DDK - Die Deutschen Klassiker

Hi, I’m not doing a full backdate on the door, just the mirror holes and a few rivnuts for the handle. I know the front corner of the door trim mounting is different, but it can be overcome with a little bracket.

The cosmetic bits of the grommet holes etc I’m not worried about, it will match the other side now anyway That’s had a 964 door for years!

I’m making new door cards so I’ll make sure it all matches.

I was thinking about making more brackets if there’s an interest, I’ve got it down to about 20 minutes each now after all my test runs!

Much as I’m not doing a shiny rebuild some of the parts are just a mess so I’ve cleaned up this lot ready for powder coating.

Gary71 wrote:Much as I’m not doing a shiny rebuild......

....who are you kidding!

If I start plating bolts you have permission to shoot me

Or making sure they all point in the same direction

Gary71 wrote: If I start plating bolts you have permission to shoot me

If we have to shoot you, can I have your car

Or have the right lettering for the year and month of assembly on the bolt heads, and get the colour of the bloody grill screws right!

I think most feel a deep rebuild DIY will be the death of them.
It will feel very strange when the garage is empty for a while, but oh-so-goooood when Barry has tweeked it all.

Peter is very practiced at rubbing down, he's your man for the next stage!

I looked at the wiring harness yesterday. Then put it back in the box

The only bolts I want to get right are the ones for the door, but the 964 doors have a larger adjustment hole for a flange head bolt so the usual small headed ones don't look right, and need a washer.

So I'm going to try and source a set of early hinge halves to enable use of the early bolts without a washer.

Edit: Didn't type the last line!

Decided to do the backdate on the rear crossmember today. I was going to leave this to Barry, then thought hey I’m bored, I’ll give it a go!

I spent two hours shaping a really thick bit of steel into a form tool then switched to the much better plan of cutting the end off the old one and letting it in!


Came out ok in the end, but it’s like welding tissue paper, and I don’t have the skills for that



Just need to do the other side now, which is a much smaller section, just the curve not the label indent.

And if I get really bored the section in the middle around the latch. The early part has a little return flange around the hole. The later part is just a hole.

Jobs for tomorrow!

Ever thought of getting a tig?
Jeff in Oz is using his more and more.
I'm tempted.
Seems a bit like electric gas welding with filler rod etc.

I got a TIG secondhand - the model with all the bits I wanted and only 6 hours use (allegedly), but unfortunately, I got it just as I finished all my welding (for now)

In hindsight yes I’d have bought one two years ago, but it’s too late now! This was definitely a TIG job.

I was known many years ago as being able to gas weld like a god, (! )
wonder how similar it is?

Finished the other side today. I made this part from scratch using the form tool I made yesterday as the original part was too rusty. This made the welding much easier as I made it out of 1.2mm.







Overall pretty happy with that outcome fixing the most obvious backdate clue for the anoraks!

I’ve decided to leave the centre section as the work is too intrusive for very little visible change.

If Boris is going to let us out soon I must talk to Barry and start the next phase

Quality work there Gary. At least you will make Le Mans next year now.