DDK - Die Deutschen Klassiker

My other big mental leap forward concerns my wheel arches. the other week I happened to see a Dutch project which is recreating the Stan Townes speedster (http://www.porsche-rescue911.be/project ... el_5_e.htm). Looks a really cool project. About half way down the page I noticed they smoothed out the crease around the edge of the arches to create a slightly wider, smoother look. I've been thinking for a while about my arches, toying with something wider but not wanting to move into stratospheric tyre costs or spoil the chuckability of my car. These arches do it for me. A tiny bit of extra width and a smoother hot rod/racer look. I may space out my wheels or experiment with different tyres.

The next thing was how to achieve it. I've just bought a brand new wing. Am I really brave enough to take a hammer and dolly to it?

Then I remembered that I've still got two spare LH front wings - I could try it out on those. If I cock it up massively no harm done, and if I find out I can't do it then I've wasted crap wings. Also I can try different techniques to get the look I'm after.

so Saturday night I started with the hammer and dolly. I'm basically knocking in the crease around the arch and at the same time pushing out the bit below the crease.

Here's the standard one



More detail of the standard crease



And here's my spare wing after a first go



Here's another view showing the curve



I'm pretty pleased with the results - I'm going to do it to all 4 wings. My first go has left a few bumps and ridges, but a bit of extra hammering will smooth those down. I've also ground down a couple of dollies to match the curve of the wing a bit better - this should make the next one easier to do. Finally, even if it's not 100% perfect a thin layer of filler will smooth it out. Looking to make that layer as thin as possible though.

Although part (alright, most) of me wants the car back on the road TOMORROW! And this mod means more delay, I'm really really excited by the look of the arches - and what better time to do it than when the whole of the body is being sorted.

Grinding down a couple of dollies in your shed must be applauded, bravo

That Speedster project is cool. I like the front and rear treatment

sladey wrote:so Saturday night I started with the hammer and dolly

neighbors must really love you....Looking fantastic Mark, a unique shape you're making your own, brilliant!

I like the arches on the Dutch car, but I am not so sure about some of the other metalwork - That hump on the back looks a bit odd to me.

Go for it on yours, it'll look good.

Thanks for the comments.

Yes I'm not sure on the speedster - the Stan Townes one is cool, though. Haven't seen any finished pics yet so reserve judgement until I do. That rear hump is difficult to cope with though, I think you need to reduce the rear lid height as well.

Are you going to roll the arch as well? If so can I suggest you put a wire in, it will give it some strength and might be a cool effect, something you can also experiment on you scrap wings.

Yes I might do that Jon - on my experiment one I've just tapped the arch up but a wire would be better

Nice touch on the arches Mark, I'll get the drawings adjusted

DustyM wrote:Are you going to roll the arch as well? If so can I suggest you put a wire in, it will give it some strength and might be a cool effect, something you can also experiment on you scrap wings.

Is the wire tack welded in place and then the lip rolled over it? What gauge wire ....bit of old coat hanger ? Seriously though, I would be interested in seeing this process...


Keep it up Mark, great work !!!

jury wrote:Nice touch on the arches Mark......Seriously though, I would be interested in seeing this.......

So would I........Barry's taking a lump hammer to mine!

Never done it before (obvs) but on the bodywork dvd I've got he:-

- Clamps the wire in place in a few places
- Hammers over the wire in a couple of places to hold it in place
- Then gradually hammers it over all round, so the hammered over bit has gone 180 degrees
- then uses specially adapted pliers to fold the bodywork right round the wire

There is a formula for calculating the width of the flange/width of the wire


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Thanks Mark, it sounds like a pretty involved process, but I imagine very rewarding when you get it correct.......I think I will give it a miss on the Fibreglass

Been thinking about it some more and I think I'll give it a miss too. I think it's used to give strength where it's needed - e.g. Around flat panels or on fenders that sit on open wheeled cars. It's also used to make a feature of the edge - with a nice ridge topside and the wire underneath.

I don't see the arch curve as being either a stressed or weak point on the 911. If I did it right then the best I could hope for is that no-one will see it. There is an enhanced capacity for buggering up the good work I do on the wheel arch. Ive also worried about future corrosion - you're essentially locking bare metal against each other and moisture will get in eventually.

When I looked at the video again he was doing some pretty fierce beating on the bench to hold the wire in place - I'd be nervous about doing that after I've spent a lot of effort reshaping it.

So in summary I think it would be a lot of effort for something that no-one will see, and wouldn't give any particular advantage.

I got excited about it for a while though....

Managed to grab a bit more time tonight - family all busy elsewhere

Took a deep breath and attacked my brand new wing

Turned this


Into this


And then into this


Very happy with it - 1 down, 3 to go.

Before I started I cut the front corner as I realised this would be fighting against the re-shaping.


Then once I'd finished I welded it back up

Once


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Looking good

Excellent! Brave indeed hitting brand new panels