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1959 356A S/R coupe project chassis # 108625

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  • Stitching it all in.
    Click image for larger version  Name:	IMG_8025.JPG Views:	0 Size:	620.6 KB ID:	111896 Floor patch all plugged and stitched in. Couldn't throw as much heat at the seam weld as I wanted because its thin but its bonded well enough. I'll double check it once its ground back level.
    Click image for larger version  Name:	image_64789.jpg Views:	3 Size:	490.9 KB ID:	111897 The backside of the lap joint was a much better and hotter meld.
    Click image for larger version  Name:	image_64790.jpg Views:	3 Size:	526.2 KB ID:	111898 Now onto final trimming and fitment of the upper corner patch.
    Click image for larger version  Name:	image_64791.jpg Views:	3 Size:	610.8 KB ID:	111899 Trimmed and set screwed into best adjusted position.
    Click image for larger version  Name:	image_64792.jpg Views:	3 Size:	482.6 KB ID:	111900 Ready to weld in for good. A bit of a gap to the left side but its easily bridged with some weld. It just wasn't worth the time to add on literally a sliver of steel.



    Last edited by JTR70; 09-15-2021, 08:16 AM.
    Justin Rio

    Comment


    • Welded and begin metal finishing.
      Click image for larger version  Name:	IMG_8032.JPG Views:	0 Size:	448.9 KB ID:	111902 Tacking and tapping for a flush fit and shape as I went.
      Click image for larger version  Name:	image_64794.jpg Views:	3 Size:	546.7 KB ID:	111903 Just about there...
      Click image for larger version  Name:	image_64795.jpg Views:	3 Size:	548.9 KB ID:	111904 Welding all but complete. Now the unpleasant chore of grinding all this down smooth; both sides .
      Click image for larger version  Name:	image_64796.jpg Views:	3 Size:	525.3 KB ID:	111905 Completing a section at a time to keep my sanity. The face that will show the most finished out first. So happy I addressed this before adding in the floor pan, having unobstructed access made life a bit more pleasant.
      Click image for larger version  Name:	image_64797.jpg Views:	3 Size:	549.1 KB ID:	111906 Continuing on with more weld dressing.

      Thanks for looking!
      Justin
      Last edited by JTR70; 09-15-2021, 08:33 AM.
      Justin Rio

      Comment


      • Great work. I always love when you can improvise to shape metal into a specific shape.
        1960 356B T5 - under major resurrection.
        356 Registry main thread;
        http://forum.porsche356registry.org/viewtopic.php?f=4&t=35854
        1968 912 - running like a scalded cat.

        Comment


        • JTR70
          JTR70 commented
          Editing a comment
          Thanks Scott, I usually manage to find some piece in the shop that I can form off of.

      • Little Stuff:
        Click image for larger version  Name:	IMG_8071.JPG Views:	0 Size:	621.2 KB ID:	111934 I have a lot of weld finishing ahead of me on these latest repairs so to break things up I made and installed a few final parts for this corner. Began with the reinforcement plate for the hand brake mount. A small square of 16 gauge to replicate the original.
        Click image for larger version  Name:	IMG_8072.JPG Views:	0 Size:	627.8 KB ID:	111935 Bolted into final position and ready to plug weld from underneath. I already had holes drilled in the floor from the removal of the old one and its much easier on my bits to drill the remaining holes in the floor versus this heavier stuff.
        Click image for larger version  Name:	IMG_8074.JPG Views:	0 Size:	475.1 KB ID:	111936 Last two items to install are the holding tabs for the windshield washer tube line. I harvested on tab from the floor remains that I had cut out but the other one was long gone. Copied and cut out a replacement.
        Click image for larger version  Name:	IMG_8076.JPG Views:	0 Size:	514.7 KB ID:	111937 Tabs installed with reinforcement plate plug welded on. Lower tab placed just over the weld joint of the floor patch to both conceal and support it.
        Click image for larger version  Name:	image_64825.jpg Views:	3 Size:	675.5 KB ID:	111938 Same with this plate it both conceals and supports the weld joint. Other than getting past the rot this is what helped determine my final cut lines. Okay , other than weld grinding this completes my repairs to this corner of the floor. Beginning similar repairs to the right side corner next.

        Thanks for looking!
        Justin
        Last edited by JTR70; 09-19-2021, 10:05 PM.
        Justin Rio

        Comment


        • So many small fiddly bits that can take a lot of time but... will show the effort when finished ( or rather won't show the effort but just look original rust free !! )
          Roy

          Comment


          • JTR70
            JTR70 commented
            Editing a comment
            Agree Roy, a lot of tiny looses ends to address once the heavy lifting is done but no way around it. Thanks again!

