DDK - Die Deutschen Klassiker

So managed to find some time in recent weeks to move this on a bit.

I had decided I wanted to run the oil pipes inside the sill to keep the profile looking clean ( and just to make things more complicated for myself)

So I made up some pipes in aluminium.



The wing support panel needs to be changed for an early type to allow room for the pipes



Outer sill modified to allow the pipes to exit in the rear wheel arch



Fitting the B-Post completes the sill job and setting the door gap

Next onto the final wheel arch, as before screwed in place and marked



Then cut away leaving the tags in place to screw it back on, these are removed once a few tack welds are in place.





Welded and ground back.

Since the car will use coil-overs I needed to strengthen the shock turrets, there are four pieces each side to weld in





To gain access to the rear there is no option but to cut a couple of holes in the bulkhead.



I painted the rear of the strut with epoxy whilst the access is easy.

Nice work

What the Slademeister said

So the dashboard has a lot of holes for switches which won't be needed so I welded them up.



I also filled in the dash vents and back dated the radio aperture



The glove box lid also needed work to smooth it out so a new face was made for it



Washer jets also changed from the larger later heated type to the smaller ones

Despite being a fan of sunroofs I felt that on this particular car I would regret leaving it in place so...



Replacement panel comes with an aluminium former to set the correct curve to the roof



Also helped by using the original sunroof panel to prop it in place



Tack welded once happy with fitment



Spot welding will then finish it off

You're going for one of these then ?

" Another clever safety feature on the new 991 Cup is the roof rescue hatch for easier medic access and driver extraction after an incident."

On the washers Jon, I've been thinking about swapping mine for the earlier chrome type for a while - is that not just a straight swap then? Are the holes different sizes?

sladey wrote:On the washers Jon, I've been thinking about swapping mine for the earlier chrome type for a while - is that not just a straight swap then? Are the holes different sizes?

The hole for the later washers is much larger, the early washers will drop straight through

This is my new favourite thread, keep up the good work! (and the posts) personally I think you made the right decision with the sunroof.

DustyM wrote:

sladey wrote:On the washers Jon, I've been thinking about swapping mine for the earlier chrome type for a while - is that not just a straight swap then? Are the holes different sizes?

The hole for the later washers is much larger, the early washers will drop straight through

bugger

Finally managed to locate a g50 5-speed gearbox to replace the original turbo 4-speed, just need to decide whether to shorten the box or modify the shell to accept it.

G50 in the foreground, original 4-speed behind.

Having decided to take a brave pill and shorten the G50 gearbox rather than cut into the torsion tube meant no more welding so I could carry on and prep the underside.

First job to strip off all the underseal




Ok So I lied about the no more welding, I decided to add a brace between the rear crossmember and the floor pan to further strengthen the area for the coilovers




Next was a coat of epoxy primer






Followed by seam sealing, keeping it a neat as possible as I won't be coating the underside in the textured sealer.








Same treatment in the luggage compartment.






And lastly for now a coat of Epoxy Mastic (it is all one colour, the iPhone can't cope with the lighting!)

Love a freshly painted shell, looks awesome.....

.....and all that space with those flares....big rubber!