Announcement

Collapse
No announcement yet.

'63 356B T-6 Rebuild

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

  • John,

    That welding and preparation looks so good!!!

    Roy

    Comment


    • I've owned a couple of 356 coupes and really enjoy the coolness of the greenhouse in the summer. Hah!! The OEM air conditioning (front vent windows) doesn't live up to expectations, though. I've always liked the look of a sunroof 356, so I thought: why not install one?!!


      Click image for larger version

Name:	1_2017-12-22.JPG
Views:	129
Size:	103.3 KB
ID:	95255
      Back in 2014 Adam Wright had a 356 C clip for sale, which was not too far from me, so I bought it. It was missing a few parts, but I thought: how hard can it be to find 50 year old SR parts? Shouldn't be too bad. Right!!


      Click image for larger version

Name:	2_2017-12-22.jpg
Views:	130
Size:	25.8 KB
ID:	95256
      Some parts were NLA, like the SR cover inside frame. I was lucky to have a local friend who had one that was apart so I took measurements and made some drawings.


      Click image for larger version

Name:	3_2017-12-22.jpg
Views:	129
Size:	26.3 KB
ID:	95257
      It turned out pretty nice.


      Click image for larger version

Name:	4_2017-12-22.JPG
Views:	119
Size:	50.8 KB
ID:	95258
      Over the course of several years I was finally able to locate all the missing parts


      Click image for larger version

Name:	5_2017-12-22.JPG
Views:	122
Size:	47.4 KB
ID:	95259
      It was actually fun tracking them down and I was able to meet a lot of nice Porschephiles along the way.

      The saga continues.......
      jjgpierce@yahoo.com

      Comment


      • The Golde sunroofs have front and rear drains. The front drain travels along the A-pillar then under the dash then out the door well. The rear drain exits from the side of the C-pillar in the T6 cars. The rear drain on earlier cars exited into the engine bay.


        Click image for larger version

Name:	6_2017-12-23.JPG
Views:	119
Size:	66.7 KB
ID:	95265
        This the the donor right A-pillar with the OEM plastic tube inside the U-channel along the inner edge of the A-pillar. The tube is held in place with caulk.


        Click image for larger version

Name:	7_2017-12-23.jpg
Views:	137
Size:	60.1 KB
ID:	95266
        After tube removal and media blasting. The U-channel was not in the best of shape after 50 years.


        Click image for larger version

Name:	8_2017-12-23.jpg
Views:	136
Size:	96.6 KB
ID:	95267
        Time to make new U-channels out of 20 gauge CRS.


        Click image for larger version

Name:	9_2017-12-23.jpg
Views:	131
Size:	123.1 KB
ID:	95268
        Finished product. Instead of arc welding the top and bottom as OEM I added 3 holes for spot welding.


        Click image for larger version

Name:	10_2017-12-23.jpg
Views:	132
Size:	53.4 KB
ID:	95269
        Installed and primed. I added the oval hole in the lateral portion of the dash to accommodate the plastic drainage tube.


        Click image for larger version

Name:	11_2017-12-23.jpg
Views:	118
Size:	39.0 KB
ID:	95270
        I added a hole above the speaker cut-out for the drainage tube to enter the door well.


        Click image for larger version

Name:	12_2017-12-23.jpg
Views:	117
Size:	49.5 KB
ID:	95271
        I added a hole in the foremost portion of the door well floor. The drain travels behind the speaker cavity buttress so it doesn't get caught on the door when opened and closed. The water then drips out the bottom of the car.


        Click image for larger version

Name:	13_2017-12-23.jpg
Views:	116
Size:	47.5 KB
ID:	95272
        The passenger side was a little tricky as the T6 cars also have a metal drainage pipe from the cowl.

        Onto the rear drain.....
        jjgpierce@yahoo.com

        Comment


        • John, interesting project -applying some nice thinking, skills and ingenuity. Good job
          1960 356B T5 - under major resurrection.
          356 Registry main thread;
          http://forum.porsche356registry.org/viewtopic.php?f=4&t=35854
          1968 912 - running like a scalded cat.

