1959 356A S/R coupe project chassis # 108625

[JTR70]

Best place to make the changes:
Tube mounted directly to the upright as starting point.
Not only too long now but swings very high and wide with the other end just about where it needs to be.
Everything to in the inside of the guard is stock so this end of the tube would be established first. This 90 degree bend really dictates the uprights orientation. If its not just so the end of the tube would not reach the surface of the bumper. So as you assemble, they tell you exactly where they need to be in relation to one another. The cut and following changes would be made just to the outside of the bumperette mounting hole. With the tube cut I'll not only shorten it but I also be able to index it slightly for a flush fit to the bumper.
This bumper was a Euro-version so it was a clean slate as far as the tube mounting holes went. To locate the hole in just the right spot this temple was taped to the tube end and once I had the tube exactly where I wanted it was peeled free from the tube and simultaneously taped to the bumper. Ready to confidently drill the hole.
Inside of the tube bolted up snug for the first time. So far so good. You can see by this point the bumper mounting bracket has been welding back in for good. Cutting and modifying the bumper through the exhaust arches was the best place to make the changes as this bracket only conceals the weld joint but also reinforces it. Cutting the tube the in half next.

Thanks for looking.

Justin

[JTR70]

Getting ready to make the first cut.
Before cutting the bar it was slid inward by that one inch that was removed out of the bumper to establish where the tip of this tube needs to end up to fit and look correct.
Same paper template procedure to locate the mounting hole as was done on the inside. By this time all the original deco holes were welded closed as they needed a reset as well.
Commitment time. As planned the weld joint will be to the outside of the original upright mounting hole.
Both ends of the tube mounted onto the bumper highlighting how much needs to come out...about an inch.
That one inch section removed here but it won't go into the trash. Its being repurposed as reinforcement sleeve across the final weld joint. In the process of removing width out of it here so it will snuggly fit into the I.D. of the tube halves.

Thanks for looking.
Justin

[JTR70]

Right tube welded back together:
Tube mock ups began. Fully bolted down snug with the outer section indexed slightly for a smooth transition across this joint and a flush fit against the bumper out at the tip. My weld joint ended up being twice as wide as I had wanted. I was looking for a 4mm gap for a root pass with a good remaining weld shoulder left once it was all dressed even smooth for replating. I mistakenly made the final cut on the wrong side of my marker line creating too large of a weld joint.
A bit too wide to back fill with weld so I cut a quick filler ring. Two welds instead of one but I was just relieved that this mistake wasn't too serious.
Tack welded to hold the final needed shape.
Dismounted one more time so I could Zip it all together.
Shoulder at the contact point ground down quickly as I was anxious for a confirmation fit. Bolted right back up where it was before welding with a snug fit inside the bumperette recesses. So far so good.

Thanks for looking.

Justin

[JTR70]

Right side overrider bar modification:
Bar shape remains smooth and still fits against the back drop of the tail panel itself. Once its rechromed the alteration will be completely undetectable a big relief, especially after cutting up original parts.
End of the tube terminates right where it would in relation to the deco and the tip of the bumper before both these parts were tightened and shortened.
Contour looking down the assembly will look stock and appear unchanged as well.
Bar fits tight into the guard as well as the bumper without being forced into position. Making everything fit together with minimal tension was top of the list.
After that confirmation fit the bar was removed and the rest of the weld joint was ground smooth and semi-polished in preparation for rechroming.

Thanks for looking.

Justin

[JTR70]

Refitting the deco trim:
Couldn't get past some of the weld shoulder out here.
but its close enough to leave for the chrome shop to fill with either solder or copper.
Right side bar complete. Onto the left side but first,
I wanted to fit the new deco strip in first.
I filled in all the original deco holes freeing it up to be mounted directly at center with the uprights recess openings. This way there is no alignment issues or a forced fit when it all goes together for the final time.

[roy mawbey]

Justin do you know after looking at all that effort regarding the above deco bars I am actually quite pleased I have a Euro version car that does not have them! You have done well to sort that all out.
Of course having those could save you so much if the rear end of the car is hit!
Roy

[JTR70]

Thank you very much Roy! Actually, those bars won't protect a thing as they'll quickly fold up with the mildest of collisions creating more damage and expense as you'd have to replace them along with the extra damage they'd cause from being driven into the body. I don't think a RHD 356 with USA overrider bars exists; at least not from factory. These were just add-ons to satisfy the US DOT as they were mounted too low to meet their bumper regulations . You'll notice they raised the bumpers on the T5 and eliminated these tubes. Thanks again Roy.

