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Henry

'79 SC Rebuild (with 3.6 install)

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I bought my first 911 just over a year ago very exciting to say the least , after running around in my Nemo box van for a year it was fantastic to have a real car again come the weekends .

I ran the car for the summer and then started to address the COUPLE OF RUST SPOTS. When I bought the car I was aware of rust in the B posts around the striker plates and that the sills had been replaced both sides a couple of years back so hoped they were ok at least.

I have been a bit slow posting, thinking it would be a quickish repair and paint but the repairs have quickly snowballed! so some help and advice along the way may well be needed!

I started the work mid January so i am some way down the road . I was fortunate being able to take a bit of time out between jobs and get stuck in.

 

 

 

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Nice one Puddy :)

Let's see some pics then .......

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post-7780-0-56231800-1396905104_thumb.jpg Thanks Ben ,only have a few and not the best of the before pics , heres a fewpost-7780-0-24048100-1396905252_thumb.jpgpost-7780-0-15154600-1396905495_thumb.jpgpost-7780-0-49127200-1396905616_thumb.jpg hoping to get to grips with my pics tomorrow and post some of the work to date.

 

cheers Henry

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Car upon ramps waiting for engine and box removal , bought myself the Bentley manual and folowed my instructions , not to bad !post-7780-0-68114200-1396984221_thumb.jpg

 

Suspension components looked very scabby showing their age so at this stage the plan was sort the body and refresh suspension so off it all came .post-7780-0-53616200-1396985237_thumb.jpg

Amazing the amount of space needed for all the bits as the pile grows.post-7780-0-00405300-1396985907_thumb.jpgpost-7780-0-00405300-1396985907_thumb.jpg

Removing the tortion bars was no fun at all, in the end it took a lot of heat to free them , so I am thinking I am going to need new bars ? Which is a shame as when they came out they looked brand knew . Added to the list of jobs was nasty looking spring plate bush housings.

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A big sigh seeing this when I finally managed to get the tortion bars out, tackle those later after a bit of searching online for the best remedy.

 

Sills and kidneys next, drivers side had half a new sill fitted over a badly repaired inner sill a right bodge kidney had also been replaced badly over a patch in the panel below so both came off , repairs done and new panels fitted . At this time I was treating new work with epoxy mastic and also injecting dinitrol into any cavity I could wave my wand at].post-7780-0-98568400-1396988645_thumb.jpgpost-7780-0-61378800-1396988934_thumb.jpgpost-7780-0-69233700-1396988991_thumb.jpgpost-7780-0-85443900-1396987095_thumb.jpgpost-7780-0-71561900-1396987183_thumb.jpg sorry about the picture quality and sequencing still learning the uploading ropes!

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I had to fill in the indents on the new porsche sill to back date it from later 993 a bit of a faff but didnt take tooo longpost-7780-0-58901400-1396989899_thumb.jpg

 

Kidney and sill fittted I switched to the other side , after cutting off the kidney end of the sill so I could have a good peer inside I was surprised to see a good job had been done fitting a new inner sill before the new outer was put on around a year ago.,after that good work I was amazed to find that they fitted the new sill to a rotten kidney !how they could do that mind boggles . had to do a repair beneath the kidney before new was fitted and completed post-7780-0-04514300-1396991124_thumb.jpg

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Good work there Puddy you look like you know what your doing .

Are you self taught or your profession ?

Cheers Kenny

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After soughting out both sides of the car I still had to carry out repairs to the front bumper mounts , a big hole by the oil tank cap,along the top of one inner wing and it also looks a bit ropey at the window corners after taking out the screen out, whilst all doable and with the use of rust converters should last a fair while I hate the idea of any rust being left on the car and after much thought I decided as the car was pretty much in bits I would go the whole way and and get the shell dipped to get rid of all the rust , it will also save me a lot of time stripping all the paint before being resprayed to.

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Hi Kenny , no I am not a professional , I am a builder by trade my brother however used to restore old cars profesionally and I did work for him for a while this over 20 years ago , my second car was a triumph Gt6 which with my brothers help I restored and then did a BMW 2002Tii fairly soon afterward for myself , definatly should have kept that one . My brother left the car world soon after to set up a metal sheet engineering buisness , which is still very lucky for me as he can just about make anything out of metal and also has a powder coat oven v handy! Which I am planning to put to good use v soon.

 

Henry

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post-7780-0-08975200-1397026500_thumb.jpgrepairing the springplate bush housings . One side not as bad as I thought after a good clean up with wire brush on drill , just a few pin holes which I filled with weld and ground down back to shape .The other was a more serious so all rot was carefully removed with a die grinder ,fortunately the rot had not gone beyond the flange of the sandwiched panel which reinforces the area so my brother turned a new cup sectin on his lathe and I was able to plug weld through to the flange and get some weld on the inner end of the cup as well as welding the outer edge back as original ,pleased with the result.

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post-7780-0-99342800-1397027553_thumb.jpgpost-7780-0-30176400-1397027607_thumb.jpgPreviously bodged repairs to lower rear wings on both sides needed to be soughted befor going back on.

