DDK - Die Deutschen Klassiker

Floor now fully welded and ground and little foot board brackets in place. Big job!



I’ve started to make some adaptor brackets to pick up from the suspension mounts to fit it to a trolley, which I’ll make next.

Then lots of little jobs I’ve been putting off, like fixing the heater valve studs. Not 100% sure how to tackle that one.

Cleaned it and still don’t know! I need a stud welder

I think I got an M8 stud and tapped an M6 thread down the middle and screwed that on and locktighted it

Or summat like that

That's how I did mine years and years ago too.
Do that and drill the flapper body out 8.5mm to clear, M8 nut etc. Red Loctite.

Today I would take an M6 hex hd screw, turn the head down to a mm and after grinding that sheared stud flush, braze the new 'stud' over the same spot.

Open the gasket hole to clear the thinned head and M6 the flapper on.

Great ideas chaps. Will sort next weekend

Fantastic work Gary. You must be so pleased getting the floor in

Got distracted by making the trolley. Holes have loads of clearance in case it changes shape whilst on Barry’s Celette!



Now the floor is on I fully epoxied the inside of the sills and the rebuilt seat mounts. Sometimes I forget how much I’ve done as there is always the next job.



Slap of epoxy around the floor edges to protect the seams as the welded areas flash rust so quickly.

Gary71 wrote:Cleaned it and still don’t know! I need a stud welder

The studs on my flapper boxes sheared flush, so I drilled them all out and welded in top-hat nuts. Worked a treat - just use bolts now rather than nuts onto studs.
Peter

PeterK wrote: The studs on my flapper boxes sheared flush, so I drilled them all out and welded in top-hat nuts. Worked a treat - just use bolts now rather than nuts onto studs.
Peter

Snap.
Cut them off flush with the air saw, drilled them out and welded in these M6 top hats.
Should be sorted now!

Also I spent another hour cleaning around the torsion tube and fuel pump bracket. This is such a pain that I can only stand it one hour at a time! There’s no way it’s all coming off to metal without cutting a hole in the seat pan to get to it so I’m guessing those areas are just fine

Is it 'Barry-Ready' now?, or, rather, is Barry ready for it?
You must be so very close now.
Great going. I would turn a blind eye to those hard to clean recesses but I'm not a fussy as you!

Getting close now.
Need to do the studs on the other side and more cleaning over there then I’m going to paint some of the underneath before putting it on the trolley and fitting the doors, wings, bumpers etc.

I’ve got plenty of time off over Xmas so it will be ready when Barry is

Oh and the blind eye is definitely turned to some of it!

No more than Porsche did 50 odd years ago

I’m still debating the fate of my engine lid as the A surface at the lower edge is rusty, but I had a couple of hours this afternoon so made up this repair section for the bit around the lights.

This seems to rot on every lid I’ve seen so must be a dirt and water trap.

Current plan is to repair the inner then ask Barry to do the outer. Should still work out cheaper than a new one and it would be nice to have one original panel on the car!

Gary71 wrote:it would be nice to have one original panel on the car!

I only have one too - the bonnet!