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1959 356A S/R coupe project chassis # 108625

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  • JTR70
    replied
    Back edge of the fender:
    Click image for larger version  Name:	IMG_2528.jpg Views:	0 Size:	189.8 KB ID:	115931 Moved to the rear and heeled the leading edge of the fender over tightly to the splash pan. Door reinstalled for its first test fit against the new edge.
    Very rough initial shape but its a starting point.
    Click image for larger version  Name:	IMG_2530.jpg Views:	0 Size:	183.9 KB ID:	115933 Then mocked up the rocker skin. Again very rough rudimental fit but I've got a good door gap to work with.
    Click image for larger version  Name:	IMG_2532.jpg Views:	0 Size:	175.4 KB ID:	115934 A ways yet to go but its improving with each pass. Little bites at a time.
    Click image for larger version  Name:	IMG_2535.jpg Views:	0 Size:	167.2 KB ID:	115935 Moving back up to the front to continue dialing this big joint.

    Thanks for looking!

    Justin
    Last edited by JTR70; Yesterday, 08:54 PM.

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  • JTR70
    replied
    Finishing the install the patch.
    Click image for larger version  Name:	IMG_2514.jpg Views:	0 Size:	210.4 KB ID:	115926 Move back over to the top and finished stitching in the correction patch. In process here of smoothing out the weld shoulder.
    Click image for larger version  Name:	IMG_2517.jpg Views:	0 Size:	198.4 KB ID:	115927 Patch weld seam fully dressed and smoothed out. Just need to finish stitching up the run at the hood gap.
    Click image for larger version  Name:	IMG_2518.jpg Views:	0 Size:	221.3 KB ID:	115928 But before I can do that I have to finish correcting and establishing the gap and height against the edge of the latched hood in through here.
    Click image for larger version  Name:	IMG_2519.jpg Views:	0 Size:	201.0 KB ID:	115929 Steadily getting the final fit and finish I'm after. Leaving this area again for now and heading back over the top and down the outside of that long weld joint.

    Thanks for looking.

    Justin
    Last edited by JTR70; 09-30-2024, 09:24 PM.

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  • JTR70
    commented on 's reply
    Hi Roy, I hated to make those cuts but the nose side had to grow and the fender had to shrink. Once fully welded I'll pound them out together for the final shape. Thanks! Justin

  • roy mawbey
    replied
    Justin those releif cuts again so important !! Its looking good.

    Roy

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  • JTR70
    replied
    Click image for larger version  Name:	IMG_2521.jpg Views:	0 Size:	198.9 KB ID:	115921 The excess 4mm tapered strip was trimmed out and the edges where retacked. Much closer to the overall shape and transition I was after. The other major improvement was that lip of this fenders' distance to the battery box wall was now within MM's of matching the left side.
    Click image for larger version  Name:	IMG_2515.jpg Views:	0 Size:	161.6 KB ID:	115917 Now that this area was settling in I moved back up to the relief cut area.
    Click image for larger version  Name:	IMG_2516.jpg Views:	0 Size:	158.9 KB ID:	115918 While the area on the nose side was still a bit flat and shallow this area on the fender side was too strong.
    Click image for larger version  Name:	IMG_2520.jpg Views:	0 Size:	155.7 KB ID:	115919 I try to avoid changing the shape original panels but at this point it going to have to be a little give and take to get these two to flow together smoothly. Marked out a relief cut on the fender side to allow this area to shrink a little to compensate for the softer nose profile.
    Click image for larger version  Name:	IMG_2526.jpg Views:	0 Size:	131.5 KB ID:	115920 A ways yet to go still but like the area below , it was all gradually improving.
    Last edited by JTR70; 09-28-2024, 07:38 PM.

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  • JTR70
    commented on 's reply
    Thanks Dick! Agree, having a 356 that you're actually driving and enjoying is an enviable position. Looked through all of your shots and your car still looks amazing. Thanks for posting those. Justin

  • JR
    replied
    Great work Justin.
    I have been absent for a while. All I can say is I sure am glad that I have the Roadster done.
    I posted a 'New Event' of our Richmond Porsche Meet that was held a week ago with some pictures.
    Dick

