Announcement

Collapse
No announcement yet.

1959 356A S/R coupe project chassis # 108625

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

  • #46
    Bruce, I remember seeing a similar treatment on "pimp my ride" once. The guy cut out little windows for plexi-glass in the skins so curious onlookers could watch his chrome plated window regulators operate. The insides of these doors won't be nice enough to justify that treatment. On a serious note having the skin off really makes me aware of what a false sense of side impact protection these old doors really offer the occupants.
    Justin
    Justin Rio

    Comment


    • #47
      10/14/17

      Loose ends and new bottom install
      Click image for larger version

Name:	IMG_5699.JPG
Views:	166
Size:	71.6 KB
ID:	92420
      Finished out that looong seam weld finally.
      Click image for larger version

Name:	IMG_5700.JPG
Views:	165
Size:	59.8 KB
ID:	92421
      These twin prepunched holes in the center of the bottom are not for an A-car; must be a T5 or 6 thing so now was as good a time as any to back fill them.
      Click image for larger version

Name:	IMG_5702.JPG
Views:	162
Size:	73.9 KB
ID:	92422
      Plug weld holes punched and all other loose ends complete. These two are finally ready.
      Click image for larger version

Name:	IMG_5704.JPG
Views:	165
Size:	66.3 KB
ID:	92423
      Started welding up front. After clamping the hinge down I fully welded up the ends of the old pins to fully secure them once again.

      Click image for larger version

Name:	IMG_5706.JPG
Views:	163
Size:	62.9 KB
ID:	92424
      As a final finishing detail I took a pair of washer and plug welded them on to replicate the old heads.
      Click image for larger version

Name:	IMG_5710.JPG
Views:	166
Size:	70.5 KB
ID:	92425
      Just a touch larger than the Originals but since I'm not using Plexi-glass it should be just fine once the new skin is all mounted on.
      Click image for larger version

Name:	IMG_5734.JPG
Views:	163
Size:	54.9 KB
ID:	92426
      Then moved to the outside and plug welded up the flange and also started gas welding up the edges as they were done before.

      Click image for larger version

Name:	IMG_5735.JPG
Views:	161
Size:	55.9 KB
ID:	92427
      More seam welding to the rear. All flange plug welds dressed and followed up with my spotter for final detail
      Click image for larger version

Name:	IMG_5737.JPG
Views:	166
Size:	67.6 KB
ID:	92428
      No more and no less on the spots for a more authentic look; The best that I can do anyway. Should have this all buttoned up by tomorrow then its onto fitting the new skin.
      Thanks for looking!
      Justin
      Justin Rio

      Comment


      • #48
        Thanks for posting this Justin. This will be my next project so good for me to start studying.
        Mark Erbesfield
        57 356A
        65 911
        68 912
        73 911S
        66 Toyota Land Cruiser FJ45LV
        79 450SL Dad's old car

        Comment


        • #49
          Thanks a lot Mark! Best of luck with your door repair!
          Justin

          10/15/17
          Left door shell inner frame repairs complete.
          Click image for larger version

Name:	IMG_5738.JPG
Views:	160
Size:	57.9 KB
ID:	92447
          Inner pan flange to bottom all welded up. Originally there were just 5 spot welds widely spaced holding this together here. I put extra plug welds in for added strength but replicated only the 5 spots for an original detail.
          Click image for larger version

Name:	IMG_5739.JPG
Views:	159
Size:	52.0 KB
ID:	92448
          Back corner fully gas welded up and the small repair patches on the wall finished out.
          Click image for larger version

Name:	IMG_5740.JPG
Views:	159
Size:	56.1 KB
ID:	92449
          forward gas welds in and replicate what was there originally.
          Click image for larger version

Name:	IMG_5741.JPG
Views:	157
Size:	43.8 KB
ID:	92450
          Front repair section also seam welded up as found.

