DDK - Die Deutschen Klassiker

Swallowed the brave/stupid pill and cut the back out...



Porsche sneakily hid a load of spotwelds inside the crossmember to the longit.



So there was a fight to get that out!
Now I see why Barry cuts a hole in the side of the longit, other than crash repair it’s just to replace these welds.

The new xmbr pretty much fits straight on, even though I had to release the jig to get the old one off due my poor design!

The jig went straight back on really well so I’m happy nothing has moved, and it has dead size holes.

New panel sort of goes where it should, this is literally just pushed into place.

Happy with that for the evening. Time for a beer.

Crikey - saw the first photo with the cross member missing and jig on the floor and thought the worst!

Remember you only have to blink and these shells will move ( and from first hand experience that's not much fun ).

Glad the jig went back on quickly and you can now have a breather and beer.

Hopefully it can only start looking better from here, and nice to know you have all that new metal in there.

Keep up the good work.
Andrew

Thanks Andrew, I know from bitter experience on my Beetle that one cut too many and it all goes to shite very fast. As you do for different reasons on your car.

My shell is sat on the two stands at the back on only one in the middle at the front to eliminate any artificial torsion load.

Really pleased there is no inherent load just sat in the shell as I was expecting it to ‘twang’ (technical term!) when I removed the bracing.

Measure twice, cut once and all that.

It’s going to take ages to fix all those flanges and get it ready to weld. 99% fettling and 1% welding.

Sorry to be the correctness police here, but you do know that the replacement slam panel you have there isn't the right shape for '72, yes? ('72 has shallow, gentle curve as it meets the edges and no 'dimple' on LHS, vs new pressing sharper angled edge taper, with dimple LHS)

MikeyC wrote:Sorry to be the correctness police here, but you do know that the replacement slam panel you have there isn't the right shape for '72, yes? ('72 has shallow, gentle curve as it meets the edges and no 'dimple' on LHS, vs new pressing sharper angled edge taper, with dimple LHS)

It’s in hand don’t panic!

This is just a trial fit, I’ll be rescuing the ends of the old panel and/or asking Barry to make a replacement for the crusty RHS.

Gary ... that’s a scary photo with its arse chopped off !!!

Gary71 wrote:

MikeyC wrote:Sorry to be the correctness police here, but you do know that the replacement slam panel you have there isn't the right shape for '72, yes? ('72 has shallow, gentle curve as it meets the edges and no 'dimple' on LHS, vs new pressing sharper angled edge taper, with dimple LHS)

It’s in hand don’t panic!

This is just a trial fit, I’ll be rescuing the ends of the old panel and/or asking Barry to make a replacement for the crusty RHS.

Phew! Thank goodness. World harmony is resumed.

Now you are rolling with it!
Good stuff.
I think the hard bit is replacing all those rusty bits of flanges to reach the new panel, but has to be done well, worth taking your time.
G.

Well done Gary, that's some brave pills you've taken there. Like you said 99% fettling 1% welding. You'll become very close friends with a tape measure too. If you're like me you'll end up measuring things multiple times and you'll still forget what the measurement was. It becomes like those times when you look at you watch for the time and then seconds later you think to yourself, what is the time!

Christ Gary, your making progress now. Mighty impressive

Indeed, very impressive.
Your progress is so fast, do you have time to go to work??

keith fellowes wrote: Your progress is so fast, do you have time to go to work??

Occasionally! I’ve been leaving early each day this week as the family was away so I could commit a few hours each afternoon.

Visual progress will slow rapidly now though as making flanges and fitting up aren’t ‘money shot’ moment!

Just out of interest, what are your 'socially acceptable ' grinding hours?
I'll be lucky enough to do my small bits during the day, 9am to 4 pm, doubt I could get away with evening hours anymore round here.

It's amazing how much time you can find when you need to!

No one moans, but I always work garage door closed and stop by 19:30, so hopefully no one will.