DDK - Die Deutschen Klassiker

The bottom of the A post / wheel well is poor on both sides.





You can see how the bottom of the A post has become detached from the central sill.





The bottom of the B post is not much better

The torsion bar area has seen its fair share of repairs.









Also the back side of the tube area neer the antiroll bar has been repaired, this will all get sorted.

The rear screen area has been repaired and then lead filled.





The parcel shelf needs quite a bit of work too

We have purchased floor edges at the moment so hopefully these will repair the worst areas.





This area is in the bottom corner of the rear seat floor just infront of the torsion tube.

I was hoping the door frames are going to be salvageable, we will have to see.

This is the bottom of the door frame with an old repair.



The shiny stuff is lead.









So it looks as if Barry has his work cut out. Its frightening to think I was driving this car around 2 months ago I still have a valid MOT for it

The shell has generally been full of filler and lead, so it should be quite a bit lighter when it has been reincarnated.

I did have it weighed when we did the corner weights set with standard seats in and it was 1086KG wet. It will be interesting to see how heavy or light it it when finished.




Kind Regards

Getting to the heart of it now!

Whilst it's been repaired before someone clearly has put a lot of time and effort into it, probably 15+ years ago.

Having just come out from under my car trying to make a heater tube to go around the torsion bar I can sympathise with whoever did it! Are you (Barry) going to cut this all out and start again?

My recommendation on the doors is to put them in a skip and get some 964 doors. I went through this with mine and after many wasted hours trying to patch a rusty door decided that welding up a mirror hole was much easier! Not too mention properly galvanised and with a side impact beam I know it adds money, but you don't need many hours of sheet metal work and paint rectification before they will pay for themselves and last longer.

The plan is to cut all the old repairs out and then repair the sections to a better standard. As for the doors I have a second set of doors but they are not early ones, I will let Barry decide what the best way forward is, if new 964 doors are the best soultion then that's what we will do.

Good to here you have not given up with yours, can you see the light at the end of the tunnel yet?

That lot will need some work i think?

I'm sure you are right to remove the old repairs and build from there.

I did all this to mine 22 years ago and removed genuine Ford Cortina MkIII outer sills (had the lables fresh on the inside).
The areas around the torsion bar tube was not as bad but had seen MoT welding to get by, but the front cross member came clean out of the car front when i jumped on it!

It too had genuine GTX oil can pop rivited all into it and good layer(s) of underseal.
I keep the remains of the cross member for old times sake in the loft.

The rot was everywhere.

Barry will transform it.

My TR4 had a 'Gunk' tin making up the footwell .

John: I'd better order some extra steel . Still, it's all been done before, but this is looking like it's edged up into the 'fairly serious' camp, from the 'pretty straightforward' one it was in when I visited. Still, most of it is big manly lumps, as opposed to the one that's here now that was very solid in most places, but had loads of very tricky repairs. As we've said several times now, it is quite incredible how few of these areas even hinted at trouble. Lesson there for purchasers perhaps? The amazing thing was that these repairs have obviously lasted a very long time: certainly not a case of blowing through in a few months.

Looking forward to getting it on the jig and kicking off .

Oh yes, Gary, the 2.2 shells had the heater tube going up and over the torsion tube, unlike your 2.4 (and later) shell. One less thing to deal with. In fact the 2.2 shell is quite different from the rear seats back (other than the rearmost crossmember I think). Certainly chassis legs, inner wings, engine bay (shock absorber) crossmember, seat pan area and parcel shelf are all different.

All packed and ready to go. Mike Bainbridge and myself have built a dolly for the shell to go on, this will make transporting the shell easier and also once painted the car can be completely assembled on the dolly and it will be mobile, so can be pushed around the workshop.

johnM wrote:

There's a radiator in there ~ and I thought you were 'ard John
Nice work though and probably explains why you and Mike are still pratting about with my car

Mick Cliff wrote:
There's a radiator in there ~ and I thought you were 'ard John
Nice work though and probably explains why you and Mike are still pratting about with my car

Ard... i'm seldom soft that rad is just to stop spanners freezing to stuff.

And as for pratting around... less of your cheek young man we are doing our best

Kind regards

[/quote]Nice work though and probably explains why you and Mike are still pratting about with my car [/quote]


Mick,Mike and John have put yours to the back of the queue,they said they were concentrating on mine first
Regards,

No!
Mike has been concentrating on my gearbox.
Better have as i'm there on Sat to pick it up!

How come he's doing everything for everyone?

johnM wrote:less of your cheek young man we are doing our best

Ah that's it - flattery gets you anywhere