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  • JTR70
    replied


    Click image for larger version  Name:	IMG_2510.jpg Views:	0 Size:	159.4 KB ID:	115889
    Initial tack most of the way down the outside.
    Click image for larger version  Name:	IMG_2509.jpg Views:	0 Size:	191.7 KB ID:	115890
    The panel shape in through the side was already too strong and bulbous.
    Click image for larger version  Name:	IMG_2511.jpg Views:	3 Size:	173.2 KB ID:	115886
    The tack welds just under the relief cuts were released so I could overlap the panels and draw in this profile.
    Click image for larger version  Name:	IMG_2512.jpg Views:	3 Size:	185.1 KB ID:	115887
    While not 100% correct just yet it was all definitely headed in the right direction. A new cut line was etched on the nose side next.
    Click image for larger version  Name:	IMG_2513.jpg Views:	0 Size:	175.2 KB ID:	115888 The next cut line tapers but at its widest I'm removing a good 4 MM's. This is why I was not afraid to make the initial cut; I knew I was going to have remove a little more as the fitment progressed.

    Thanks for looking!

    Justin
    Last edited by JTR70; 09-24-2024, 09:06 PM.

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  • JTR70
    commented on 's reply
    Thank you Roy! While I can't realistically show everything that goes into this I still shoot for a good sample of all the goings on during the process. In the beginning I would just shoot for close with a few tacks then weld it all up and try to correct any short comings after the fact. I've learned the hard way that the final product is much cleaner and nicer to tack weld in series and then reassess and make the needed changes as the panel shapes develop. Especially when you're trying to join reproduction parts with crash damaged originals without the advantage of a jig. I have to take in stages to have any real shot at it. Thanks again! Justin

  • roy mawbey
    replied
    Justin now that was a great advance ! You make it look so easy which I know isn't the case. Since you started theis bodywork 'relief cuts' have opened my eyes to so much I did not know or understand till you had done it a few times. Now its something I will never forget I hope others that look on also begin to realise just how important they are !! I recon that body work is going to look fabulous in the end when you look back on what you have done.

    Your accounts, photos and procedures are better than any book on bodywork repair I have ever read.

    Super !

    Roy

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  • JTR70
    replied
    Click image for larger version  Name:	IMG_2502.jpg Views:	0 Size:	247.3 KB ID:	115875 Continued the same process down the rest of the way. Cut the tacks zipped the joint wider and raised both sides up to soften up the transition to the headlight opening.
    Click image for larger version  Name:	IMG_2504.jpg Views:	0 Size:	235.8 KB ID:	115876 This inner correction section was now finally ready to seam weld up. Moved onto tacking the crown of this joint . Everything was matching up pretty nicely as I made my way to the top.
    Click image for larger version  Name:	IMG_2505.jpg Views:	0 Size:	163.7 KB ID:	115877 A contour issue cropped up once I crested the top and was making my way down the side. A small section of the fenders' edge as it makes the final turn would not draw in to meet the edge of the new nose. The fender has not been damaged in this area so I interpreted it as mistake on the repop side.
    Click image for larger version  Name:	IMG_2507.jpg Views:	0 Size:	171.8 KB ID:	115878 This area had to grow to be able to reach the edge of the fender so two relief cuts were added to allow this to happen. Not perfect but it allowed the needed movement for an initial tack weld so I could move forward. BTW: notice how the top contour of the new nose runs a little flat and drops away from the fenders line a little too quickly. This will need some hammering and maybe a relief cut to correct that line. All part of the fitment and contour evolution.
    Click image for larger version  Name:	IMG_2508.jpg Views:	0 Size:	176.0 KB ID:	115879 Continued tack welding down this initial cut line. This was just some place to begin and like the adjustments made to that upper patch previously this major joint will have to be recut, trimmed, and retacked as its overall shape and contour is developed into a final form that I can live with.

    Thanks for looking!

    Justin
    Last edited by JTR70; 09-19-2024, 07:28 PM.

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  • JTR70
    replied
    Right fender mounted:
    Click image for larger version  Name:	IMG_2494.jpg Views:	0 Size:	199.0 KB ID:	115869 After a grocery list of prep work this right fender was finally remounted for the last time. The fender itself still need a lot of finishing work but it was about as far as I could take it loose off of the car.
    Click image for larger version  Name:	IMG_2496.jpg Views:	3 Size:	155.6 KB ID:	115870 A quick tack was added as a jumping off point but mainly to keep it from sagging and dropping out. This will be just the beginning of a long serious of tacks, readjustment and retacks as the final fitment and contour between these two panels develops.
    Click image for larger version  Name:	IMG_2498.jpg Views:	3 Size:	215.0 KB ID:	115871 Establishing the inside first then working my way over the top and then down the side. After the leading edges of the fender and nose were tacked in their best adjusted position through here the previously tack welded joint along the replacement section became too sharp and deep in relation to the newly attached fender.
    Click image for larger version  Name:	IMG_2499.jpg Views:	3 Size:	226.7 KB ID:	115872 Eventually all the tacks along this joint were cut and the joint was ground opened to allow both sides of these panels to come up slightly softening this radiused turn. This is exactly why I left this area only tack welded until the fender was on for good. I knew it wasn't going to be a match right out of the gate. I never get that lucky.
    Click image for larger version  Name:	IMG_2501.jpg Views:	3 Size:	151.4 KB ID:	115873 Eventually got the continuation profile shape off of the fender I was shooting for. This area is now ready for a final seam weld.