 

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Thats as far as I have got with the body work , I spent a week stripping the car completely and boxing and lableing every thing as best I could as its amazing the amount of stuff you have to remove to get to a bare shell. I was ummming and arghhhing from the start realy about doing a bare shell restoration once the decision was made it felt great knowing that everything will be as good as possible all new shiny bits to bolt back on to a shiny tub.

The shell was picked up by Alan from Enviro-strip 3 wks ago , very helpful and got the impression it will be well looked after durring its transition back to shinny metal, although I am sure there will be more rust hole than I thought ,we shall see , today in fact as its due back this morning!

 

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One of the few nasty bits of rust remaing in the corner trapped in the seem , not the best pic but the seam has expanded with rust also there is a hole the sise of an egg right in the corner of the rear inner wing which is very hard to deal with and get to to eliminate all rust.

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The above pic shows the hole also the engin lid release cable guide tube has completely rusted away!

 

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the above shows the rear light areas which are prety messy , so will be good to see all this dissolved away.

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Finally I had a bare shell all be it with a few holes , but most of the work is done I reckon annother week to sought out the remaining issues . Normally the car is stripped first then repaired so I have done it a bit back to front !

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Car loaded safe and secure .

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Just like to report my shell arrived back safe and sound today . The shell had been etched pimed which I had'nt asked for but apparently went through the system by mistake which actually turned out realy well for me as its about £400 extra ! pleased to say I only had to pay the original quote which considering the work done and transport involved was very reasonable , I did get it a fair bit cheaper than usual as I didnt need the doors ,bonnet and engine lid doing as these were in great condition, the valences ,sill trims and bumpers were all done though . Realy pleased ! whilst primed it is a thin coating and you can still see the areas that need the work especially the holes ! just have to sand back a little .

Annother good job today was sending a load of stuff of to the blasters prior to powder coating . A load of fasteners bits and bobs and my crusty spring plat went off to be zink plated to, you cant beet a bit of bling!

Unfortunately reality is bitting and cant spend a lot of time on the car for a week or two as a customers large reclaimed York stone patio and large mezzanine is getting in the way :cry: so weekends and the odd evening but hope to get the rear trailing arms built back up again soon and a few other bits ready to go back on when painted . Btw thinking of powder coating trailing arms silver , what do most people do with theirs ?

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Back in one piece ,a lot lighter too without paint and sound deading matting .

post-7780-0-84187800-1397332413_thumb.jpgA lot of time has been saved cleaning up and stripping wings ,valenced and bumpers was'nt looking forward to that ! Still quite a few repairs to do including reinstalling the heater pipes that were taken out prior to dipping, just glad the sill work is behind me . Trouble is now that the car is fully stripped I have been thinking about a possible colour change still have a month to decide though.

 

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post-7780-0-39561000-1397335493_thumb.jpgSpent the morning refurbing the oil tank , used a combination of paint stripper and a cup brush took most of the morning ,some tough old paint but cleaned up well a few rust areas were treated with rust converter then epoxy mastic, also painted the drive shafts and bumper shocks that I had blasted .

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Henry,

 

You are doing one hell of a good job there and keeping a record of the restoration in photos will be invaluable in the future. Keep going, we are loving your step by step record of the work. :ani_clapping::signs85:

 

Grant

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Thanks Grant , I have been lucky taken time out from work to get this far ,every nice sunny day makes me feel like I am missing out driving my car so quite an incentive , this is my first 911 and first decent car in a while so its exciting to be moving forward . Can'nt wait to start putting it back together . Shopping for new bits is my new pastime !

 

Henry

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Thanks steve , just been reading your thead , looks like some serious weight loss! mines all in carboard boxes waiting to go back in , but you have me thinking I may shed a few kg 's where possible but I do like my pipe and slippers comfort too ,getting old is terrible thing .Pleased with my decision to Dominic I feel I am going to end up with a car as good as it can be .

 

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After spending some time degreasing the cv joints , I decided to replace them all , they drove fairly with only a very slight clunk when pulling away so I thought maybe some may be good . The car had done 160,000 miles so no surprise realy, decided to renew all wearing parts on chassis /tub bearings etc .

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There was a fair amount of where which you feel with your finger on spiders and outer , the boots however in good nick for their age cv 's original as you can see 79 stamped on them .

 

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good work Puddy!

 

I quite liked taking apart and rebuilding CV joints - found it quite therapeutic!

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yeh me to, watched a youtube vid ,the guy did say you can reverse the spiders if they not to bad, it would have been nice to reuse them after all that cleaning but I need mine in perfect shape as they may be taking a bit of extra strain in the future ;) 4x CV joint = mucho £ having said that I recently visited Matthew at Type911 and bought a load of stuff and he did a good deal for me . I have been catching up on your thread too , that is some car you have built must be sooo quick , looking forward to picking up that exhaust !

 

Henry

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Trouble is now that the car is fully stripped I have been thinking about a possible colour change still have a month to decide though.

I'd definitely change colour as you're documenting the rebuild and a cooler colour is only doing to add to the cars appeal.

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Still thinking thinking through the whole coulour thing Greg, well the whole look really, I am liking silver at the moment but we will see . :unsure:

 

 

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