DDK - Die Deutschen Klassiker

I even had welding gloves on!
Today I'll try not to draw (too much!) blood, but I do have to finish off cleaning the sealing flange up before welding it back on, but I might use sandpaper

I used a tight flame plumbers blow lamp to soften and the scrape that plastic coating off, then a wire brush, but not one as aggressive as yours!
It looks evil to me.

Heat gun and scraper have got the worst of it off, but getting back to nice bright steel needs a bit more aggression.

Done nothing today as my wrist is too stiff and swollen.
Hopefully tomorrow I’ll be back on it!

Started to rebuild the inner wings today:

The reveal:

After the clean, plenty of work needed with some tricky shapes:

First section complete but not welded in yet:

Next step is a big panel to meet up with it.
Slowly but surely...

You’re bossing it Gazzer

Bootsy wrote:You’re bossing it Gazzer

....he certainly is!

In awe of your ability, superb!

Cheers guys. This bit is pretty crude metal bashing, but luckily it’s all hidden!

Anything visible (like fitting 1/4 panels) will be by the magic Barry touch, not me!

I’ve had a fairly productive time today and made bulk of the big panel. Annoyingly I had to cut the end as I couldn’t make the 3D curve.

I’ve a day off tomorrow so this should be welded in and then I can start on the other side, which is in much better condition.




I’ll dress the welds back a bit, but I’m not getting obsessive about a smooth finish inside the arch as I’d rather keep the strength. The inside is visible, but covered in stone chip and behind the CDI box!

Tough panel Gary, and you really need a sand bag and appropriate mallets to even hope to get the compound 'dish'.
I too would leave the hidden welds full, far too easy to thin the steel for no real gain in anything.
Graham.

I have sandbag and mallets, I got half way there but needed to lose about 10mm of steel so that was never going to happen!

Great work Gary. You are everlastingly optimistic which is to be admired. I also admire your bravery on taking all this on and in your own garage too. Hats off!

Where do you buy your new sheet metal?

Regards
Mike

Thanks Mike,

I hope it all works out in the end, without the right forming tools this stuff is really tricky. It’s just bent in the vice/over my knee!

I bought the metal from a local fabrication firm a few years back and I’m still working my way through the big sheet! Luckily everything seems to be 18g.

Biggest problem is holding the reference line for the 1/4 flange as the original was long gone.

Today was a productive day.
Paint was involved!











I’ve cut the quarters back a bit further to get at the foam inside and improve access for the parcel shelf and the top of the RH inner wing.

The paint is epoxy 121 rollered and brushed on, masked off where more welding is needed. There’s weld through primer covering those areas. I couldn’t stand to see all that shiny steel go rusty again!

Next is the end of the LH inner wing and working out what to do with the bit where the oil breather pipes go through as it’s mainly lace!

Great start Gary. Good job.

Really excellent work. I am really enjoying this thread already.

Gary, please can you give me the source of the 121 epoxy primer you rolled on?
I've been told to cover my stripped car with this prior to going to the paint shop.
Thanks, Graham.