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1959 356A S/R coupe project chassis # 108625

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  • Rear parcel shelf reinstallation completed:
    Click image for larger version  Name:	IMG_8434.JPG Views:	2 Size:	511.2 KB ID:	112544 All plug weld holes filled and dressed.
    Click image for larger version  Name:	IMG_8435.JPG Views:	2 Size:	650.9 KB ID:	112545 Being so thin to start with this panel is trying and tricky to weld in. The weld has to be hot enough to bond to the seat pan but while doing so the shoulders of this panel often blew out so I'd have to chase it with more weld creating more finish work in the end. I went through the same thing when I installed this panel back in my car.
    Click image for larger version  Name:	IMG_8436.JPG Views:	2 Size:	551.6 KB ID:	112546 Just thankful to be all done with this. Onto the next deal.
    Click image for larger version  Name:	IMG_8446.JPG Views:	2 Size:	504.5 KB ID:	112547 B-pillar lower gusset repair: I needed a little break so this little panel was a quick and fun distraction. Paper template left over from the coupster project.
    Click image for larger version  Name:	image_65223.jpg Views:	3 Size:	547.3 KB ID:	112548 Basic panel cut out with more recycled original steel from this car.
    Last edited by JTR70; 02-25-2022, 07:52 PM.
    Justin Rio

    Comment


    • Click image for larger version  Name:	IMG_8448.JPG Views:	0 Size:	588.9 KB ID:	112550 A few vendors sell this gusset new but its so simple and either way it still has to be made to fit into this corner properly in the end. I also prefer the control of making this part a little oversized in areas if needed.
      Click image for larger version  Name:	IMG_8449.JPG Views:	0 Size:	637.5 KB ID:	112551 Final trimming and shaping continued. My original shows a double bend shoulder along the lower flange so I wanted to replicate that a little.
      Click image for larger version  Name:	IMG_8450.JPG Views:	0 Size:	568.8 KB ID:	112552 Final shape and position all but set at this point.
      Click image for larger version  Name:	IMG_8451.JPG Views:	0 Size:	513.0 KB ID:	112553 Its built but not ready to go on for good just yet. As you can see there are a lot of loose ends in, around and behind it to tie up first. This was just a simple project for a mental break while keeping the progress going.
      Click image for larger version  Name:	image_65228.jpg Views:	3 Size:	515.3 KB ID:	112554 Back to the big stuff. Rear floor pan section going in for good.

      That next... Thanks for looking!
      Justin
      Last edited by JTR70; 02-25-2022, 08:15 PM.
      Justin Rio

      Comment


      • Finishing out the floor pan installation:
        Click image for larger version  Name:	IMG_8471.JPG Views:	0 Size:	513.9 KB ID:	112577 Lots of hole filling and making sure the pan sits tight against the flange in small runs as it goes. Begin welding from the center outward on the lateral runs.
        Click image for larger version  Name:	IMG_8472.JPG Views:	0 Size:	506.3 KB ID:	112578 Ready weld that forward conduit bracket too.
        Click image for larger version  Name:	IMG_8486.JPG Views:	0 Size:	513.8 KB ID:	112579 but before I could do that I had to close up the plug welds directly under them first for access to dress down the weld heads.
        Click image for larger version  Name:	image_65247.jpg Views:	3 Size:	468.1 KB ID:	112580 Bracket plug weld holes drilled and now ready to synch down and weld in for good. My original floor shows almost 30 spot welds securing this bracket to the floor.
        Click image for larger version  Name:	image_65248.jpg Views:	3 Size:	472.7 KB ID:	112581 I have half as many but the welds are bigger; its not getting loose anytime soon. All welded up and ready to grind smooth.
        Last edited by JTR70; 03-04-2022, 05:44 AM.
        Justin Rio

        Comment


        • Rear pan install continued:
          Click image for larger version  Name:	IMG_8530.JPG Views:	0 Size:	519.7 KB ID:	112583 Forward lap joint all welded up top and bottom.
          Click image for larger version  Name:	IMG_8526.JPG Views:	0 Size:	466.3 KB ID:	112584 Rear lateral run was next. Fortunately the center of the original mount flange under the conduits was preserved. Would have been very tricky to fix this section with those tubes in my way. Thank goodness for leaky transmissionss.
          Click image for larger version  Name:	IMG_8499.JPG Views:	0 Size:	501.3 KB ID:	112585 Adding set screws from the center outward. Once this was complete I ran couple of screws along the sides to ensure a snug fit along those runs. No issues. Ready to weld this up.
          Click image for larger version  Name:	IMG_8531.JPG Views:	0 Size:	554.5 KB ID:	112586 Welding along the rear flange complete.
          Click image for larger version  Name:	IMG_8529.JPG Views:	0 Size:	511.6 KB ID:	112587 Most of the weld dressing will be to the inside but I have a little clean up to do out here. Onto welding up both sides of the pan next.