            Justin

        • Begin unpeeling the right side upper trunk corner.
          Click image for larger version  Name:	IMG_8077.JPG Views:	0 Size:	527.8 KB ID:	111943 I found that left corner sort of unusual as to have rotted so badly and is such a concentrated area but to have both corners go?? Even weirder, a can only guess that the old tar paper peeled forward and created a nice pocket for rain water to settle down into.
          Click image for larger version  Name:	image_64827.jpg Views:	3 Size:	427.8 KB ID:	111944 Another small item to address while I'm under here is some tapping and welding to the bottom of the hinge pocket.
          Click image for larger version  Name:	IMG_8079.JPG Views:	0 Size:	548.3 KB ID:	111945 I want to disturb as little as possible so I settled on this cut line. It gets me past the rot while preserving that row of factory spot welds below.
          Click image for larger version  Name:	IMG_8080.JPG Views:	0 Size:	590.4 KB ID:	111946 First layer peeled away. A thick chunk of rust fell out and I was trying to figure out which layer of metal it originally was but I'll get my head around it.
          Click image for larger version  Name:	image_64830.jpg Views:	3 Size:	591.8 KB ID:	111947 Inside view. I'll have to cut away this outer corner and fabricate another as well but its far simpler than the left side and not as rusty either; the trunk floor is intact thankfully.
          Last edited by JTR70; 09-24-2021, 09:53 AM.
          Justin Rio

          Comment


          • Front floor pan pre-fitment :
            By the next session I was sick of working in that confined space under the dash so I changed gears and began fitment of the front floor pan. Once I have it trimmed and dialed in I'll go back under the dash to finish up.
            Click image for larger version  Name:	IMG_8084.JPG Views:	0 Size:	472.6 KB ID:	111949 Dialing in center and best match against the corrugation shapes in relation to the leading edges of the mount flanges.
            Click image for larger version  Name:	image_64832.jpg Views:	3 Size:	567.5 KB ID:	111950 A peddle assembly was mocked up next to dial in the floors best adjusted position further.
            Click image for larger version  Name:	image_64833.jpg Views:	3 Size:	484.7 KB ID:	111951 Relief cuts where added to clear the longitudinal leading edges to allow the floor to lay flush for a closer fit.
            Click image for larger version  Name:	IMG_8087g.JPG Views:	0 Size:	443.7 KB ID:	111954Much to my great relief the initial floor position gave me this outline trace as to where the slotted mounting holes on the peddle assembly are in relation to that circular relief. Other floor installs I have done were nowhere near this close to being right and required a lot of messaging to fix. The final mount stud placement should be at the back end of the slotted hole when the peddle assembly is mounted flush to the wall highlighted in green. I'll end up pushing the floor just a touch more forward to ensure that the eventual bottom stud is out of the relief shape but its close.
            Click image for larger version

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ID:	111953 All the while the shoulders of the corrugations are lining up nice against the leading edge.
            Last edited by JTR70; 09-24-2021, 10:39 AM.
            Justin Rio

            Comment


            • Dialing it in further:
              Click image for larger version  Name:	IMG_8092.JPG Views:	0 Size:	496.7 KB ID:	111956 Floor moved forward just a touch more to ensure mounting stud clearance.
              Click image for larger version  Name:	image_64838.jpg Views:	3 Size:	409.6 KB ID:	111957 That should doer...
              Click image for larger version  Name:	image_64839.jpg Views:	3 Size:	623.3 KB ID:	111958 Original reference the final confirmation I needed.
              Click image for larger version  Name:	image_64840.jpg Views:	3 Size:	488.4 KB ID:	111959 remounted to etch in the flange leading edge to dial in my final cut lines.
              Click image for larger version

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ID:	111960 Etched and will measure backwards from the chassis at intervals for the final trim line.
              Last edited by JTR70; 09-24-2021, 10:59 AM.
              Justin Rio

              Comment


              • trim and trial fitments:
                Click image for larger version  Name:	IMG_8104.JPG Views:	0 Size:	525.3 KB ID:	111962 Basic trim line added and now onto cutting off the excess.
                Click image for larger version  Name:	IMG_8109.JPG Views:	0 Size:	520.1 KB ID:	111963 Excess removed and first trial fitment. I of course only got this far on the first try before it bound up.
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ID:	111964 A series of fine shaves and retries got it closer each time.
                Click image for larger version

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ID:	111965 Just about home with only a touch further to go...

                Thanks for looking!
                Justin
                Last edited by JTR70; 09-24-2021, 11:09 AM.
                Justin Rio

                Comment


                • Very interesting lesson there Justin. There is much more thought than you might think in completing a new floor fitment. I am thankful all my floors are original. Datums are so important to have, When guys buy rusted out wrecks with no floors or even pedal clusters how do they ever make a start!
                  Roy

                  Comment


                  • JTR70
                    JTR70 commented
                    Editing a comment
                    Thanks Roy, like I've said many times before I'd be at a loss without an original reference example...

