Coupe into Speedster Conversion

[JTR70]

Bruce, thank you very much for saying that! A very generous compliment coming from a long time Porsche expert. Probably more than a regular 356 grunt like me deserves but I'll take it! Seriously it is greatly appreciated, thank you again Bruce!

Justin

4/30/15
Been dealing with a lot of loose ends and a couple of redo's so its been hard to get motivated to post an update but here are a few things from earlier this week.

While sucking up this corner to fit within the A-pillar flange I was having a real time trying to get it to lay or orient right with the A-pillar.

After a direct comparison with the original it was clear that shaped profile was also off at this corner. It swoops out and away too much at the top.

The left side profile match comparison.

Cutting a relief along the raised profile allowed the necessary overlap to bring it in line with the original. With this little tuck it immediately fit so much better. The new flange was tacked on shortly after.

With both corners now tacked and reset it seemed like the right time to catch the rest of the dash duties up. I began making a profile template for the final shape and cut length of the cap.

The end of the cap stops and profiles right along the edge of the lower WS frame.

Once I had the pattern, final shape-cutting to the leading edge of the cap began.

left defroster vent was next on my mind.

Began making a template for both shape and location from the original.
More tomorrow. Thanks for reading this! Justin

[JTR70]

5/2/15
More left defroster vent from earlier this week.

Template now transferred to the car to see how the vent horn was going to line up.

With rubber collar in place was the real tricky part.

Had a hell of a time getting the horn to stay in position but a pair of hose clamps turned the trick.

Within striking distance. now onto metal.

cap in place to mark the initial cut line. An original vent cover tried here to see how if it was going to look okay.

Initial cut line in. Edges had to be carefully flanged over by hand next.


Slowly flanged in stages and staying true to the curve was tough. The basic shape is crude but I'll clean up the lines as the horn gets welded in. These flanges also stiffen this area so I may have to stretch or shrink them to correct the top profile as its all welded together but will cross that bridge later.

It took some doing but by sessions end the horn finally fit the opening.

Again following that shape was tough but its in; one more to go.


I brain faded, I got so caught up installing that hole that I forgot to set and locate the cap completely. I only had this one screw in during that procedure. that's just asking for alignment trouble.

Installing them here along the corners to finalize its position. The gauge relief makes this area contort a bit so more screws closer together were needed on this side to draw it up tight. Should have done this before I cut that hole! I think I'll just get away with it; I think.

Alright, dash is officially in its final set-screwed position.

General profile still looks right.

Definitely wanted it set before I install that next vent hole. I'm sure I'd have run into a problem if I had not finished setting the caps position first. Another lesson learned...until I make the same mistake again.
More post catch up tomorrow.
Thanks for looking! Justin

[JOP]

Good work Justin, you have spent more time on your pre fab dash with cutting, drilling, beating and welding than Porsche used to assemble a 356 back in the good old days!

I have seen more replica parts getting available and I do hope they are of a higer quality that does mean a simple and straighforward build. Anybody reading your story would not take a chance on getting it right unless you had a tub or a nos dash laying around to compare it with.

( the value of the real thing needs to double before I spend my hours and attempt any Coupster project )
/ Per

[JTR70]

Thank you Per! Yes, the factory probably could of had several cars made by now. Agree, I'd be at a complete loss without that original dash here and I am curious as to what other guys doing a similar conversion are going through. Hope its not just me.
Thanks again!!
5/3/15
Finishing up left corner. Before the vent horn goes in for good I wanted to get the corner built and set.

Trimmed the excess off the flange over the arch to replicate the original. Cap would be mounted on the original dash next to profile shape what remains of this corner flange.

After some heat and careful pecking the flange was shape-profiled to my original dash. As you can see the face is just a bit too tight.

I decided to cut a relief in to allow the face to be drawn into the flanges new shape with set screws.

New extension piece was cut and ready for a tack-weld here.