          Thanks for looking!
          Justin
          Justin Rio

          Comment


          • Looking very nice Justin !
            Roy

            Comment


            • JTR70
              JTR70 commented
              Editing a comment
              Thank you Sir!

          • Justin - very nice fitting on deed.
            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
              Appreciate that Scott! As you well know that requires several cycles of test fits and fine trimming.

          • Rear floor pan installation complete.
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ID:	112610 Pan all welded in and now for the unpleasant chore of dressing all of those plug weld heads. Small bites at a time.
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ID:	112611 Additional weld details are the seams found originally along the lap joints. A long seam ran across the lap joint at the pan halves.
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ID:	112612 A blob of weld was placed at the lap joints along the vertical walls to the pan.
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ID:	112613 Several found at the rear corner where edges intersect.
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ID:	112614 Towards the front: A seam weld across the span of that delta-V lap joint.
            Justin Rio

            Comment


            • Click image for larger version  Name:	IMG_8464.JPG Views:	0 Size:	561.2 KB ID:	112616 Forward lap joint again received a supporting weld.
              Click image for larger version  Name:	IMG_8465.JPG Views:	0 Size:	546.1 KB ID:	112617 Like at the rear corner the leading edges at the front where they intersect where reinforced with a seam weld. Again, this is where having an original reference car is so invaluable. I never would have thought to add these otherwise.
              Click image for larger version  Name:	IMG_8573.JPG Views:	0 Size:	542.2 KB ID:	112618 In between plug-weld head grinding on the inside I took little breaks and finished out the final spot weld presentation along the outside edge. The lateral lap joint along the pan halves where not originally spot welded together. They where joined ahead of installation and where welded with a continuous roller spotter type attachment. So to replicate that as close as possible, the plug heads are dressed but not followed up with my spotter.
              Click image for larger version  Name:	image_65278.jpg Views:	3 Size:	586.0 KB ID:	112619 All welding and detail duties finally completed along this longitudinal. Back to plug weld finishing on the inside but will complete the left side details to match in between.
              Click image for larger version  Name:	image_65279.jpg Views:	3 Size:	657.8 KB ID:	112620 Gas weld seam detail completed at this back corner continuing on into the pan as originally done.

              Thanks for looking!
              Justin
              Last edited by JTR70; 03-11-2022, 09:32 PM.
              Justin Rio

              Comment


              • Begin tunnel repair and installation:
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ID:	112653 Left side perimeter spot details and clean up completed.
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ID:	112654 Gone as far as I can go on this side for now. Back over to the top side to begin adding the tunnel.
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ID:	112655 Begin tunnel repair and prep next.
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ID:	112656 A little bowed and a little rusty but definitely savable.
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ID:	112657 Some quick torch heat first to remove those twisted off seat rail screws.
                Justin Rio

                Comment


                • Click image for larger version  Name:	IMG_8557.JPG Views:	0 Size:	509.4 KB ID:	112659 Leading corners straightened back and grinding back the gas welds in prep for refitment.
                  Click image for larger version  Name:	IMG_8590.JPG Views:	0 Size:	522.6 KB ID:	112660 Initial try and my forward repairs at the toe-board had to be cut and trimmed back to allow the tunnel to slide underneath and back into position.
                  Click image for larger version  Name:	IMG_8591.JPG Views:	0 Size:	522.0 KB ID:	112661 A couple of tries gave me just enough clearance for the ends of the tunnel to slide under and maintain a tight weld joint when the time comes.
                  Click image for larger version  Name:	IMG_8593.JPG Views:	0 Size:	477.9 KB ID:	112662 drilled out spot welds along conduit flanges confirm that the tunnel is back into original position.
                  Click image for larger version  Name:	IMG_8592.JPG Views:	0 Size:	520.3 KB ID:	112663 Begin repairs to this rear housing and the lower flange run up next.

