DDK - Die Deutschen Klassiker

sladey wrote:T

Getting there Mark! I'd have a poke at that crusty looking crater just to the right of the repair you've done before you cover it all in mastic.

Good call Gary - ill check it out tomorrow - that area has been repaired by a good body shop with some thick steel but Ill have a good poke


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That WAS a good call


And patched


Then went to the front


Also added in a strengthening bar (the top hole is where the bracket that holds the bumper fixes onto)


Then some of the epoxy mastic


Nearly there (hopefully - I went out to check the paint after a few hours and it wasn't dry yet so hope it's OK)


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Takes ages to dry, but goes all of a sudden. Be fine in the morning, good work Mark. Sorry to have been dismissive of your man skills to start with.

Thanks for that Nige - I was worrying I'd mixed it wrong somehow.

No worries on the doubt thing - I know you were only being helpful


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Spent the day mainly piddling around sorting this and that - I managed to bend the aerial at some stage and in the process of straightening it catapulted the nut holding it in over to god knows where - so I'll have to sort that.

Spent ages fannying over some minor rust repaid at the foot of the A pillar. Still not happy with it but it will do for now.

Welded on a fresh captive nut to the headlight, and also glued back together the rubber mounting for the oil cooler.

Also sprayed the dinitrol on top of all the epoxy mastic - looks to be a good covering

Made a template for the adjustments I'll have to make to the 'new' wing. Thought it would be better in metal than in cornflake packets:-




So this is what I finished with


And this shows how far out the new wing is


I've put the (original, crappy, bubbly) wing on now but it's a bit tight near the top of the door, so I'm going to be doing some more fannying tomorrow - hopefully not too much before its ready to drive to work on Monday


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so I'm going to be doing some more fannying tomorrow - hopefully

just stick to telling us about the welding thank you

OK so just a quick update before my hols.

After the above repairs and a great blast round Germany on the DDK POB (Place of Birth) tour. The car held up well.

After I got back the rear suspension was creaking a lot so I went to re-grease it (which went OK) but whilst looking under there I happened to glance at the passenger floor next to the sills. Not good.

I'll put some pics up later but suffice to say it won't pass an MOT.

Therefore the plan of action is to wait until September when my eldest returns to Uni, so I'll have use of her Mini.

I'll then take the 911 off the road and basically do the whole internals on the passenger side. By whole internals I mean the front inner wing, the sills, kidney bowls, door jambs, and floor repair. I've just ordered repair sections from Type911 and the OPC - on advice I've gone for genuine Porsche panels wherever possible.

Dusty (Jon) has been incredibly helpful, sending me pics of similar repairs he's done to customers cars - all good stuff and very inspiring.

I'm really looking forward to the work. With the car off the road it can take as long as it takes.

And needless to say there will be plenty of pictures.....

Looking forward to following your learning curve!

As a wise owl once said....

"There comes a time when a rolling resto project just can't keep rolling"




Thomas Lubbock, Norwich 24th July 2013, 15.30

Thought you had a great big fat Range Rover to rock about in whilst the Porsche is ill?

Thomas - yes I've reached that time - but in spite of the backdate works in 2006 this is the first time since 1987 this work has been done so now it's being done properly it should last a long time. When they did the backdate stuff they seemed to assume the corrosion visible at that time would self-heal.

Nige - the Rangie is Suzanne's - I'll be able to nab it on days when she cycles to work but other than that it's her car

Currently looking into a timelapse app for the iphone to show the work taking shape

Good luck

Remember to measure at least a dozen times and cut just the once.

Soon to be everyone's favourite restoration thread on DDK!

Looking forward to it Mark, best of luck.

I just spent half an hour typing up an update only for my ipad to run out of battery. Aaaargh!

Firstly to finish off the work on the drivers wing. You may remember the repaired panel had the supporting beam in the wrong place so it wouldn't fit.

I made a jig for the right position


Made a slit to allow it to move into the right position


And welded in a repair patch to hold it in the right position


I've then welded it up and also sorted out some other problems with previous repairs




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Looking forward

Basically I'm going to start on the extensive sill work the day after classics at the castle.

The car will come off the road at that point, and I will be focussing on the passenger side and will be -

Repairing front inner wing and front outer wing, fitting new inner and outer sills, kidney bowls and jacking points, new door jambs, repairing damaged floor. While in there Ill also repair the 4 bits of corrosion in the rear wing.

Ill then prime it in the non- porous primer you get from rustbuster.

I've got the parts and paints in stock now and am looking forward to the work.

his weekend I've been getting ready. You probably know you can't buy the early outer sills any more, but instead you get ten 993 version, containing 5 indentations, 2 larger holes, and 2 small holes.

First I made up 5 repair patches and sanded back the bits to be welded


Then I welded them in



And dressed them back





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