Shrek
Moderator: Bootsy
-
- Nurse, I think I need some assistance
- Posts: 19008
- Joined: Mon Mar 10, 2008 6:26 pm
- Location: West Midlands
Re: Shrek
I close both my eyes when I look at mine from 1989...
Solid, but very easy to see my welds.
Solid, but very easy to see my welds.
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Episode 32: Finishing up at the back
The rear engine gutter in the corner where the c-pillar had rotted was not to Barry's liking, so it came out.
Repair patch fabricated
And let in to make it perfect
Barry engaging in a bit of teasing by mocking up the rear wing to make sure all the c pillar fabrication has worked out - note the perfect fit of the screen jig
Including original porsche engine lid to ensure fit
good gaps
good fit
And nice from the inside as well, note replaced parcel shelf fit as per previous post
And with that the back end was officially done.
Summary
Offside inner wing straightened and oil console area repaired
Offside chassis leg and cross member straightened
Rear bulkhead and rear seat pans (cut from donor car) replaced
Offside c-pillar (cut from donor car) replaced
Rear parcel shelf (new Restoration Design part) fitted
Rear slam (new Porsche part) replaced and backdated
Rear screen surround repaired
Time to move onto the front of the car which Barry says will be very satisfying as change occurs very quickly!!
The rear engine gutter in the corner where the c-pillar had rotted was not to Barry's liking, so it came out.
Repair patch fabricated
And let in to make it perfect
Barry engaging in a bit of teasing by mocking up the rear wing to make sure all the c pillar fabrication has worked out - note the perfect fit of the screen jig
Including original porsche engine lid to ensure fit
good gaps
good fit
And nice from the inside as well, note replaced parcel shelf fit as per previous post
And with that the back end was officially done.
Summary
Offside inner wing straightened and oil console area repaired
Offside chassis leg and cross member straightened
Rear bulkhead and rear seat pans (cut from donor car) replaced
Offside c-pillar (cut from donor car) replaced
Rear parcel shelf (new Restoration Design part) fitted
Rear slam (new Porsche part) replaced and backdated
Rear screen surround repaired
Time to move onto the front of the car which Barry says will be very satisfying as change occurs very quickly!!
Last edited by Dougieboy1 on Sun Sep 23, 2018 7:54 pm, edited 3 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Episode 33: WTF is going on at the front - assessment!!
The easy bit first. Where the wing closer was welded to the off-side inner wing, there was some typical 911 areas of rot.
Which required one of Barry's famous repair patches
To make it perfect again
Then, the beady Carter perfectionist eye was cast over the front end. And his professional opinion was 'Yuck'.......
For the following reasons: Minor patching
Medium patching - note the high quality welding
And some absolutely hideous patching, again done with superior welding skills
Typical rot in the battery boxes
And elsewhere
The front slam was a mess for a variety of reasons including rot
surface rust that developed post dipping
Some more of the fabulous patching, this time on the outside
Perforations from rot
Some tearing of the metal from front end impact
Dents, again from the impact identified much earlier in the process
Distortion, more impact
And general scabiness
And then the piece de resistance, this final photo shows there was no structure underneath the replacement tank support. We should be looking at where the longitudinal tank support dips down into this area forming a complete box section. There's also a complete small panel missing that should bridge the two rearward mountings.
As an aside, there were a number of stress cracks in this front end area and having seen this mess and the poor execution of the repairs, it is not really surprising.
To reiterate Barry's professional assessment, Yuck!!!!!
So, whats the solution?
Yes, cut it off, chuck it all away and start again........ as the man said, you can make pretty rapid progress in this area!!!
The easy bit first. Where the wing closer was welded to the off-side inner wing, there was some typical 911 areas of rot.
Which required one of Barry's famous repair patches
To make it perfect again
Then, the beady Carter perfectionist eye was cast over the front end. And his professional opinion was 'Yuck'.......
