Shrek

Ongoing and archived Porsche (and other marques) restoration threads from DDK members

Moderator: Bootsy

Post Reply
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 16 - A small diversion

And then, as Barry put it, 'a little friday project' because, and i am grateful for this characteristic, he is a perfectionist.

So the nearside front wing closer, an area that will be all but invisible in the finished car, needed a bit of attention, with some minor surface rust at the top

Image

And somewhere along the line, a bunch of holes that should not be there

Image

Ending up with a perfect panel

Image
Last edited by Dougieboy1 on Fri Sep 21, 2018 5:29 pm, edited 2 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Barry
Nurse, I think I need some assistance
Posts: 4322
Joined: Tue Aug 24, 2004 8:50 pm
Location: East Sussex

Re: Shrek

Post by Barry »

Just to point out that photographically, this is somewhat the abridged version of events so far, and there is quite a bit more to the structural side of things than shown here.

Anyway, having not been on DDK for a bit, I thought I'd clarify the distortion / dipping / pulling and checking stuff.

1) The dipping hasn't affected the shell from a shape perspective from what I've seen. It didn't look any different to me when it arrived here from when I first saw it. If it has changed, it's certainly not been an issue compared to what we're doing, e.g. we're pulling / jacking anyway.

2) I assemble the car as far as possible to get a start point on door and window frame gaps. These plus the main jig brackets, my screen jigs and my own jig external measuring 'system' allow me to get a pretty good steer as to the starting point prior to pulling, and to monitor progress as things move along. The dozer can exert over ten tons, as can the little Porta Powa hydraulic ram, not that I've needed anything like that here. The dozer clamps hard onto the jig bed, and just about every angle can be achieved for maximum pulling fun. There's even a vector pulley to allow for pulls that go downwards.

3) Of the two pictures Nick quoted the 'negative gap' one is of the shell being lifted at the back, before being allowed to drop to it's new position. It's illustrating the degree of lift required, not where the shell is resting (either before or after).

4) I straighten as far as possible with all old panels in place, this then pulls much of the surrounding area back into place without actually touching it.

5) Only then do I remove the damaged panels to be replaced.

6) The shell was 'welded to the rotisserie' simply because there were two compromised rear bumper mounts that couldn't be used / trusted. The rest of course was bolted up as usual. I couldn't do these mounts first for various reasons. More pragmatic just to put a couple of little seam welds in, and cut them later on.

7) Although I'm happy to weld floors or sections of floors in on the spit, I'd never weld on sills on it. I get as much floor-work done as needed, plus some localised repairs in the same areas before returning to the jig for the sills to be welded in. This ensures that an incorrect shape isn't locked in.

Now the centre of the shell is fixed, solid and straight, I'm returning to the scene of the (accident) crime to contine fettling the metal back to it's correct shape.
DDK Member1243 07741 273865. Home of the RY Austin 7 Trophy's and Austin Single Seat Racers
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

thanks for the clarifications Barry, you know better than I!

And as you say, whilst i enjoy looking at all the photos, the posts are hugely truncated!
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Barry
Nurse, I think I need some assistance
Posts: 4322
Joined: Tue Aug 24, 2004 8:50 pm
Location: East Sussex

Re: Shrek

Post by Barry »

:)
DDK Member1243 07741 273865. Home of the RY Austin 7 Trophy's and Austin Single Seat Racers
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 17 - The Barry Carter work out, step 2

so having been duly chastised by Mr Carter for omitting photos of his carefully executed craftsmanship, I shall endeavour to give a better representation.

On original inspection prior to dipping, it was observed that the inner offside wing was severely distorted due to a previous smack on the backside. The inner wing was effectively pushed into the engine bay in a nice compound curve. When Barry originally saw it, the curvature was so 'nice', he speculated that it looked like a factory mod. Sadly not though as these photos reveal.

Following some prior pulling, some of the bend had been removed but as these shots show with the rear wing removed, there was still much to do in terms of removing the bends. .

Image

Barry took advantage of the fact the oil pipes are very firmly brazed into place on the wing, and brazed his own tags on for more pulling. These were brazed these behind the 90 degree join in the pipes which already exhibited some cracking.


Image

Image

After a lot more pulling and some judicial work with the hammer and dolly, the profiles were 'adjusted. As you can see though, there is considerable damage around the oil console pressing.

Image

Image

Image

Finally, the pulling tabs were released, and the pipes themselves tweaked into their correct positions and straightened back into round pipes.

Image
Last edited by Dougieboy1 on Fri Sep 21, 2018 5:23 pm, edited 3 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 18 - Bang bang, kiss kiss

The areas beneath the torque tube apparently appear to look like they are easy to make but....they arent...... Barry has developed some tooling which allows him to form virtually any shape and so with these tools, he produced the two sections needed. The nature of the forming dictates that he has to make almost the whole area, albeit some of it in rough form, before cutting the panel down to what is actually required.