                • Front floor pan installation prep.

                  I was going to finish the repair to the right upper trunk corner next but access won't be affected whether the floor pan is in or out so I'm going to get the pan in first.
                  Click image for larger version  Name:	IMG_8125.JPG Views:	0 Size:	415.0 KB ID:	111996 Repairing the flanges on the toe board mounts first. The lower runs at the tunnel are little short and torn away.
                  Click image for larger version  Name:	IMG_8127.JPG Views:	0 Size:	448.1 KB ID:	111997 New sections added back on with a little excess for insurance. I left this repair for last on a previous floor and it was a PIA after the fact. Did not want a repeat so added them now.
                  Click image for larger version  Name:	image_64867.jpg Views:	3 Size:	523.3 KB ID:	111998 Lower flange repairs: Not rusty but the remover of the original floor had ground these back paper thin. I tried a little gas welding to see if I could save them but they where just too weak now. Any plug welding attempts to attach the floor would just bow right through...
                  Click image for larger version  Name:	image_64868.jpg Views:	3 Size:	545.5 KB ID:	111999 In process of adding some new flanges.
                  Click image for larger version  Name:	image_64869.jpg Views:	3 Size:	1.73 MB ID:	112000 Repairs complete and now ready to accept the new floor pan.
                  Last edited by JTR70; 10-12-2021, 11:01 AM.
                  Justin Rio

                  Comment


                  • Front floor pan installation:
                    Click image for larger version  Name:	IMG_8132.JPG Views:	0 Size:	1.62 MB ID:	112002 Most the plug welding will be to the inside but I drilled a few along the outside just to ensure the floor remains drawn tight to the flanges.
                    Click image for larger version  Name:	IMG_8138.JPG Views:	0 Size:	519.8 KB ID:	112003 Eventually got all my plug-weld holes drilled both to the flanges and the floor. Primer cleaned off along the contact surfaces so my panel spotter doesn't short and blow out a hole during the detail follow up after the plugs are dressed.
                    Click image for larger version  Name:	IMG_8139.JPG Views:	0 Size:	541.7 KB ID:	112004 Floor pan set screwed and installed for the final time.
                    Click image for larger version  Name:	IMG_8141.JPG Views:	0 Size:	515.7 KB ID:	112005 Begin welding from the center outward.
                    Click image for larger version  Name:	IMG_8142.JPG Views:	0 Size:	516.5 KB ID:	112006 Grinding rows of weld heads is very tedious so I like to do it a section at a time. All dressed and followed up with my panel spotter for its finished detail. Continuing down the sides of this flange next.
                    Last edited by JTR70; 10-12-2021, 11:21 AM.
                    Justin Rio

                    Comment


                    • Click image for larger version  Name:	IMG_8144.JPG Views:	0 Size:	484.7 KB ID:	112008 Plug welding continued.
                      Click image for larger version  Name:	IMG_8146.JPG Views:	0 Size:	532.9 KB ID:	112009 My OG reference shows a gas seam weld run at this intersection.
                      Click image for larger version  Name:	IMG_8145.JPG Views:	0 Size:	530.0 KB ID:	112010 Added this detail along the bulkhead and pan but the lateral run will have to wait until the flange repair for the outer gusset is completed. That repair won't happen until the front beam is pulled out.
                      Click image for larger version

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ID:	112011 As plug welding proceeds I'll be bouncing between this last section of floor flange repair. Then I can begin fitting and trimming the rear floor section.

                      Thanks for looking!
                      Justin
                      Last edited by JTR70; 10-12-2021, 11:30 AM.
                      Justin Rio

                      Comment


                      • Looking good Justin A lot of holes to plug !!

                        Roy

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                        • JTR70
                          JTR70 commented
                          Editing a comment
                          A ton of them...Thanks Roy!

                      • More front floor pan:
                        Click image for larger version

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ID:	112065 Went down both sides plug welding the screw holes first to ensure the pan stays tight against the flange.
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ID:	112066 Moving to the inside next to finish out the rest of the plugs.
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ID:	112067 Finished out the lateral runs with my panel spotter to complete the welding details. Lose ends being tied up a section at a time.
                        Click image for larger version

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ID:	112068 Bounced back to the last of my perimeter repairs and cleaned out the remains of this lower kick panel.
                        Click image for larger version

Name:	IMG_8163.JPG
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ID:	112069 Torch heat used to destroy the remaining rust and scale along the reinforcement flange.
                        Justin Rio

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