          Click image for larger version

Name:	IMG_5742.JPG
Views:	157
Size:	71.5 KB
ID:	92453
          Officially done welding and repairing the door shell frame.
          Click image for larger version

Name:	IMG_5744.JPG
Views:	160
Size:	69.5 KB
ID:	92451
          Begin fitting the new skin on next.
          Click image for larger version

Name:	IMG_5745.JPG
Views:	157
Size:	60.8 KB
ID:	92452
          New adventure begins tomorrow.
          Thanks for looking!
          Justin
          Justin Rio

          Comment


          • #50
            10/17/17

            Begin new door skin fitment.
            Click image for larger version

Name:	IMG_5750.JPG
Views:	153
Size:	58.5 KB
ID:	92498
            Getting ready to cut the cap of the new skin off by making extra sure I gave myself enough overlap to deal with any unforseen adjustments as this goes. The last thing I need is to be short and have to weld more length back on.
            Click image for larger version

Name:	IMG_5751.JPG
Views:	156
Size:	61.6 KB
ID:	92499
            Capped and now slowly figuring out best adjusted position on the shell frame. Then it all has to fit in the car.
            Click image for larger version

Name:	IMG_5752.JPG
Views:	151
Size:	61.9 KB
ID:	92500
            Of course the initial fitment is very crude and misaligned.
            Click image for larger version

Name:	IMG_5754.JPG
Views:	150
Size:	56.9 KB
ID:	92501
            Small series of trimming to the flanges and repeated test fits slowly made it better.
            Click image for larger version

Name:	IMG_5756.JPG
Views:	152
Size:	51.8 KB
ID:	92502
            I debated about whether I was going to use Trevor's step flange or not. As the fitting progress it just seamed to be holding things up.
            Click image for larger version

Name:	IMG_5758.JPG
Views:	148
Size:	49.6 KB
ID:	92503
            I decided to cut free. I was very unsure about it as the cutting went but
            Click image for larger version

Name:	IMG_5757.JPG
Views:	148
Size:	47.3 KB
ID:	92504
            Once I laid it back over the frame everything seemed to fall into place. It was the right way to go.

            Click image for larger version

Name:	IMG_5761.JPG
Views:	152
Size:	45.0 KB
ID:	92505
            Remembering Bruce's warning about door handle height discrepancies I set about making sure this cup is in the right spot.
            Click image for larger version

Name:	IMG_5753.JPG
Views:	148
Size:	48.9 KB
ID:	92506
            Both original doors to this car have the center of the handle coming in at center to that mount screw hole in the jamb. This wasted T2 door I have here highlighted perfectly what Bruce was warning about. Its a factory door but notice how it is almost a quarter inch lower than the marked position of the doors for this car. Thanks again for the tip and for bringing it to my attention.
            Click image for larger version

Name:	IMG_5755.JPG
Views:	143
Size:	69.7 KB
ID:	92507
            More tomorrow...
            Thanks for looking!
            Justin
            Justin Rio

            Comment


            • #51
              10/21/17

              New skin initially mounted.
              Click image for larger version

Name:	IMG_5763.JPG
Views:	142
Size:	53.4 KB
ID:	92625
              Flanges on the frame side were fine trimmed, test fit and repeated until they slid together in good alignment.
              Click image for larger version

Name:	IMG_5764.JPG
Views:	140
Size:	57.2 KB
ID:	92626
              I could now tighten up the skin flanges more and bring them over center.
              Click image for larger version

Name:	IMG_5765.JPG
Views:	137
Size:	61.6 KB
ID:	92627
              Best way I had to achieve this without messing up those initial bends.
              Click image for larger version

Name:	IMG_5766.JPG
Views:	144
Size:	53.6 KB
ID:	92628
              Thankfully turned the trick with no distortion to the outer surface.
              Click image for larger version

Name:	IMG_5771.JPG
Views:	141
Size:	49.9 KB
ID:	92629
              Rear vertical flange was carefully pecked over next. Skin was then mounted onto the frame for the first time in its best adjusted initial position. Mounted to the car next to see what I ended up with.
              Click image for larger version

Name:	IMG_5773.JPG
Views:	136
Size:	53.3 KB
ID:	92630
              Just three cleco's and off it goes.
              Click image for larger version

Name:	IMG_5767.JPG
Views:	142
Size:	39.5 KB
ID:	92631
              Its very close. Edge of the new section carries on the line of the upper original edge and the door gap remains pretty good.
              Click image for larger version

Name:	IMG_5768.JPG
Views:	143
Size:	39.0 KB
ID:	92632
              Rocker gap is promising too.
              Click image for larger version

Name:	IMG_5769.JPG
Views:	142
Size:	40.1 KB
ID:	92633
              Forward gap is still factory but devoid of lead so a lot of wiggle room up here. Lower corner is hanging loose BTW.
              Click image for larger version

Name:	IMG_5770.JPG
Views:	136
Size:	54.3 KB
ID:	92634
              More fine tuning and prep yet to go but its starting very close. A great relief.