For the following reasons: Minor patching
Medium patching - note the high quality welding
And some absolutely hideous patching, again done with superior welding skills
Typical rot in the battery boxes
And elsewhere
The front slam was a mess for a variety of reasons including rot
surface rust that developed post dipping
Some more of the fabulous patching, this time on the outside
Perforations from rot
Some tearing of the metal from front end impact
Dents, again from the impact identified much earlier in the process
Distortion, more impact
And general scabiness
And then the piece de resistance, this final photo shows there was no structure underneath the replacement tank support. We should be looking at where the longitudinal tank support dips down into this area forming a complete box section. There's also a complete small panel missing that should bridge the two rearward mountings.
As an aside, there were a number of stress cracks in this front end area and having seen this mess and the poor execution of the repairs, it is not really surprising.
To reiterate Barry's professional assessment, Yuck!!!!!
So, whats the solution?
Yes, cut it off, chuck it all away and start again........ as the man said, you can make pretty rapid progress in this area!!!
Last edited by Dougieboy1 on Sun Sep 23, 2018 8:02 pm, edited 5 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
- Darren65
- Nurse, I think I need some assistance
- Posts: 7873
- Joined: Mon Dec 13, 2010 10:55 pm
- Location: North Wiltshire
- Contact:
Re: Shrek
Loving this thread
Thanks for sharing
Thanks for sharing
Darren
72T 2.5... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=56183
73 2.4E ... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=44242
77 Carrera 3.0...to 74 3.0RS ... http://ddk-online.com/phpBB2/viewtopic.php?f=28&t=63389
72T 2.5... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=56183
73 2.4E ... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=44242
77 Carrera 3.0...to 74 3.0RS ... http://ddk-online.com/phpBB2/viewtopic.php?f=28&t=63389
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Episode 33 Back to the Front
As per postings on other restoration threads, preparation is all important to getting a high quality final result.
So a little bit of careful cutting doesn't go amiss as the longitudinals were trimmed back.
Laying out the new front end 'kit' prior to spending a couple couple of hours prepping/backdating the modern panels (964) to be the correct spec for an MY72 car.
The front pan had the later style drain removed
Cut outs on front flange being reprofiled. The correct half moons to be cut later where the large holes in the vertical are located, washer bottle mount fabricated using a jig although this was not photographed
The towing point was added
Having completed the backdating and prep, the pan was placed with help from the jig.
Then, after a LOT of measuring and double checking, the first RD inner wing repair could be scribed in and welded - reprofiled front flange clearly visible
This done, a small section at the base of the inner wing was fabricated and let-in.
As per postings on other restoration threads, preparation is all important to getting a high quality final result.
So a little bit of careful cutting doesn't go amiss as the longitudinals were trimmed back.
Laying out the new front end 'kit' prior to spending a couple couple of hours prepping/backdating the modern panels (964) to be the correct spec for an MY72 car.
The front pan had the later style drain removed
Cut outs on front flange being reprofiled. The correct half moons to be cut later where the large holes in the vertical are located, washer bottle mount fabricated using a jig although this was not photographed
The towing point was added
Having completed the backdating and prep, the pan was placed with help from the jig.
Then, after a LOT of measuring and double checking, the first RD inner wing repair could be scribed in and welded - reprofiled front flange clearly visible
This done, a small section at the base of the inner wing was fabricated and let-in.
Last edited by Dougieboy1 on Mon Jun 11, 2018 1:17 pm, edited 2 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
- inaglasshouse
- DDK 1st, 2nd and 3rd for me!
- Posts: 2427
- Joined: Fri Mar 28, 2014 9:35 pm
- Location: Surrey, UK
Re: Shrek
That front end was pretty nasty in places. Not for long!
Thanks for posting the pics, I'm enjoying it. Happy days!
Thanks for posting the pics, I'm enjoying it. Happy days!
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Indeed, Barry and i shared a christmas mince pie last friday whilst he showed me round the almost complete shell - this thread still has some catching up to do with reality!!
I enjoy visiting and chatting, one of the unexpected benefits of Barry being just down the road.
I enjoy visiting and chatting, one of the unexpected benefits of Barry being just down the road.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Episode 34: Back to the Front, 2
Nothing seemed to make sense on the nearside, even with the obvious damage beaten out.
