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XLO bodywork refresh


Flat 6

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And masked again to put the body colour on…

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But worth the effort!

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Attention to detail on the removable panels was excellent (IMHO)…

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OK, so I’m not sure we should have painted the heat shield above the rear exhaust banana, I’ll be keeping a close eye on that!

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I know from previous experience that a lot of painters would have just blown over the underside of the engine cover. Not so here.

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  • 2 weeks later...

So, got the car home in May, just after moving house.

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The new place I’ve moved to is an old farm and there is an outside inspection ramp. Where better to start a cleanup of the underside!

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I hadn’t originally intended to spend much time detailing the underside but having come this far I felt I should continue the ‘war on rust’. The underside of the car had no real issues, just surface rust and crusty edges in places. I started at the rear end and worked my way forward starting with a wire brush on a grinder and then the same process as before with degreasing, treatment, two base coats of zinc epoxy and then two of top coat. I either used great stuff called Simonez Tough Black or good old black satin Hammerite which I think is fine as a top coat (rubbish as a rust treatment..).

This is a shot part-way through the cleanup…

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I had started to remove some of the black underseal that was already there but then I decided I would only be putting something similar back on again. I had seen enough to suggest that it was all solid under there…

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Overall I’m happy with the way the underside cleaned up.

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At that stage I had yet to replace these rusty unknown ‘made in Japan’ rear shock absorbers with nice new proper Boge numbers. Didn’t want to get paint on them!

I also decided to do a job on my existing rear exhaust banana, time will tell whether or not this stands up to proper use but it was thoroughly treated and then painted with multiple coats of a very expensive high temp (750 degree) paint called ‘hard hat’ from Rustoleum. I tried a different rust treatment on this, stuff called Fertan which I was recommended. It is used a lot by the marine industry and my local Porsche mechanic who had recently come back from Germany swears by the stuff.

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Same process on the oil pipes, although I was more sparing with the paint on these since I read that paint may insulate them too much?!?!

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Having done much of what I wanted on the underside it was time to move the car into the ‘build’ garage. By this stage I had gathered together quite a lot of parts, some new and some from fellow IB’ers!

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This allowed me to finish off some detailing and move onto assembly.

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Ignore the fuel pump and undertray, these had yet to be done at this stage – the cap bolts that hold the undertray on at the rear were seized solid…

Some final tidying of rear arches, including nice new spring covers…

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Ended up replacing the front hub backing plates because the originals just weren’t tidy enough.

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And then of course that leads on to the calipers. Thought a lot about what colour to paint them and did think about anodizing but decided against because they have to be split open and the last time I had that done the caliper never did seal up again properly. So I went with the closest colour I could find to yellow/gold anodising and then rebuilt the piston seals.

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I used E-tech caliper paint. It comes in a small pot but I didn’t like the way it went on by brush so I thinned it by 30% and used my trusty airbrush kit. Very effective, albeint means 4 coats needed to achieve decent level of thickness.

Happy enough with the final outcome. With the calipers being nice I couldn’t leave the hubs looking like they did. At the front I just cleaned up the alloy a bit.

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Oh and the oil tank got the same treatment as the exhaust and oil pipes…

Wasn’t that bad when it came out of the car

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But could be nicer…

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I had spent quite a while preparing the flapper boxes but I wasn’t happy with them so bought some new ones. Since I don’t ever want to be removing these again they were given the same rustproofing treatment and everything else!

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These were a b*ll*cks to fit. I had to buy an extension piece for the temperature probe to fit to and then it all had to be bolted and clamped into place. Those bolts are not easy to get to.

These went on a lot easier... But then the engine had been rebuilt a short while ago and the old rusty ones had been off and on again.

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Photos to follow…

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  • 5 months later...

Must get on with a proper update on this thread - a lot of progress has been made...here's a teaser!

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New wheel nuts, lip spoiler and front bumper strip waiting ready to go on...

Al.

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  • 1 month later...

still testing...

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  • 11 months later...

If anyone is wondering what all this palaver is at the end it was because of the Photobucket debacle in mid 2017 when they temporarily removed access to thousands of people's images and tried to get them to pay hundreds of dollars to get them back. They eventually reinstated access but by that time I had rebuilt the thread here:

Having done that I think there might be some issues with my rebuild thread due to changes at Postimage. I'll link back to this thread just in case.

Al.

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OK, some looks like the photos on the version of this thread titled 'restoration' are indeed unavailable so I will post the end of the story on here.

If any of you get 'Total 911' Magazine, there is a next months issue teaser at the back of the current edition comparing and contrasting earliest and latest SCs.  You may recognise the silver one!! I am indeed fortunate to own both cars, although they are both now for sale to fund completion of a '73T and another house move. 

I will try and post some final shots to show the finishing stretch but it was all done in a mad hurry last July so that I could take the car to the Silverstone Classic. Since then I have really enjoyed owning and driving it. This was my fourth SC and it really is a sweet car to work on, drive and just be in. Everything came together beautifully and everything just works which is all so often not the case in classic cars. 

More soon,

Al.

PS..if anyone on here is going to the Le Mans Classic come and say hello in the DDK section of the Travel Destinations site near the Porsche Curves.

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