DDK - Die Deutschen Klassiker

It was necessary to take the door off to fettle the front end of the sill, so I drilled the hinges and pushed in a welding rod to ensure an accurate replacement in their original positions.



And while the door was off I sealed the seam of the wing bracket.



The sill went on nicely. Much easier this time, having done it before, and knowing the name of the game is confident fettling with a heavy hammer.

It's amazing how the little details suck up the time. This tiny area of rust took half a day.



Tricky to get in and cut it out.





We don't want a lumpy carpet so I ground the welds flush.





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Next up the slam panel.



Visible here so again, I got it nice and tidy.





I suspect there are a lot of users on here who have at some point possessed one of these.



I was happy to keep the original pre-72 profile with the straight profile at the top

Another little detail - not sure what this is but the bottom inch or so was rusty.



Holes as per the original and for spot welds.





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Next up the quarter panel / rear wing. My 13 year old daughter was thrilled to help me bolt the door back on so as to get the quarter panel on with the gap perfect. I had to bribe her with the promise of helping her install some Minecraft mods in return.

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One door hinge had an aluminium spacer behind it, and I'll probably add another to adjust the door gap. Are these original equipment or aftermarket?



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Yes, they're original - part no - 901.531.391.20


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I used one of those hand triggered spot welders on my car all those years ago.
Hired it endlessly, bloody heavy too.

Great progress Rob, light getting closer now.

I found evidence of a previous repair in the rear quarter. The patch had three tiny welds on it.









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Good progress today. This side must have taken me a quarter of the time the first took.



Somehow, this feels like a big moment — the last of the big welding jobs on the main body of the car.



However, there remain the front wings, which I have to get back on to, which are not to be underestimated. It's tempting just to buy new but I want to save the originals which are in perfect condition aside from the base behind the wheel arch (and save £3k in the process!).

I left the wings because once the main body is ready it can go off to the painters giving me some free space in the garage.

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I think Dansk do a repair inner/outer panel set Rob. There are some light curves involved in that repair.

As the evenings get darker and colder, they seem strangely shorter. it's harder to get out to the garage and progress things after work. Nevertheless, tonight I plucked up a little energy and once I'd started momentum kept me moving until 10pm. I continued coating some of the magnesium parts from the spare engine I'm working on and carried out a bit more soundproofing.



I know it's soundproofing but these bitumen pads will definitely keep any stray drips from windows from making contact with the steel floor and I'm determined this will be the best-rustproofed 911 in the country. The Kilmat is turned up the sides of the floorall the way around.

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I tried in vain to get a spot weld on this captive nut for the bumper, which had come loose. Eventually I cut a hole to get it out.



...welded it onto a plate and fixed it back in.



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Attention then turned to these modifications made to accommodate a long since removed aftermarket air con.







I noticed it's becoming increasingly difficult to find a spot for the mig earth - everything's painted. That's a definite sign the body is nearing completion.

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I think the body is actually done... except for the front wings.

Due to an enforced break from working on the 911E engine, I decided to return to the scene of this crime against metalwork.







I previously cast this jig in situ out of wood and epoxy for the mounting flange so it's a case of shaping my creation around that.



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