DDK - Die Deutschen Klassiker

Skills Mark ! Coming along nicely.....but glad someone is keeping an eye on your ( Lug ) nuts

Agreed, I don't think shaving those nuts is ideal.

A gun in a case! Must be quality. I always use cheap ones as throwing away after use is far easier than cleaning.

Congrats on the work so far.

Thanks Guys.

I can't believe how little time you actually spend spraying, compared to the time sanding, masking, and even cleaning the damn thing

Another weekend, another update...

Actually I've started doing a bit in the evenings a couple of nights a week - it helps you to knock down the big jobs by doing an hour here or there

Thursday
Did the last of the long wheel studs. In case anyone is thinking of doing it, it's an easy job - probably about an hour a corner if you take your time. I went for 66mm studs and this is probably the longest you can go without having to remove the rear hubs

The old ones just knock out with a BFH


And the new ones can be pulled in with a sacrificial nut and a sleeve (part of the G50 shifter)


The finished ones (can't wait to put the wheels on)


Saturday
Just finished off the petrol breather pipe. Neil also came round and gave me some advice on the best way to go from here in relation to the filling, sanding etc

Sunday - front wing day
When I trial fitted the front wing yesterday there was a disappointing gap near the top of it - it wasn't lining up with the door)
(This is looking down onto it)


I ummed and ahh'd about it and had decided I was going to fill the wing to match them up. However, Neil had looked at it and reckoned once I got the correct trim piece in at the top it would space out and be a bit closer.

I did that, and have worked on it today. I must have had the wing on and off about 15 times. Although I could get the top part lined up OK, the bottom part was too far out - the profile of the wing and the door were slightly different (the wing is a proper porsche part)

Eventually I decided the only way to match the profile was to do some cuts in the supporting strut


This allowed me to get a good fit all the way down. I held it in place with the bolts, and tacked across the cuts. I then took it off and welded up the slits. Put it back on and IT DIDNT FIT!!! Not a good moment. I thought it through and the heat from the welding had shrunk the metal around it and moved it out of alignment.

I therefore had to go back to square one. I put new slits in and re- bolted the wing on. Once again I got a good fit. This time I welded them up with it all bolted in place


It's not clear from this photo but the wing and door line up much better now, and I'm happy with the gap which is consistent with the rest of the door.

Whilst all this wasn't the lightening progress I was hoping to make today (still got shitloads more rubbing down to do), it was rewarding to start with something I thought I was going to have to fill, and end up with it fitting quite nicely. Of course you do get paranoid about the fit of it after a while - I'll see what I think of it tomorrow.

Mark, I can sympathise with your front wing fitting hassles! But it satisfying when it all comes together... Great job!

Mark, you are the man, really enjoy reading your hands on DIY, give it a go approach to the whole project. Keep up the good work, and get that sunroof panel fitted, ha ha..regards Mark..

I'm having to resist the urge to just dive into the sunroof job - and make sure I finish the current jobs off first. It is going to happen though

Still wasn't happy with he fit of that front wing. As I thought it through that night, the second time I cut the slits I used an air tool that cut a really really thin cut. When I fitting it, the bottom 2 slits open up, and the top slit closes up. Because the top slit was so thin I remember the two pieces were tight against each other. Overnight I realised I'd have to do it again.

Last night did it all again - re-cut all the slits - thicker cuts again this time. Finally I was able to get a good fit - one that I was happy with



The door is slightly proud at the top but it's better than the other side - which I've lived with blissfully for the last 14 years. The rest of it fits nice and the gap side-on matches the rest of the door.

looking good...like the profile of the arches a lot..

Intense stuff Mark, but why haven't you sent your tax disc back for a refund? When you started this project there must have been loads of time left on that.

Nige wrote:Intense stuff Mark, but why haven't you sent your tax disc back for a refund? When you started this project there must have been loads of time left on that.

Never got round to it Nige - Kept thinking it would be back on the road before long.

You've still got 3 months or so let, you never know.

Are you changing those oils lines too?

Those arches are looking great!

sladey wrote:In case anyone is thinking of doing it, it's an easy job - probably about an hour a corner if you take your time. I went for 66mm studs

Can you (or anyone else) recommend a good source for longer wheel studs?

dragonfly wrote:Those arches are looking great!

sladey wrote:In case anyone is thinking of doing it, it's an easy job - probably about an hour a corner if you take your time. I went for 66mm studs

Can you (or anyone else) recommend a good source for longer wheel studs?

Got mine from type911