DDK - Die Deutschen Klassiker

sladey wrote:Nice work Gary. When I saw the heater tube pic I initially thought it was the torsion bar tube!

It’s nearly that bad

Without context that photo is a bit hard to work out.

sladey wrote:Nice work Gary. When I saw the heater tube pic I initially thought it was the torsion bar tube!

So did i

The 3D bit is tricky...

Started with this former, bandsawed through a bit of thick timber and bashed it for a bit:


And a bit more to get to here:


Time passes and eventually with trimming and a lot more bashing it looks about right:



Still needs detail fettling in which nothing obvious will happen over 4 hours, but it will sit nicer!

111/10!
Lovely job that, tricky but all DIY, the best.

Your work makes me realise how good my 73 shell is as much of the repairs you have done I had to do, but not the whole floors and none of the side members as here.
It will be fab when done.

CLM 2020 must be do-able?

From underneath you can see it’s not quite straight so I’ll have to stretch the flange a bit to open the radius out. Guess the shape changed with all the forming up top.

Fits ok to the floor:





You can see the rest of the carnage here. Next stage is to recreate the outside of the double skin inner to the floor. Difficult to work out what it’s supposed to look like as there was nothing here on either side!

Well done Gary, making some great progress there.

Cheers, still using your tooling

.... and while you’re going great guns, I’m still struggling to make the time to fettle my bodywork and splash some paint on .

Great stuff Gary - in awe
Peter


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Nice work Gary

Gary71 wrote:Cheers, still using your tooling

Great, thought I saw a few spots it would have been used on. Glad it's getting used!

I’ve decided to leave the back (again!) as I’ve a feeling anything more I make down there Barry will (quite correctly) throw away!

So onto the front floor, half at a time as before.

Step one finish the sill flange:

You can never have too many clamps...

Then grind the new flange back and heat gun the insulation off the edge of the floor so the air saw will work (lovely in this weather!)


A hole!

New vertical flange going in as the original was a bit thin:


Then remove the old floor on the outside and clean up the flange by filling the little divots from the spotweld drill with weld and grinding back:



Next step is the bottom of the front bulkhead that I repaired many, many years back that’s coming out for a better job. It’s solid enough, but I’m not happy leaving it. Then the tunnel floor edge needs to come out, and I know the front 200mm needs a light repair.

Still going forward... I think!

Has Barry given any comments as to how far you are to go before he 'takes-over' the decisions on replacing what and how?
Never gave that a thought until you just mentioned it.
Good progress every day in the garage.

Grinding skills reaching BSc 2:1 levels!

Oddly you’ll look back and miss this stage one day so make the most of it!

I know, I’ll need to get another project once this is a running car again!

sladey wrote:Oddly you’ll look back and miss this stage one day so make the most of it!

I agree with that!