914-SHO Project Thread

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3d914

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Got to take a break last weekend and make a run out to the G&R 914 Swap meet in Riverside. Was able to meet up with my son. Got to drive his Targa. Also picked up a couple of rear trunk lids.

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You might be thinking - what do you need two for? Well to do the mods planned (see first pic) I need to cut the ribbing along the front, and I'm cutting two small openings for the NACA ducts, and a big chuck out to clear the intake tube. That will get a new piece, but I want to reinforce the underside with the same ribbing - so one trunk is for the finished lid, the other is for the ribbing. Plus I have my original white lid for ribbing also.

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I lucked out and found one that already had the duck-tail spoiler - which I was thinking about adding. Unfortunately it's got a slight tweak to it - but I thought I can fix that - so bought it with that in mind. It's in pretty good shape & I like the smooth transition from the spoiler into the lid.

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From the on-end view you can see how the right side (left in photo) doesn't curve as much as the left, and so its raised up slightly.

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On the underside, you can see the bent rib. I'm thinking I can make a wood form of the correct curvature & use that to re-bend the lid into shape. If it doesn't work, I can use this lid for its ribbing, and use the other lid for my final one. I'll just have to add the spoiler myself.

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This one still needs some minor work, you can see there's some cracking under the paint. They probably used just bondo, instead of something with a little more strength.

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Also decided to up the height of my rotisserie stands by 7.5 inches. This will enable me to move the car right from the dolly onto the rotisserie and back onto the dolly without having to do a lot of jacking. I just have to raise the adjustable pads on the dolly to their max, connect the rotisserie, then lower the pads & slide the dolly out. Now I just have to get over to Tucson to buy the steel.
 

3d914

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No work this weekend on the teener. Got the mini torn down for a new thermostat housing - what a bogus design. Put up some extra fencing for the horses, and replaced rear struts & springs on a neighbors Toyota.
 

3d914

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Finished work early so got to spend some time on the teener. Added almost eight inches height to each stand to match the car's position on the car dolly. I'll probably need to jack the front up a little extra to get the height I need. Probably won't get it on there until Sunday.

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3d914

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Got rained out on Saturday morning, so spent the time getting car on the rotisserie. Had just enough space to jack the front a couple of inches and fit that end of the rotisserie on. Slid jack out, then slid dolly out. Now swinging free.

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3d914

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Spent several hours today removing front struts and suspension. This is all original so I know it was going to be a bear. The only easy part was the nuts on the top of the struts - neither was torqued properly. Everything else took grunting and penetrating oil, and more grunting. No broken knuckles though.

The 914 suspension is actually well designed and easy to maintain. I haven't decided completely on what's going in to replace it. Soo many options.

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And one with it all off. Going to wait to remove the steering. Need to do a little more research.
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Now that its up on dolly, I'm finishing up the welding on the inner longs and grinding all the welds. It'll be a while before that's all done. Lots of welds!
 

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Making progress on the welding and grinding. Its much easier to do certain areas with the car on the rotisserie. Spent more than a couple of hours on this section. Lots of welding and I had to let things cool before continuing. Filled in the time gaps with grinding.

This is what it started out like.
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Mostly finished except for the gaps along the top. There was no material there, but I'm thinking about cutting some pieces to fit and fill it in.
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Got this area finished along with rest of the grinding for this side. Got a couple of welds in areas near the floor where my 4" won't fit. Need to find something to get these few welds down.

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Also fixed the two plugs in the floor that were bent inward. Looks like the seam sealer was supposed to hold them in place - but these two were pushed in. So I cleaned off the seam sealer and welded instead. They'll get more seal sealer once the rest of the floor is done.

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Reinforcement kit is done and ready for primer - which I just happen to be out of. Now I just have to remember if seam sealer goes on after primer or before.
 

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Right again, Tom - goes on top the primer.

Got some time this afternoon to get the steering rack out and look closer at both sides of the floor-board under the pedal cluster.

Now to the cleaning. It looks like the outside was light surface rust - no pitting at all. I think I'll go ahead and re-enforce the portion I've cleaned. Even another layer of metal the same thickness will help a lot.
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Got far enough on the inside to see that its not as clean & there is some pitting, but it's not as bad as I thought. Definitely salvageable. Treatment with some rust inhibitor should do the job.
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That glob of white & brown in a circle is the seam sealer that was under a sheet metal plug. The plug is rusted on both sides so I'm going to cut a new one out of slightly thicker gauge material.

I've cleaned out the sealer on both sides - now you can see the shelf for the plug and the piece on the back side. First will be rust treatment, then weld in a new plug on both sides, then finish off with seam sealer.
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I've cleaned out the sealer on both sides and cut the end off the support piece - now you can see the sheet metal tab. I'll cut a new support piece that covers this and extends up into the area where the master cylinder mounts.

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On the inside there's a shelf for the plug. I'll need to cut a new one out of slightly thicker material and weld it in. First will be rust treatment, then weld in a new plug on both sides, then finish off with seam sealer.

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Working up front on the underside, here is something else I discovered. I know this car was beaten up when it was previously stolen - but I thought I had found all the damage - Not!

Gonna look to see if I can find a decent replacement section. If not I'll have to cut it out, repair it and weld it back in. Got a break with the floor - just to find more work under here.

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3d914

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Finished up the underside of plug by welding the piece I cut off back on. I filled in the hole and then drilled a couple of holes for spot welds to keep the plug in place.

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Welded in the plug cap on the inside, and with all the rust already treated, was able to get several coats of self-etching primer on. All that's left will be to fill this area with seam sealer.

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Needed to update the scope of metal work left on the under body and track what's getting done:
  • Inner suspension (dog-ear) reinforcement
  • Model pieces and weld while on dolly
  • Limit material thickness to 0.075"
  • Remove Doorway supports & keep doors
  • Repair small sections in floor pan
  • Install engman inner long kit while on dolly
  • Repair floor under pedal cluster
  • Weld outer body patch panels - currently exposing wheel wells (L & R)
  • Cement L side to FG flare
 
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