          Comment


          • You're doing a nice job on this conversion John! Did you buy that entire clip as pictured or just the roof. It seems you could have used those rear fenders as well. (before you fixed them)
            Justin Rio

            Comment


            • Hey Justin. I bought the rear clip as shown in the first picture. Once everything was media blasted things did not look as good as originally shown. During the rebuild of my B-pillars and rear longitudinals I was able to use the OEM clip dimensions to help rebuild my car. The rust worm got ahold of some of the clip metal and it was better to make replacement parts with fresh metal.
              jjgpierce@yahoo.com

              Comment


              • Onto the rear sunroof drains.


                Click image for larger version

Name:	14_2017-12-30.jpg
Views:	117
Size:	42.1 KB
ID:	95393
                The rear sunroof drain empties out of a hole in the C-pillar in the T6 cars.


                Click image for larger version

Name:	15_2017-12-30.jpg
Views:	116
Size:	57.4 KB
ID:	95394
                The factory placed lots of lead in the drainage hole and around this area to give a smooth transition.


                Click image for larger version

Name:	16_2017-12-30.JPG
Views:	130
Size:	73.6 KB
ID:	95395
                Unlike the front drains, the rear drains flow from one metal drain to a second metal drain, connected by a short piece of plastic tubing. Cars earlier than the T6's had a plastic drain emptying beneath the engine bay.


                Click image for larger version

Name:	17_2017-12-30.JPG
Views:	126
Size:	33.9 KB
ID:	95396
                The drains are easier to see after media blasting. The inner roof edge was also cut back to accommodate the metal drain. The holding tab was spot welded to the rear window flange and sandwiched between the quarter window flange.


                Click image for larger version

Name:	18_2017-12-30.jpg
Views:	127
Size:	58.2 KB
ID:	95397
                I cut both rear drains out of my clip for deconstruction. You can see how these were installed by the factory.


                Click image for larger version

Name:	19_2017-12-30.jpg
Views:	113
Size:	52.6 KB
ID:	95398
                The extraneous metal was removed leaving just the drains, which I primed as they cannot be primed after installation. I had to remove a lot of OG lead from the bottom of the drains. They will be installed next.

                Thanks for following and Happy New Year to everyone.
                jjgpierce@yahoo.com

                Comment


                • Now for the big leap. Sunroof deconstruction and transplantation.


                  Click image for larger version

Name:	20.JPG
Views:	121
Size:	59.0 KB
ID:	95522
                  The sunroof frame has 2 front braces and 3 braces along each side to stabilize it.


                  Click image for larger version

Name:	21_2018-01-07.jpg
Views:	120
Size:	67.4 KB
ID:	95523
                  The front and sides of the SR opening are flanged then spot welded to the SR frame while the rear flange is longer and bent 180 degrees to wrap around the frame cross brace.


                  Click image for larger version

Name:	22.jpg
Views:	131
Size:	62.6 KB
ID:	95524
                  Ron Roland and Jim Kellogg list 4 ways to transplant a sunroof. I chose the method of cutting out the SR frame and leaving a piece of donor roof around the edge which will be flanged for welding. After lots of reading and contemplation I thought that this would be the easiest approach and least fraught with potential misalignments.


                  Click image for larger version

Name:	23_2018-01-07.jpg
Views:	125
Size:	85.5 KB
ID:	95525
                  The process began by taking LOTS of measurements to ensure proper alignment.


                  Click image for larger version

Name:	24.jpg
Views:	126
Size:	105.8 KB
ID:	95526
                  Each 356 was manufactured with holes in the windshield which allowed good points of reference.


                  Click image for larger version

Name:	25.jpg
Views:	112
Size:	77.7 KB
ID:	95527
                  I then made templates of the correct roof curvature so I could replicate it on the recipient.


                  Click image for larger version

Name:	26.jpg
Views:	103
Size:	57.2 KB
ID:	95528
                  Template for the side curvature. A rear opening curvature template was also made.


                  Click image for larger version

Name:	27.jpg
Views:	106
Size:	75.6 KB
ID:	95529
                  Boom!! 2.5 cm front and side flanges with a 7 cm rear flange to incorporate the frame cross brace.


