can't be that hard!

good on you Mark, grand effort to see you having a go at the bodywork....keep us up to date

regards
Jp

Hi Mark, really well done to you for trying to do it yourself, fantastic work!
Really love it when you wear that helmet too.......

sladey wrote:
last year I bought a couple of front wings. They were quite rotten but not nearly as bad as the ones on my car.

Who'd have thought that 13 days into the year we'd already have the Quote of 2012 winner!





Good work bud, keep it up....I think

Nige wrote:I think you should try and bash a new wing out in aluminium, can't be that hard!

That's what I thought! And rather than buying any, I'm saving my baked bean cans

Mike wrote:Hi Mark, really well done to you for trying to do it yourself, fantastic work!
Really love it when you wear that helmet too.......

I get a lot of comments about my helmet

jtparr wrote:good on you Mark, grand effort to see you having a go at the bodywork....keep us up to date
regards
Jp

Thanks Jp

964RS wrote:

sladey wrote: last year I bought a couple of front wings. They were quite rotten but not nearly as bad as the ones on my car.

Who'd have thought that 13 days into the year we'd already have the Quote of 2012 winner!
Good work bud, keep it up....I think

Yes Jason - I finally realized that those bubbles wouldn't buff out

Going to the scrapyard today to try and pick up a slapper (I'm taking this quote thing seriously now). Will post pictures when/if I get one

Looks like an excellent result - well done.

Well done Mark, excellent work

Nice one Mark!!

Hats off to you, great fan of your car

Nice work Sladey. Very self satisfying to to the job yourself and for it to turn out as nice as that.

Where did you source your original material?


Regards
Mike

Thanks for the kind comments guys

I got the metal from a local metal supplier Mike - IIRC 18 gauge is 1.22mm but they sell in metric sizes so it's 1.2mm thick. Cost me £15 for the biggish piece in the first pic

I picked up a leaf spring from a local scrapyard this morning so am currently making a slapper - will be posting pics later

looks great Mark

Just read this thread from the start, great way to spend a Sunday morning lie in. Fantastic stuff.

Do you have a link to your thread on IB re fitting the 993 headers?

Cheers
Jon