Slowly heating and heeling it over beginning from the inside.

trimming and tack welding continued.

The original shape is a soft turn and the initial shape was too harsh so a little dolly work was needed before it was welded up.

Basic profile good after welding. The heat and working has hair-lipped the outer flange of the cap but I'll fix all of that when the horn and final mounting begins.

Its looking more and more like the original so this keeps me calm.
Wrapping up this corner next. Thanks for looking! Justin

[roy mawbey]

Justin,

That last series of photos were really great. My goodness what a lot of work to get to this stage. From now on every Speedster dash I see at at a show will be my first port of call. That has been a real challenge to convert from coupe to speedster. So much of the work you will never see, but you and all of us know now, its not a bodged up job. Well done indeed.
By the way over here we call those 'clips' by the name of 'jubilee clips' they have got me out of trouble many times.

Roy

[JTR70]

I really appreciate that Roy! I know what you mean, this has been far more work than I could have imagined the day these panels showed up. I too have a new appreciation for a fully built cowl and dash assembly. Thanks once again! Justin

5/7/15
Left corner and vent just about complete.

Began fitting the original vent to the new opening.

The horn is such an odd-shaped piece that finding the sweet spot for both good alignment for this rubber collar and good uniform fit up at the mouth proved challenging as it fought me all the way.

I was eventually able to lay down the first few tacks starting from the center inner lip out to the ends. I figured it best to leave the outer lip for last for any last minute manipulations to the edge of the cap.

perimeter synched up to the cowl then the tack welds were added to the outer run of this opening. Basically set here.

Another test fit with the vent cover. Could not have turned out better as far as contoured orientation and placement with the edge of the cap and the gauge relief. I'm just glad that rubber collar still fits underneath after all of this.

A few loose ends still to tie up before its over but this corner is now basically built at long last.

Beginning templates for the right side now. I'm hoping this side will go easier as its smoother and less complicated but we'll see.
Thanks for looking! Justin

[Jack Staggs]

Does the wooden "eyebrow" fit this wonder dash?

[JTR70]

Eye brow fitment was one of my initial issues several weeks ago Jack. The face profile would not allow for it to seat flush so it had to be relaxed in the corner.

If you mean the general profile of the relief hump in relation to the profile of the eye-brow then I actually caught a small break on this one.

They contour out okay.

Once all is said and done I should be able to draw these two up tightly enough as the dash covering will mount between these two anyway.

[JTR70]

5/18/15
Was out of town last week so these next couple of updates were completed before I left and are a bit dated.

Right defroster vent.

Template with defroster horn mocked up and set. Ready to transfer the pattern onto the cap once it remounted.

Hose clamps again held her in the correct position as it progressed.

Marked and ready for the cut down the middle.

Some nice confirmation came with these "landmark" punch detents made by the manufacture. This outside corner lined right up.


Inner corner also lined up pretty close. We are either both right or very wrong. Actually its about right as it lines up with my original dash.

Cut and flanging the edges.

For the small amount of rewelding required to attach the outer edge I found it loads easier to have it out of my way as the flanging went along.

Inner lip flanged and horn tack welded into position.

Outer section shaped and now ready to be tacked back on. leading edge now ready to be shaped next.

Vents now set.

Reskinning this corner is next.

Ever so slowly...but surely.
Thanks for reading this!
Justin

[JTR70]

5/19/15

Right upper corner of cap.
Decided it would be much cleaner and easier just to begin with a fresh piece instead of trying to save the old one.

secured to the original dash which once again became the hammer form to carefully heat and spoon this section over.

A very promising initial shape but the grab-handle hole ended up being to low some how. Had to close and reposition it.

Closer still but lots more contouring yet to come.
Thanks for looking! Justin

[JTR70]

5/21/15

Rough shaping the dash complete. Now cleaning up the mess in prep for install.

New corner section welded on and in basic contoured shape. A bit more pecking an filing but I have a complete cap now.