                  Thanks for looking!
                  Justin
                  Last edited by JTR70; 03-14-2022, 09:04 PM.
                  Justin Rio

                  Comment


                  • Rear tunnel repairs:
                    Click image for larger version  Name:	IMG_8594.JPG Views:	0 Size:	508.5 KB ID:	112674 A bit of rust on top and mount flanges to fabricate but I'll be able to save most of it. I have this OG section from my T1 as a reference.
                    Click image for larger version  Name:	IMG_8612.JPG Views:	0 Size:	479.2 KB ID:	112675 I really wanted to ensure I got this pleat relief shape correct.
                    Click image for larger version  Name:	IMG_8611.JPG Views:	0 Size:	506.2 KB ID:	112676 Once I really got to looking at it I was surprised to find that this shape was only on the left side of this later tunnel. As you can see the early T1 housing has this shape on both sides . No signs of this shape ever being stamped over here. Makes my life easier.
                    Click image for larger version  Name:	IMG_8613.JPG Views:	0 Size:	491.0 KB ID:	112677 Some rust on top to fix but most of this area will be savable.
                    Click image for larger version  Name:	IMG_8615.JPG Views:	0 Size:	533.3 KB ID:	112678 New flange section cutout here. The bend is very soft so I folded it over a pry-bar to replicate that feature.

                    One more to go. Thanks for looking!

                    Justin
                    Last edited by JTR70; 03-20-2022, 09:07 PM.
                    Justin Rio

                    Comment


                    • tunnel repairs continued:
                      Click image for larger version  Name:	IMG_8616.jpg Views:	0 Size:	516.6 KB ID:	112680
                      New flanges for this rear section ready to install. A couple of runs through my shrinker jaws to get those sweeping curved profiles.
                      Click image for larger version  Name:	IMG_8628.jpg Views:	0 Size:	573.3 KB ID:	112681 Begin with the right side first. Tunnel clamped square to my table to dial in the final trim line so this new section sits at the right height.
                      Click image for larger version  Name:	IMG_8630.jpg Views:	0 Size:	535.6 KB ID:	112682 New section all stitched in. I left myself a bit of excess all the way around for a final fine trim right before it goes in for good.
                      Click image for larger version  Name:	IMG_8631.jpg Views:	0 Size:	491.8 KB ID:	112683 Moving onto the small tears and rust holes on the upper shoulder.
                      Click image for larger version  Name:	IMG_8633.jpg Views:	0 Size:	512.1 KB ID:	112684 Much faster and simpler to back fill it with a gas weld versus creating a replacement patch. Left side repair up next.

                      Thanks for looking.
                      Justin
                      Last edited by JTR70; 03-22-2022, 07:22 AM.
                      Justin Rio

                      Comment


                      • Rear tunnel repairs continues:
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ID:	112710 Left rear flange repair complete.
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ID:	112706 Onto the top side to repair this corner and the mid-section of the flange.
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ID:	112709 Straight forward little add-on here.
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ID:	112707 Changed my approach about removing the entire corner and just enlarged the original hole until the rot was eliminated.
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ID:	112708 Simple backfill and will redrill the hole detail even though its a T1 relic and no longer used.

                        Justin Rio

                        Comment


                        • Click image for larger version

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ID:	112712 Forward portion of this repair complete and now onto back corner. Basic patch with flange for starters.
                          Click image for larger version

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ID:	112713 A gentle sweep profile added in with my stretcher dies.
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ID:	112714 Then the final rolling corner shape profile added in.
                          Click image for larger version

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ID:	112715 Tunnel mounted to dial in the final position of that new corner patch.
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ID:	112716 Had to make sure the new flange butted tight against the kick panel opening. Ready for final trimming and welding.
                          Thanks for looking.

                          Justin
                          Justin Rio

                          Comment


                          • Remaining tunnel flange repair sections:
                            Click image for larger version  Name:	IMG_8657.jpg Views:	0 Size:	586.7 KB ID:	112735 A bit of hunting around my shop to find a form both long enough (40+ inches) and also with the right shaped corner that would create the soft radius bend I'm looking to for. A strut from my cherry picker was just the ticket. This little test piece confirmed it.
                            Click image for larger version  Name:	IMG_8675.jpg Views:	0 Size:	576.0 KB ID:	112736 Marked, clamped to my table and ready to begin hammering it over.
                            Click image for larger version  Name:	IMG_8678.jpg Views:	0 Size:	570.2 KB ID:	112737 Right repair section cut free and ready to begin final fitment to the tunnel.
                            Click image for larger version  Name:	IMG_8697.jpg Views:	0 Size:	584.6 KB ID:	112738 Went ahead and finished making the left side repair run while I had it all set up. Its a touch wider than the right side especially along the forward recess shape for the gas pedal and the drivers foot.
                            Click image for larger version  Name:	IMG_8707.jpg Views:	0 Size:	613.2 KB ID:	112739 Tunnel clamped square to the table to establish the final trim line for a butted joint.
                            Last edited by JTR70; 04-05-2022, 07:16 PM.
                            Justin Rio

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