[JTR70]

Deco refitment continued:
Redrilling one of two holes needed here to create that elongated hole.
All the deco holes redrilled with good clearance from the bumper bracket mounts. Its all falling into place thankfully.
Bumper remounted for another test fit and beginning to add in the strut as the final piece.
Strut coming out at center of the hole for now but would need some adjustment before it was all over. Full mock up with old rubber insert. It can be reused as there is now an inch of excess out at the sides.
Modifications just about complete on this side.

[JTR70]

Bumper modification fine tuning.
I was ready to move on to the left sides jewelry refitment and modification but first...
I had to go back and cut this corner of the bumper free to reset it. The general contour needed some tightening up in relation to the tail.
And the tips were angled off from one another at about 3 degrees which was driving me nuts. One side of the sat level while the other side ran downward slightly. I couldn't leave that so this left side corner was cut free and reset to match the right. Running at 0 degrees here
Matching the right side.
Once I had this corner reset where I needed it the joint was a complete mess. The profile shape where they meet was mushrooming up revealing more residual crash damage. Messaging this out as I stitched it back together.

[JTR70]

Finishing up the left side bumper reset:
Final confirmation fit directy against the body.
Final contour runs as closely to the tail as I could hope for. The tip tucks in a little tight.
on both sides but will wait to see what the final reveal shape looks like once its mounted on its irons and spaced away from the body.

Finished welding up the joint and then finally onto adding the exhaust arch back in.
Ready to drill the hole to mount the bumperette. Along with its lateral location I also have establish the angle. Shooting for 90 degrees but most importantly it just has to mirror the right side when its over.

Thanks for looking.

Justin

[roy mawbey]

Justin your comments are correct I can visualize the problems that could happen if hit up the back. Now it makes sense with the really strong market for Porsche in the States at that time the factory had to meet the safety ruling for the rear bumper.. Yes I have seen imported 356 cars with them fitted that's all. So much work there.

Roy

[JTR70]

Thanks once again Roy! I just recently realized this as Drew's RHD coupe has USA over ridder bars fitted to it. Always learning about these old cars. Justin

[JTR70]

Finishing up the deco and upright mounting.
Uprights officially running parallel with one another.
Left guard mounted in its best adjusted Position.
Deco remounted with the new holes and position I had established on the right side previously. The old mounting hole for the upright in this deco lined up near perfectly with the newly drilled hole in the bumper. It was a promising sign. This hole just had to be enlarged a touch to accept the shoulder of the mounting bolt.
Same process as on the right side. The upright was mounted next to establish center in the relief opening for the deco's final placement. This ensures a trouble free final fit once the rubber inserts are introduced. Redriling the deco mounting holes next.
Deco and uprights fully mounted and set. Now onto the cutting and reshaping this right side bar to fit.

Thanks for looking.

Justin

[JTR70]

Final piece of the puzzle: Left Tube shortening
I can finally modify this tube to fit with the guard set in its final adjusted position.
Same process as before, everything to inside of the guard is stays factory correct so establishing this side first before any cutting.
Paper templates took all the guess work out of finding the exact spot to drill the hole.
All bolted up and set in here. Ready to make the first cut.
Outside end of the tube now mounted and set.

[JTR70]

Welder up:
Excess section removed and will be used as a reinforcing sleeve across the weld joint. Notched to reduce its OD so it will into the tube sections.
Sleeve inserted and now ready for a test fit to determine the final length, needed shape and tube end indexing so I can begin tacking it back together.
First full mock up with tube sleeve. Fit and contour was the best I could hope for. Would have tacked it but the weld joint is too tight for a root pass.
A few more MM's shaved off for a clear shot at that sleeve. Remounted and finally ready for some tack welds.
Tacked, dismounted and fully welded up here.

[JTR70]

Over tubes complete.
Weld dressed and polished.
Thankfully after all the welding and heat the tube maintained the needed shape and dropped right back into position snuggly.
Bars are ready to head to the chrome shop for replating.
Assembled the bumpers jewelry one more time to make sure this assembly is going to pass the smell test. From the sides everything looks to scale again. The tips of the deco and the tube end were they should in relation to the end of the bumper.

[JTR70]

Final presentation:
One last direct mock up mounted against the body to confirm symmetry from left to right. Again the guards are still in their factory spaced position so their relationship with the tail light openings remains golden.
Once the bumper is finally mounted on its brackets we should have a really nice and uniform reveal all the way around.
Most important thing at this moment was that the overrider bar contour matched from side to side and that they seated into the guards correctly.
After all the alterations to both the bumper and the bars everything fit and mirrored each other as best as I could hope for.
Then the final test was how it matched up to the car itself. Tail light opening reveal against the crown of the tubes was very promising. Now onto getting it mounted on its brackets.

thanks for looking.

Justin