              Thanks for stopping by!
              Justin
              Justin Rio

              Comment


              • #52
                Not for the faint of heart!! Great outcome.
                jjgpierce@yahoo.com

                Comment


                • #53
                  Looks good, but man I am not too excited about my having to do this. Maybe mine will not be as extreme.
                  Mark Erbesfield
                  57 356A
                  65 911
                  68 912
                  73 911S
                  66 Toyota Land Cruiser FJ45LV
                  79 450SL Dad's old car

                  Comment


                  • #54
                    Thanks a lot guys! Not quite out of the woods with it yet but slowly getting the fitment I need.

                    10/23/17
                    Prep work for final skin install.
                    Click image for larger version

Name:	IMG_5792.JPG
Views:	138
Size:	72.4 KB
ID:	92716
                    Sanding and prepping the inner surface for a good coat of sealer.
                    Click image for larger version

Name:	IMG_5793.JPG
Views:	137
Size:	50.5 KB
ID:	92717
                    Also began pecking out the remaining damage while its easy to get at.
                    Click image for larger version

Name:	IMG_5794.JPG
Views:	137
Size:	58.5 KB
ID:	92718
                    A little picking and filing leveled it closer but I can only take it so far until the new skin is fully attached.
                    Click image for larger version

Name:	IMG_5789.JPG
Views:	136
Size:	62.2 KB
ID:	92719
                    As for the skin prep itself I needed to harvest this original backing plate for the door handle.
                    Click image for larger version

Name:	IMG_5791.JPG
Views:	138
Size:	60.1 KB
ID:	92720
                    Final hole location for the handle was etched from the original to position the old plate.
                    Click image for larger version

Name:	IMG_5796.JPG
Views:	137
Size:	54.9 KB
ID:	92721
                    Original plate was acid dipped to remove all the old rust that was on the mating surface. Plate in final position and ready to weld in. A lot going on at once and more yet to do before I can close this door shell up for good but its on its way.
                    Thanks for looking!
                    Justin
                    Justin Rio

                    Comment


                    • #55
                      10/30/17

                      Loose ends and final trim. Getting closer to skin installation.
                      Click image for larger version

Name:	IMG_5803.JPG
Views:	137
Size:	46.3 KB
ID:	92883
                      Plate installed
                      Click image for larger version

Name:	IMG_5806.JPG
Views:	140
Size:	63.4 KB
ID:	92884
                      Opening up the hole in the skin. I wanted to procrastinate on this one but now was the time while I have clear access and could see how far I needed to take it.
                      Click image for larger version

Name:	IMG_5808.JPG
Views:	135
Size:	41.6 KB
ID:	92885
                      One more pre-installation chore complete.

                      Click image for larger version

Name:	IMG_5801.JPG
Views:	136
Size:	62.1 KB
ID:	92886
                      Through all this I decided to take the final joint a little higher still to get past more of that old damaged section.
                      Click image for larger version

Name:	IMG_5802.JPG
Views:	136
Size:	48.2 KB
ID:	92887
                      Usually I like to save more of the original but that new profile is so nice and we're only talking about two more inches. Also the length of the final joint is an inch+ shorter going this route. Most importantly I'll still have access from behind when the time comes to pick and file the weld joint. I lose the original side mirror holes but I marked and pre-punched them back in the new section first. Notice the downward angle of the holes; the owner told me that original Aero mirrors have a limited pivot angle so the mirror was offset to compensate for this.
                      Click image for larger version

Name:	IMG_5805.JPG
Views:	137
Size:	79.4 KB
ID:	92888
                      One more careful cut. My worst nightmare is to cut too much off.
                      Thanks for looking!
                      Justin
                      Justin Rio

                      Comment


                      • #56
                        10/31/17
                        Prepping for sealer and paint.
                        Click image for larger version

Name:	IMG_5809.JPG
Views:	135
Size:	53.9 KB
ID:	92895
                        Need to get a good coat of primer and paint on the inner surfaces before I close this door shell up. Etching the new metal with some 100 grit to give the sealer something to hang onto.
                        Click image for larger version

Name:	IMG_5813.JPG
Views:	135
Size:	66.1 KB
ID:	92896
                        Initial coat of epoxy applied to both sides.
                        Click image for larger version

Name:	IMG_5810.JPG
Views:	135
Size:	44.0 KB
ID:	92897
                        Between coats some heavy drip check was applied to the joints I wanted to seal out.
                        Click image for larger version