Very hard to believe after all that has been required but with this piece in I am now officially done roughing in this dash assembly.

I have completed all the cutting, adding, and subtracting that I need to for a basically correct speedster dash.

Now with the final shape established I can begin stitching up all this mess.

Another chance to practice with the TIG.

The outlook is so much brighter with this corner in one piece. Working on the left side tomorrow. Thanks for looking! Justin

[merbesfield]

What is your feeling on the TIG at this point? I have been thinking about one but what concernes me is the fact that so much of the metal we work with is crap and I know TIGs don't like dirty metal.

[JTR70]

Hey Mark, My opinion is that the TIG is a superior weld in every respect over a MIG. As you know MIG welds are very hard and prone to fracture. The TIG remains soft and doesn't crystalize the work like the MIG. It also grinds and finishes so much easier than a MIG weld! Also the TIG is a much more thorough meld throughout. Its a complete flow right out to the edges of the weld bead. As you grind finish a MIG weld the edges of the bead are not thoroughly incorporated and are sort of stuck to the surface of the work no matter how hot it went on.
However, there is a trade-off. The TIG requires much more finesse and practice to get right. Its also more trouble to set up. A MIG is easy and quick as you know AND yes the metal doesn't have to be perfectly clean. You can't beat the MIG for a quick tack and for plug-welding; its just easier and simpler. I'm glad I know have both and would not consider doing without either one at this point.
5/23/15
Loose ends on the right side.

It was just easier to stitch this corner most of the way up with the MIG as it had a lot of air gaps Mark.

Filling all these damn drill holes from that reinforcement plate that had to go was also easier with the MIG.

I'll stitch it up the rest of the way with the TIG and go back over the MIG seams to stress relieve those areas.

So close to final install time.

Corner now gone over with the TIG for much needed practice. A few hiccups in there but I know that its thoroughly bonded.

With that corner welded up I spent the rest of the session pecking and filing the upper leading edge of the cap and going back over the corners of the face.

At this point these two pieces are finally ready to go back together for good. At long road to get here but I finally made it.
Punching plug weld holes next.

Holes punch and dash assembled and fully mounted one more time to make doubly damn sure nothing changed on me!

While the worked areas are smoother I of course could have spent even more time filing and picking to get them better but I had to draw the line here as I have spent so much time just correcting these pieces that its no longer practical to chase them further. Its close and will only take a swatch of filler to be perfect. I think my original dash at this point is this rough.

dismounted and began gluing it back together at the cluster.

Finished the welds in prep for another important test.

The Eyebrow fits flush!

Will have this welded up by tomorrow and just maybe I can begin actually welding this piece in for good before the sessions out.
Thanks for looking! Justin

[John Pierce]

Justin,

Looking with 20/20 hindsight, it would've been easier for you to have made the piece yourself. What a calamity!! I hope the manufacturer is following your build blog to see where improvements can occur. Great job you did, but very costly and time intensive.

John

[roy mawbey]

Yes I agree with John in hoping the supplier can improve the items. I honestly think a high percentage of us would have just given up long ago on this area of fabrication and welding.
I said before without suppliers actually making formed repair area's it would be most difficult to get anywhere near what they achieve at the moment without having the tooling they use. So, actually I think home restorers are in their hands and have to rectify by any means the items sent.

As a press toolmaker till I changed profession in my late 20's to sell machine tools and demonstrate them, rather than use them, I would say the inspection fixtures for pressed items are the most important items they need. Not impossible to produce providing, they have original items to make use of. Of course many of these items do not employ the use of a punch and die, they need the skill of the man making them. So much easier if the punch pushes the sheet steel into a formed die! But... hell, the cost involved then these days, would be very high as also needing the correct press to use them.

I have really every regard for the hand formed parts, its just the fact they need to be inspected properly at a number of areas around the form. They never will be perfect in my opinion, but could be much closer than Justin's were.

He needs a clap on the back for his effort. Great thread reading though

Roy