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Expanding foam 3.2 carrera resto


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I brought this as my first 911 that I had always dreamed of owning one ,it had only been mot’ed 2 weeks before I brought it so didn’t at all imagine to find it full of filler and foam !!!!! 
It started out with me chasing a water leak as the first time it rained I got wet feet ........after changing various window seals I found out that it running down the a piller filling the cill up and then running into the cockpit 

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My good friend and excellent metal worker whitehouse classic and retro is doing the repairs for me , 5 days in and he’s managed to make the pass side strong again 

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That is heartbreaking , you would not believe your car had that much rust from the first picture . However looks like you'll be back on the road to fully enjoy a great car.

Still sad what some people will do to get some extra money for their classic car, and a real warning to get you car checked over before purchase

Good luck

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Warning to others for sure.

Never go to see an old car without a magnet!

Good work RRSCarerra. Take some comfort from knowing that you're doing a job that most of us on here have had to have done at some point. 

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Oh boy!! I feel your pain😳 Some people should be shot, for the time and effort that went into making it look good they couldve done it properly!  Mine was similar but they had welded new sills over the rusty old ones! Makes you wonder what goes on in peoples heads🤔

Looks like they are making good progress though👍

Keep the pics coming, always good to see how others are tackling these jobs🧑🏼‍🔧
 

Edited by Robos911
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The guy who did mine should be a sculptor the way he shaped the foam n filler !!!!

drivers quarter is removed now and outer inner cil removed , the inner wing had previously been plated so they have been removed and a new peice let in , rear chassis on pass side has now been repaired also I’m just waiting for a new rear slam panel to put a section in 

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On 29/10/2020 at 22:04, Robos911 said:

🤣 i said exactly the same, he was wasted working on cars, shouldve been a sculptor! If youve not seen mine, its the next thread in this section, very similar😳

I just had a quick look through yours , yes you definitely have a similar looking car 🙈

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  • 2 weeks later...

Good effort mate on the rust work. Proper 911's all rust like this in the end. The expanding foam does not have a part number but many Porsches have it!

The sunroof drains are a pain one of mine needs doing but I have been putting it off for about 10 years now.  Short of cutting out sections out of the rear of the pillar the only thing I could think off was to very carefully grind the top and the bottom of the existing tube so its loose (assuming no fixings within the pillar) and pulling it out. Then straighten the new one at the top and thread it up the pillar from the base. The weld in and grind flat at the top. The bottom is of course welded where it exits the pillar. Easier said than done obviously. Hopefully one the bodywork experts on here can help. You obviously the skills so good luck my friend!

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11 hours ago, R2D2 said:

Good effort mate on the rust work. Proper 911's all rust like this in the end. The expanding foam does not have a part number but many Porsches have it!

The sunroof drains are a pain one of mine needs doing but I have been putting it off for about 10 years now.  Short of cutting out sections out of the rear of the pillar the only thing I could think off was to very carefully grind the top and the bottom of the existing tube so its loose (assuming no fixings within the pillar) and pulling it out. Then straighten the new one at the top and thread it up the pillar from the base. The weld in and grind flat at the top. The bottom is of course welded where it exits the pillar. Easier said than done obviously. Hopefully one the bodywork experts on here can help. You obviously the skills so good luck my friend!

I was thinking that was the only way to try and change them I was just hoping someone on here may have previously done it to confirm that’s the process 

thankyou !!!

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As it's usually just the lower section that rusts out, the typical repair method is to remove approx 100mm of the A pillar outer skin, cut back the drain pipe to good metal, flare the end of the new section and braze it in. Watch out for wires within the A pillar.

Cheers

FF

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My friend I have just been through an 8 month restoration with work carried out similar to what you're having done. The only difference being that I've had the car years and I knew it needed doing. If I had bought it like that I would be taking people to court or breaking knee caps, that is criminal and you were robbed. Did you pay full market price for the car and have you looked into legal recourse?

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7 hours ago, SurlySurdi said:

My friend I have just been through an 8 month restoration with work carried out similar to what you're having done. The only difference being that I've had the car years and I knew it needed doing. If I had bought it like that I would be taking people to court or breaking knee caps, that is criminal and you were robbed. Did you pay full market price for the car and have you looked into legal recourse?

I should of approached the mot station as they only tested it 2 weeks before I brought it but it’s one of those things I’m just glad I didn’t have an accident in it tbh 

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RRS you are being very forgiving...... But, let's be honest, EVERY 3.2 needs all these repairs by now unless they have been kept in cottonwool or already been fixed. Money I know but take satisfaction in the fact that you now know it is 100% right. 👍

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3 hours ago, Chris T said:

RRS you are being very forgiving...... But, let's be honest, EVERY 3.2 needs all these repairs by now unless they have been kept in cottonwool or already been fixed. Money I know but take satisfaction in the fact that you now know it is 100% right. 👍

I’m hoping for good karma !!! 
I have been totally surprised how bad they rot but like you say I will be safe in the knowledge that it will be good car in the end 

Another bit done !!!!

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1 hour ago, RRScarrera said:

Yes he is very good and quite fast , if anyone in the uk needs some resto work doing I can pass on his details , from small work to complete turn key projects 

For future reference whereabout are they based?

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