DDK - Die Deutschen Klassiker

Family out shopping then Rob doing all that in the house.
I would be in A&E by now...

911hillclimber wrote:Family out shopping then Rob doing all that in the house.
I would be in A&E by now...

I've no room in the garage. And the wing is completely clean in fresh primer, so no harm done. And I'm a lot less messy than I used to be so i think she thinks herself lucky on that count.

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This project has slowly but surely instilled in me a growing antipathy towards grinding - the same antipathy I already felt towards sanding.

I think a large part of the resentment derives from my lack of skill mig welding. It's simply so quick to add material with the mig and it takes so long to abbrade it away afterwards with the disk.

With this in mind I was planning to upskill myself with the tig welder. Despite some experience with gas and mig, I have found the tig to require new levels of precision and care. For every two minutes welding, I spend ten minutes gringing back a balled up tungsten tip. It's just so easy to touch it with the filler rod or touch it against the work, and the game is instantly up.

That said, if you are careful it does weld much more flush and one can do so whilst putting less heat into the work, thereby causing little to no distortion.

After a few practice runs I was ready to tack the corner on the left wing.



Getting a few more welds on.



And all painted up.



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The offside wing has a better bottom corner than the near. I was able to retain the rear edge.



Also starting to master the tig welding. This wing does have some prior accident damage so it'll need a skim with filler.

I bumped into the guys who are painting the car last week. They're finally starting to make the right noises... I'm next in, apparently.


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I'm determined to preserve the original wings. The offside one needs the headlamp bowl repairing or replacing and either way, I decided the best way would be to remove it from the wing.



One of the reasons I did, is there was some evidence of rust hiding in the join. It soon began to look like a worthwhile endeavour. I'm going out of my way to ensure there's none of this hiding away under the respray.



Getting that out reminded me of the birth of my second daughter, a fraught affair involving a 20 stone African doctor using a great deal of his available strength and a suction cup.



Does anyone have experience of fitting the replacement bowls and whether they fit well? There would be no point if they're not precisely made.

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Pressing on with the ethos of having the best-rustproofed old 911 on the planet, I coated the backs of the finished wings and inside all the crevices with black epoxy over the zinc rich epoxy already in place. This is to form a waterproof base for the stone chip.



I also forced PU sealant into all the seams.

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This follows on from welding in a new headlamp bowl into the one corroded side, a bigger job than i expected but really happy with how it turned out.



I modified the purchased item with the fittings etc. from the period-correct original.



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Followed by stone chip on the insides of the wings and underside of the bonnet, to match the rest of the car.



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Great progress

Just treading water really now, waiting for the paint shop to have availability. I pressed on yesterday with black epoxy in the front inner wings, followed by stone chip.





I'm starting to get impatient now but if they're busy that's a good thing, right?


Bumpers too.



These guys had a sunbathe for everything to cure.



Not sure if this should have been orange but it's matt black for now.



And I realised the hood lights will need holes for the wires too!





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So this little guy emerged from his cave on Monday and went off to get painted. I should've got a picture of him on the van.

Started on the button as always, and my neighbour whose pots always fall off their shelves when I start the engine also emerged from her house to see him leave.






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A landmark moment !

Who are you using to paint it - someone local ?


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As Andy says, a real milestone, well done Rob

Lightweight_911 wrote: ↑Sun Jul 06, 2025 2:58 pm .

A landmark moment !

Who are you using to paint it - someone local ?
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Butlins Classic Cars in Swadlincote (e type specialists). They painted another DDK-er's 911.

Yesterday I made the 30 minute drive up to Swadlincote to run through a few details how I'd like the car painted. Lots of details inspired confidence. They're being meticulous about getting it back to bare metal. They found a tiny patch of rust I'd missed in the roof seam, where they're introducing some new metal.





We noticed that the car may have had a new roof at some point. I guess this isn't standard detailing at the back of the roof where it meets the c pillar?



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