DDK - Die Deutschen Klassiker

i imported this car earlier this year from the States, via a dealer with a womans' name in it....i was warned, but carried on regardless.


This restoration will have to be done outside where you see it, not enough garage space.
This won't be a "correct" restoration, far from it.
The car already came with a Type 4 engine and non-matching number gearbox, so its already 'special' (better word than 'outlaw').
On the plus side, the original colour was tangerine (now red), and i might paint it that colour.

Thought i'd start on the rear seat area

typical both sides....ended up with:

all mid-panel joins butt welded, then washed, phosphated and 2 coats Epoxy Mastic, all overlapping panels treated with Wurth weld-thro primer, plug welded and treated as before

next went on to floor, saved nearly all of left side, not so much of right...i try not to replace more metal than necessary



just one small area on right

treated floor with Epoxy Mastic again...brush finish not marvellous, but it should be durable.

I'm not making the mistake of over-restoring this car, and then not daring to drive it.

whilst i was doing the cockpit area, i added seat belt fixings, one on the tunnel (for the stalks) and one towards the end of each inner cill, as i dont plan to retain the original seats (MX5 seats will be used, with adaptor mounts i have already made)

also decided to remove the engine lid release cable assembly from the rear left wheelarch....too much of a mud trap...i'll have to think of some other way of releasing lid

then onto the cill areas....i am fed up with replacing Porsche jacking areas, so i blanked both of them off





even the outer cills, apart from the immediate jacking vicinity, were in excellant condition and kidney bowls were savable

then onto the front of the car

various rusty areas at the front


same both sides, took ages to make repair pieces



gutter



finished as



wing mountings needed some work



battery boxes both needed work



I did not have the car media blasted....much of the original PVC coating and sealant was adhering excellantly, even in the wheelarches....its fairly easy to see where rust is developing....so, i will retain this original coating

Next, onto the front suspension mounts

cleaned up the right front mount and it was as good as it can be, no sign of rust at all...had to cut out rust in tank support above it and that confirmed no rust

but the left side was rusty....very



thats it all cut out....reused the tapped bushes, used new reinforcement piece on top, and made up the heavily dished panel to take it all....needed heat to get it dished sufficiently, took ages


used jigs top and bottom as suggested by Barry and finished with

that got a coat of Epoxy Mastic as usual and finished as



i then repaired the piece of tank support i had cut off and welded it back on

and finally



i fitted a large spreader plate under the battery strap mounting to avoid pulling through and did not reinstate the battery support....i will make that a removeable piece

the other hole in the tank support panel is just above the front bolt area where there is a large cavity between the reinforcement piece and the main panel , so i can inject anti-rust fluid

also, did not reinstate the towhook, that had caused havoc with rust.....i'm not intending to be towed along by anyone

onto smugglers box next

You seem to be cracking on at quite a pace - you'll be finished soon.

Wow - and all that's being done outside! Respect. Can't wield a welder to save my life!

How long have you had the car and how did it get over to the UK? Any stories you're up for telling us?

All the best in your resto.

R

Top work

Sent from my X5pro using Tapatalk

Was the car better or worse than the warnings about the lady seller - I know someone with a big Merc coupe that actually was nowhere near as bad as the rep

thanks for the encouragement....i'm spending vast amounts of time on this car

it came in earlier this year, it was previously owned by a Registry member in the states......the problem with the "lady dealer" is that they won't really tell you anything about the condition of the car other than what is fairly obvious....I got it independently inspected but I don't think the inspection was particularly thorough....never mind, the yanks ain't gonna let us have their best cars are they?

they sent me a pic showing engine number, but, foolishly, I didn't check it out till sale was virtually agreed....ah well, maintenance will be cheaper and the Type 4 is supposed to be more robust

plans are for a bespoke interior (original stored away carefully), Webasto heater to replace original and, years down the line, fuel injection

Impressive work going on there

I am sure Beverly and the rest of her club will be impressed with the work and the completed car!

What cooling fan is fitted to the engine? Original fan on the end of the crank, an upright set up like the 912 or 911 style fan?

You're doing a lovely neat job!

i was wondering that myself Bruce....i know virtually nothing about flat 4's generally, but i know i want to work towards the most efficent possible fan set-up, stock or not, with thermostatic control

....but, yes, it currently is upright similar to stock 912 (i think!)