After a while Barry concluded that the original inner wing needed a fractional lift. With deft bodgerism (another technical coach-building term apparently) Barry executed the lift and tacked in the second Restoration Design wing repair after scribing it in.
Meanwhile, the Carter Crap Metal Detector (Patented) went about its work and identified that the whole of the valance of the inner wing was corroded
so Barry fabricated yet another repair - if you say that quickly, it sounds easy to do but even Barry was, by his own judgement, 'modestly pleased to form it all out of one piece of metal with no welds'.......
Which was offered up
And then let in
And ultimately made perfect again
The CCMD (patented) identified a further part of the inner wing that was damaged,
so this was removed and a new section let in.
This went well into the new front end metal to spread the joins around the panel as much as possible.
And repaired to the usual high standard
As the front end had already been dry assembled, the welding went fine.
Here right at the front, you can see the washer bottle mount and i now have the correct structural components in place over the suspension mountings and the chassis legs/longitudinal tank supports fully engage with the front suspension pan, unlike before.
As uncovered with the suspension mounting plate missing
As Barry has progressed through all of the welding, parts have been etch primed and weld-thru primed as appropriate.
Close up of the half-moon detail added to the front pan lip when backdating the front slam earlier
With the lower front end panels welded in, another front end trial was undertaken to ensure nothing had moved prior to welding in the front slam panel.
At last, front end all welded up.
There's just some finishing off underneath left, which Barry will tackle when the shell is next on the rotisserie.
Nothing seemed to make sense on the nearside, even with the obvious damage beaten out.
After a while Barry concluded that the original inner wing needed a fractional lift. With deft bodgerism (another technical coach-building term apparently) Barry executed the lift and tacked in the second Restoration Design wing repair after scribing it in.
Meanwhile, the Carter Crap Metal Detector (Patented) went about its work and identified that the whole of the valance of the inner wing was corroded
so Barry fabricated yet another repair - if you say that quickly, it sounds easy to do but even Barry was, by his own judgement, 'modestly pleased to form it all out of one piece of metal with no welds'.......
Which was offered up
And then let in
And ultimately made perfect again
The CCMD (patented) identified a further part of the inner wing that was damaged,
so this was removed and a new section let in.
This went well into the new front end metal to spread the joins around the panel as much as possible.
And repaired to the usual high standard
As the front end had already been dry assembled, the welding went fine.
Here right at the front, you can see the washer bottle mount and i now have the correct structural components in place over the suspension mountings and the chassis legs/longitudinal tank supports fully engage with the front suspension pan, unlike before.
As uncovered with the suspension mounting plate missing
As Barry has progressed through all of the welding, parts have been etch primed and weld-thru primed as appropriate.
Close up of the half-moon detail added to the front pan lip when backdating the front slam earlier
With the lower front end panels welded in, another front end trial was undertaken to ensure nothing had moved prior to welding in the front slam panel.
At last, front end all welded up.
There's just some finishing off underneath left, which Barry will tackle when the shell is next on the rotisserie.
Last edited by Dougieboy1 on Mon Jun 11, 2018 1:23 pm, edited 1 time in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Episode 35 Why Barry is the best!
His attention to detail is exceptional. Here he identified an area of stress creacking that needed elimination.
Helpfully, Barry had never seen stress cracking in this area before, but as discussed earlier, with the damage sustained and the poor quality of the original repairs, its not a great surprise.
Bit of cutting
Bit of pasting
And again, as good as new
His attention to detail is exceptional. Here he identified an area of stress creacking that needed elimination.
Helpfully, Barry had never seen stress cracking in this area before, but as discussed earlier, with the damage sustained and the poor quality of the original repairs, its not a great surprise.
Bit of cutting
Bit of pasting
And again, as good as new
Last edited by Dougieboy1 on Mon Jun 11, 2018 2:34 am, edited 3 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Re: Shrek
Some nice detail Andrew
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
Thanks Garry, i need to call you at some point re fitting up of some bits as we discussed!
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
-
- I luv DDK!
- Posts: 867
- Joined: Mon Jan 04, 2016 7:27 pm
- Location: Definitely round here somewhere
Re: Shrek
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)