Coupe into Speedster Conversion

[JTR70]

Thanks for the "Komenda-Commendation" Jack! but I'm just a hobbiest hack with a wire-welder and a lot of cardboard to make templates with.
Thanks again! Justin

2/29/14
Left side inner flange repair in steel.

basic part trimmed out of steel and in for an initial fitment.

Had to pie-cut two reliefs into the face so the mount flange would hug the embossment at the top as it did before. Back filling the spaces here.

New piece fully welded and dressed here. You can clearly see how the inner flange in no way runs parallel with the outer flange.

Very similar to the way it came from the factory but a bit beefier with that heavier gauge square stock in there...

Mounted again to make sure it still fit like it was supposed to.

Couldn't be happier, fits just like its paper cousin.

Anchor plate flange will be eventually plug-welded onto this new inner wall as it was done originally.

Will cap the bottom up tomorrow and begin the right side inner flange.
Thanks for looking! Justin

[Carrera_The_Kid]

Man, Justion I thought I had been up close and personal with a 356 from time to time but this takes it to a whole different level.

Given the scope of your project would an investment in a good spot welder be warranted? I can imagine it would safe you a ton of time having the grind plug welds.

Cheers,

JK

[merbesfield]

Justin, looks awesome. Do you feel like you should keep your paper Origami patterns after you finish a part? I always feel like I should save them, but eventually the become trash or smaller patterns. If you buy a spot welder, don't go cheap and buy one of the many Chinese crap units, they suck. I have one and for a few spots here and there they are ok, other than that, it's a boat anchor. Buy a good one. The small units are ok, but limited. Eventually you would need a much bigger unit. I am sure by now your manual spot technique has gotten to point of minimal after grinding. Thanks for posting.

Oh yea, do you use a camera or cell phone to take pics?

[Murf]

a master class ,, many thanks as always from Bangkok

[JTR70]

Thanks a lot Murf, So glad you find this worth following!

Hey Joris, If I have my MIG all dialed in as far as wire speed and heat there really isn't very much to grind off. I don't entirely trust spot-welders for thorough penetration through two panels but I'm probably being a little paranoid from all the horror stories I've heard about panels breaking free. When I need to replicate a spot weld my little panel welder can handle that job going over my dresses plug-welds. My next welder purchase is going to be TIG so another spot-welder isn't even on my radar at this point.

Thanks Mark! yeah, I save a few of them if I keep them from getting wet or crumpled up.

Here's that battery floor pattern from my coupe along with several others...

Here are the one's from this job and like you mentioned some are repurposed for other patterns or get ruined by accident. I think 99% of these will never be used again and its more accurate to make a new template for the current job in front of me. Most of the time anyway..
These photos are all taken with a digital camera.
Thanks again you guys!!!
Justin

[JTR70]

4/1/14
seat pan and Cross-member ready for final install

Always a nice timer saver to be able to reuse a template by flipping it over for the other side. This one was as simple as turning the mount flange the other way.

New part ready for test fitment.

Fine trimming and adjustments next but would not take much. Inner embossed knockout cut and rewelded level here.

new section now welded in making the final required repair before permanent installment complete.

With this repair done I've gone about as far as I can go. I'll need those new panels from Steve Hogue first. They should be on their way to me before the week is out.



All repair panels fitted for a quick mock up

So rewarding to see solid metal in these blind corners again.

A lot of time and prep just to get this far.

Again none of this stuff can be welded in until the new frame runners are fully installed however with this stage now set with all the panels and parts ready I should make some very good headway in the next couple of weeks. Thanks for looking! Justin

[Jack Staggs]

Thanks for the "Komenda-Commendation" Jack! but I'm just a hobbiest hack with a wire-welder and a lot of cardboard to make templates with.

Get out your torches Funny, I just received a current early 911 muffler direct from Porsche and the entire assembly was gas welded, and quite sloppy as well... just like the old days

[JTR70]

Probably Chinese...

[Jack Staggs]

Maybe, but stamped in the normal location "made in germany" with the 911 part # stamped after it, all with good lettering and spines on the muffler inlets as og, not like Dansk. I liked it.

[JTR70]

4/7/14

Sort of hit a wall in progress until the new parts arrive but just heard from Steve this morning and they are on the way so I should have them by Wed. Here's a couple of photos he enclosed of what's coming.

Beautiful of course!

I had sent Steve photos of the cut chassis and told him I just needed the panel up to the edge of the shock embossment. As you can he must have forgotten and made each length past the embossment. I feel terrible because I know some time was spent knocking and shaping those in. I'm tempted to use the entire thing so they don't go to waste but I'll most likely end up cutting them. We'll see after they get here. Thanks for watching! Justin

[JTR70]

4/9/14
New frame sections from Steve Hogue arrive today!

Everything I need to rebuild the basic end of this frame.

I went back and forth several times in my head as to weather I'd use those pockets or cut them ahead as I originally had planned.

I decided to begin with the right first. I finally decided on this side anyway to include the pocket as the lower flange on this side was in need of replacement anyway. This also gives me a chance to address the rust in between the outer plate and this inner wall. I would be cutting the anchor plate free as I had done previously on the left side.

Anchor plate removed and in for its initial test fit. Punched in the hole for the shank. Fresh metal sure changes the outlook!

As you can see I jumped the gun and cut a forward section out before I had changed my mind again to use it all.


Continuing to message this in tomorrow. Thanks for looking! Justin

[JTR70]

4/11/14
Right side repair section ready to install.

Once I began peeling back this section it quickly became apparent that this was the right decision. A lot of heavy advanced rust leaving this outer wall very thin and weak.

Shock reinforcement plate was thoroughly wire wheeled then treated with rust converter. All ready to accept the new panel here.

The rest of this chassis is set at level and am making sure this new panel is also oriented at level.

Some very minor trimming, wiggling and heating to do but the overall fit is pretty good. That Steve Hogue makes a nice panel!

Holes are punched for the plug welds to the shock plate. Will weld this in for good once I double check the measurements and orientation.(tomorrow)
Thanks for looking! Justin

[roy mawbey]

What a nice repair you have made there Justin. Steve does make some super repair panels. good decision not to cut. It never ceases to amaze me just where the rust can get to out of sight but in your case, not out of mind.

Roy

[JTR70]

Thank you very much Roy!

4/12/14
New panel in
After few slight modifications this new panel was now ready to be welded in.

During the test fits I noticed that the bottom flange over-shot the aft seat flange section and would not line up in its best adjusted position.

Once I got to studying the original on my car I realized it was a factory fitment issue as well. You can see here how flange is folded over tight to double-back so a secondary bend can create the proper alignment.


Double bend all finished here. Actually I had to straighten the initial flange and rebend this section for a better approach angle.

Par for the course; you have to make these new parts work for your specific application.

New section all but stitched in now.

Some heat was required at the top so it would conform tightly to the crown of the shock plate. A touch more welding to do but I'll have it knockout by next session and will move to the left side. Thanks for looking! Justin

[Phil Planck]

Justin
Looking good. On Foamcar that panel is 18 ga. Some of the thickest metal on the car. Harder to form.
Phil