                  Click image for larger version

Name:	28.jpg
Views:	121
Size:	76.7 KB
ID:	95530
                  Naked frame.


                  Click image for larger version

Name:	29.jpg
Views:	118
Size:	68.0 KB
ID:	95531
                  Sanded and primed leaving bare metal at the areas to be welded.


                  Click image for larger version

Name:	30.jpg
Views:	120
Size:	54.9 KB
ID:	95532
                  Now to take a deep breath before cutting into the recipient!!

                  John
                  jjgpierce@yahoo.com

                  Comment


                  • John
                    Great documentation and we'll thought out plan of attack.
                    Phil

                    Comment


                    • looks like your taking your time fit up is crucial. from your past work i'm sure it will look great.
                      I didn't know the drains came out the side like that. It seams crude that a manufacture would do that when it could have been run on down into the wheel well area. maybe they figured more tube more area to plug up.
                      Jay D.

                      Comment


                      • John, it is a treat to see your usual superlative work.

                        I, too, always wanted a sunroof if I owned/drove a 356 Coupe (other than my "commuter" '53s [51604 and 51605] in the '60s). When I sold my last Speedster a few years ago, I bought a '58 A Coupe and decided that I was either going to re-do it to look like a "Speedster with a Hardtop" or better yet, just put a sunroof in it. The need for more headroom and less time involved won. Eventual better resale value won over 'outlaw' as well. Bad enough it has 'numbers unmatching' disc brakes and a late, late .10 trans and a betterer C/SC/whatever-I-had-laying-around unmatching engine.

                        You wrote: "Ron Roland and Jim Kellogg list 4 ways to transplant a sunroof. I chose the method of cutting out the SR frame and leaving a piece of donor roof around the edge which will be flanged for welding. After lots of reading and contemplation I thought that this would be the easiest approach and least fraught with potential misalignments."

                        Hummm, perhaps my way of doing mine was wrong?.......I did it the way Golde did it.

                        I will dig up pictures, but a few years ago I took the added parts I needed from a 'clip' I had traded time for on a Cabriolet resto. The owner of the Cab had originally intended to put the sunroof in a Cab hardtop, but the costs of his standard restoration eliminated that desire for gilding of the lily.

                        I cut a hole in my Coupe's roof, leaving the same amount for a flange as the clip. I bent the edges over carefully a little at a time and added "handles" for leverage on my shrinker tool to form the correct contours as I went (the roof is just sheet metal), then welded in the additional pieces harvested from the old clip under it.

                        Granted it's mechanically operated, has a more simplistic drain system and slightly smaller panel, but it was leaded all around, here and there, originally, so.......leading (ledding ) is to me preferable to a perimeter butt weld. To each, their own, right?

                        I just took in an SC Coupe with a sunroof and the correct rear drain outlets and the patient long-waiting long-time owner told me he had that installed decades ago, so when it is stripped I will get to see how that was done....just curious is all.

                        Keep up the great work as an inspiration to all of us. Rumor has it that your next change to your shell is the rear engine surround for that 2 liter 4 cam engine you found years ago..........I can't wait.......

                        Best for the New Year,
                        Bruce

                        Comment


                        • John,

                          Your method is very well explained and great photo's. I would have really liked a sun roof on my 'A' but it wasn't there when I bought it and its a big job to take on if thats the case. Great though on a hot day with vinyl seats!

                          Good thread!
                          Roy

                          Comment


                          • WOW! Almost time to take the plunge...Nice work and planning John.
                            Justin Rio

                            Comment


                            • Thanks guys! I got some time to work on it this week and will post some pix.

                              Bruce: I read about the way you did it like OEM and Ron liked that way the best also. In retrospect, it might have been a better way to go as there is less heat introduced that results in metal warpage. I'd like to see those pix if you find them.


                              Cheers,

                              John
                              jjgpierce@yahoo.com

                              Comment


                              • The funny thing is how many of the 911 crowd are removing their factory sunroofs in search of lightness and maybe, "thread cred". I love sunroofs, at least nice factory versions. John.

                                Comment

                                Working...
                                X