Name:	IMG_5811.JPG
Views:	132
Size:	37.3 KB
ID:	92898
                        Not all the joints however. This long run here is better left to drain if any water finds its way in behind there.
                        Click image for larger version

Name:	IMG_5812.JPG
Views:	133
Size:	32.4 KB
ID:	92899
                        Sealed out the reinforcement plate as well but I now realize I should have left the bottom of it open to allow any potential future moisture in between there to escape. I'll razor blade the bottom of it out on my next visit. Sometimes you can go too crazy with these joint sealers and inadvertently cause the damage you were trying to prevent by trapping water and not allowing it to escape.
                        Click image for larger version

Name:	IMG_5815.JPG
Views:	133
Size:	59.1 KB
ID:	92900
                        Final coat of epoxy after seam sealer.
                        Click image for larger version

Name:	IMG_5816.JPG
Views:	137
Size:	48.4 KB
ID:	92901
                        Also dumped some epoxy straight into those openings(green arrows) and sloshed it around for some additional coverage in behind there.
                        Click image for larger version

Name:	IMG_5817.JPG
Views:	136
Size:	51.7 KB
ID:	92902
                        A quick scuff and a coat of flat black next. Then the new skin will be ready to go on for good.
                        Thanks for looking!
                        Justin
                        Justin Rio

                        Comment


                        • #57
                          Eve Doorman Justin,
                          Looks very good.....better than when the door was new @ the Werk.
                          Did you want to show us something with the green arrows? Pointed at the rounded corners?
                          Thank you for your documentation of get a door together
                          JOP

                          Comment


                          • #58
                            Thanks a lot Per but nothing is ever as good as when it was new. The green arrows highlighted where I dumped epoxy into for additional protection down between those panels.

                            Painted
                            Click image for larger version

Name:	IMG_5820.JPG
Views:	135
Size:	68.3 KB
ID:	92912

                            Click image for larger version

Name:	IMG_5822.JPG
Views:	133
Size:	70.3 KB
ID:	92911

                            Click image for larger version

Name:	IMG_5821.JPG
Views:	134
Size:	67.0 KB
ID:	92913

                            Click image for larger version

Name:	IMG_5823.JPG
Views:	136
Size:	62.6 KB
ID:	92914

                            Click image for larger version

Name:	IMG_5824.JPG
Views:	134
Size:	78.3 KB
ID:	92915
                            Finally time to Begin fitting the skin on for good.
                            Thanks for looking!
                            Justin
                            Justin Rio

                            Comment


                            • #59
                              Looks great Justin. The 3M Heavy Drip-Chek is $21 for a 5 oz. tube. How thin/far does this stuff go as it seams/seems very expensive?


                              Click image for larger version

Name:	31a2i0x4JrL.jpg
Views:	145
Size:	15.2 KB
ID:	92933

                              John
                              jjgpierce@yahoo.com

                              Comment


                              • #60
                                John, that tube I'm using is left over from my project. One tube will easily do one car. 21 bucks seems about right You may find it cheaper on Ebay.

                                11/1/17
                                Figuring out final skin location and frame preload.
                                Click image for larger version

Name:	IMG_5832.JPG
Views:	135
Size:	57.0 KB
ID:	92944
                                Frame remounted on the car once again but this time with the latch mechanism to help me get a complete picture on how well or not the edge of the skin will fit in this opening.
                                Click image for larger version

Name:	IMG_5830.JPG
Views:	137
Size:	44.0 KB
ID:	92945
                                Without the skin there is a ton of flex across this frame. As it stands now the lower corner here sticks out a bit too far.

                                Click image for larger version

Name:	IMG_5831.JPG
Views:	135
Size:	53.1 KB
ID:	92946

                                With the lightest of persuasion of pressure that corner comes in and the upper corner comes back out even at the top. All is right again. As I fit this skin I not only have to make sure fits in the opening of the car but I also have to set the skin so it will preload the frame with this needed twist as I set and weld it on.
                                Click image for larger version

Name:	IMG_5833.JPG
Views:	136
Size:	70.5 KB
ID:	92947
                                Its not a huge deal but it is something I have to keep in mind and shoot for versus just blindly tacking and welding this skin on in its relaxed position on my table. Otherwise after the fact, I'd be fighting to get the attitude of the end of the door right with car and once that skin is welded its not going to be very cooperative. Anyway developing that correct union between these two now.
                                Thanks for looking!
                                Justin
                                Justin Rio

                                Comment

                                Working...
                                X