    Thanks for looking!

    Justin
    Last edited by JTR70; 09-18-2024, 09:32 PM.

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  • JTR70
    replied
    Prepping for final install.
    Click image for larger version  Name:	IMG_2478.jpg Views:	0 Size:	217.1 KB ID:	115863 Onto cleaning up the top of the splash pan
    Click image for larger version  Name:	IMG_2488.jpg Views:	0 Size:	160.9 KB ID:	115864 Once the last of the surface rust and tar was cleaned it was onto a good coat of epoxy.
    Click image for larger version  Name:	IMG_2487.jpg Views:	0 Size:	180.7 KB ID:	115865 And then the deep corner of the fenders underside.
    Click image for larger version  Name:	IMG_2491.jpg Views:	0 Size:	218.6 KB ID:	115866 Then a coat of black once the sealer cured and was scuffed.
    Click image for larger version  Name:	IMG_2490.jpg Views:	0 Size:	221.9 KB ID:	115867 With the deep blind surfaces cleaned and sealed its getting very close to final installation time for the right fender.

    Thanks for looking!

    Justin
    Last edited by JTR70; 09-17-2024, 06:39 PM.

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  • JTR70
    replied
    Final trim:
    Click image for larger version  Name:	IMG_2473.jpg Views:	0 Size:	208.0 KB ID:	115854 Much less stressful to commit to an initial cut line on this side. It has been consistently a half inch wider over here so as fitment progresses I only need it to come in tighter so no chance I'll come up short after this first cut.
    Click image for larger version  Name:	IMG_2475.jpg Views:	0 Size:	181.7 KB ID:	115855 Trim line etched and first trim in progress.
    Click image for larger version  Name:	IMG_2480.jpg Views:	0 Size:	176.9 KB ID:	115856 Getting very close to final installation. Decided now was the time to begin lifting out some of that old accident damage through the side of this fender. I thought this damage was part of the big front end collision but it seems its a separate accident. Something went down the side of it and remnants of the crease it made could still be detected.
    Click image for larger version  Name:	IMG_2479.jpg Views:	0 Size:	212.0 KB ID:	115857 Began shrinking and lifting out the big and obvious areas down the sides. Also planishing out the weld joint while I was at it.
    Click image for larger version  Name:	IMG_2486.jpg Views:	0 Size:	188.0 KB ID:	115858 Not finished working this surface but the basic profile shape was much improved. I'll chase it further once the edges of this fender are mounted and locked into their final positions. Onto more prep work for final installation next.

    Thanks for looking.

    Justin
    Last edited by JTR70; 09-16-2024, 07:22 PM.

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  • JTR70
    replied
    Click image for larger version

Name:	IMG_2470.jpg
Views:	60
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ID:	115848 Promising start with back edge contour shape and fitment but I'll know more once this edge is actually heeled all the way over and pinched tight to the splash pan flange. By contrast the wired lipped edge on the other side is going to need a bit of reshaping for a seamless flow. It also may require a little alteration on the fender side. I'll be crossing that bridge here shortly.
    Click image for larger version

Name:	IMG_2471.jpg
Views:	53
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ID:	115849 But now, back to shaping this upper run of the flange.
    Click image for larger version

Name:	IMG_2472.jpg
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ID:	115850 A little torch heat to make life easier on everyone. Entire run now into a good basic 90 degree angle.
    Click image for larger version

Name:	IMG_2476.jpg
Views:	51
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ID:	115851 Fender dismounted once again so I could tighten up the flange shape a little further.
    Click image for larger version

Name:	IMG_2474.jpg
Views:	50
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ID:	115852 With the back edge of the fender all but set I could now move forward and dial in the final trim line for the nose. This up next.

    Thanks for looking.

    Justin

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