DDK - Die Deutschen Klassiker

As always you need to fix something else before you can fix the bit you are trying to do...

The bacofoil area of the inner wing in the pic above extended to the top so it’s all got to come out. Challenge being: make a 3D pressed section, keep the door shut face and seal flange in the right place, preserve the inner kidney bowl and top B pillar reinforcement.

Should be easy then.

First task was to make a rib in a sheet, Barry has his Pullmax, I have the Twatmax. ie some crudely shaped lumps of angle and a big hammer.

The result is the right shape and depth, but the surface quality is poor. Even with follow up hammer work it’s rough but it will have to do.

Tonight I made a location jig and brace combo so I’d have a reference plane for the edge of the flange and started to gently extract the rough original metal whilst preserving the inners.

The repair panel is taking shape, still needs a few hours fettling before cutting it in, but it sits in the right place, matches the jig and also fits the new rear quarter.



You can sort of make out how the rib fits to the inner kidney reinforcement in this pic:



And oh yes the OE quarter. What a lovely panel. Bloody well should be at the price



Hopefully tomorrow evening I’ll get this repair panel tacked in place. Then the quarter can go back in its box for a few months!

That brings back some memories!
Nice work.
I too used Porsche rear 1/4 wings, the fit was simply fantastic, but I had been fighting Dansk panels before...

iirc the 2 wings, the Porsche front pan and the horrid Dansk sills and door skins cost £800 back then. I was used to MGB panel prices having done 2 before the 911 and thought £800 was a rip off then.
Hand made lots of repair panels which I quite like doing, but take huge time and effort.

On surface finish/plannishing marks, the Schuts (sp) coating will cover a lot of sins.

It will be great when done!

You're doing a great job there Gary.

I wish replacement wings and rear quarters were available for the 914, would have made my job a lot easier!

superb work gary Looking forward to following a viper green 911 to LeMans in 2020

hot66 wrote:superb work gary Looking forward to following a viper green 911 to LeMans in 2020

So am I, doesn’t Pete have one?

Another two hours with no visible progress, but it’s closer. Honest!

I’ve replaced the flange on the B Pillar reinforcement and cut the new panel to with a mm or so and added the all important dimple at the top which is clearance for the self tapper that holds the interior trim on.



Also test fitted the quarter which sits nicely.


Now I get to ruin it by welding it in

Spot welded mine on along those channels and the 1/4 lights and engine side flanges after the sill work/bowl etc.
SOOOO much easier than plug and grind.

The 1/4 will be spot welded on during the final build, luckily most of my welding will be hidden deep under the wing never to be seen.

Unfortunately the only person that really gets to see it is Barry. But I’m sure he’ll be polite

Not easy that repair, nice work indeed.

Roy

Nice work Gary...steady progress..good to see

Gary71 wrote:

Love this picture

Evening, It’s a long slog this one, but got the inner wing repair all welded in and ground back.

Sits OK on the little fixture and the welds are (sort of) flush. The bottom isn’t welded in as that bit is coming out as it overlaps the big lower repair panel. That’s the next job, but time for a beer.