I think this is a process where pictures, in the immortal words of Telly Savalas, 'paint a thousand words' so i will simply show the photos and leave you to marvel at the genius of an artist at work - Barry that is, not Telly Savalas ....

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image


And IF, ha ha, geddit, if you dont remember Telly 'singing' - used in the loosest sense of the word - IF., try this

https://www.youtube.com/watch?v=J94-_w9ARX0

Much prefered him as Big Joe in Kelly's Heroes or Maggott in the Dirty Dozen...
Last edited by Dougieboy1 on Sat Sep 22, 2018 8:14 am, edited 3 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
sladey
Nurse, I think I need some assistance
Posts: 9372
Joined: Sat Apr 23, 2005 9:08 pm
Location: Nottingham, UK

Re: Shrek

Post by sladey »

Amazing work as always and really enjoyed seeing it and reading about it - thanks for sharing
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 19 - Classy chassis

Cutting out the rotten area under the torsion tube

Image

Test fit

Image

Image

Image

Good as new

Image

What looks like a hole i think is black marker pen??
Last edited by Dougieboy1 on Sat Sep 22, 2018 8:16 am, edited 2 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 20 - Bulkhead Revisited

Now its time for major surgery. Rear parcel shelf is a bit holey at either end, there is a rotten c pillar and for those of you with a good memory, the rear seat pans are more air than metal.

So the whole of the rear bulkhead has to come out.

Image

Image

And the rotten c pillar removed - if you say it quickly, it sounds easy. But because it is a number of panels on top of each other, it isnt...according to Mr Carter. Nor was dismantling the replacement (courtesy of Dave Stretch) C pillar cut from another car, long since deceased.

Image

Image

Image

Now a nice and not rotten rear, principally because it is very little metal left.

Image

Barry has left the areas where the flanges have been drilled out, au naturel, to give reference for fitting the replacement panels. I bought a rear floor, seat pans and rear bulkhead/kick panel salvaged from an 80's SC which i preferred to buying new metal as i felt a) it had already been in a car so i knew wouldnt need much fiddling (or so i hoped) and b) it was 'original' rather than modern metal. . At least it was sort of period correct and will be used to replace the crappy bits from my car.

This is one of the many points where i look at the photos and think a) can it get any worse (answer yes) and b) what did i let myself in for here.....
Last edited by Dougieboy1 on Sat Sep 22, 2018 8:20 am, edited 4 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 21 - He never saw it coming

Because Barry is a perfectionist,, for which i am very very grateful, he used the absence of the bulkhead as an opportunity to resolve an area of rust that i had not even spotted.

Going
Image

going
Image

gone
[Image

Repair patch cut from the donor SC rear section.
Last edited by Dougieboy1 on Sat Sep 22, 2018 8:17 am, edited 2 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 22 - The remains of the wing

Here is a short essay in pictures that shows exactly why you have to wait to get on Barry's list, everyone wants this quality of work.

You may remember some posts previously, we covered the straightening of the inner off side rear wing. It had buckled quite severely bent as a result of some rear impact.

So after straightening the panel and sorting out the oil pipes that go through the wing, that left the small issue of the mounting point for the oil console. .

Image

As you can see, not only was the recess into which the console mount fits a bit of a mess, the actual openings into which the console fits were distorted and torn.

Image

Image

So a new mount point needs to be fabricated.

by hand

using a hammer.....

Image

Image

Image

old vs new

Image

Old is now gone

Image

New tacked in

Image

Does it fit?....... of course

Image

tidying up

Image

Image

Factory fresh. Compare with the second and third photos in this post!!

Image

Image
Last edited by Dougieboy1 on Fri Sep 21, 2018 5:18 pm, edited 2 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 23 - Good morning Vietnam

Having done as much external pulling as possible, the lower part of the inner wing was removed and continued on the bench. At the same time, the various buckles were worked out of the inner chassis leg and cross-member.

The area was then primed, and the removed inner wing section was reunited with it's parent.


Image

Image

Image

Image

Image

Resulting in further factory finish perfection.

Image

Image

Image
Last edited by Dougieboy1 on Sat Sep 22, 2018 8:23 am, edited 2 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
Dougieboy1
I luv DDK!
Posts: 885
Joined: Mon Jan 04, 2016 7:27 pm
Location: Definitely round here somewhere

Re: Shrek

Post by Dougieboy1 »

Episode 24 - The go between

The next few posts are a little out of synch as i realise i had a bunch of updates from Barry that i seem to have forgotten to post, so forgive me for the apparent non-chronological order for a while.

Small repair needed to the inner rail near the rear of the floor ...

Image

Image

Image

Image


Tunnel had some surface corrosion which Barry found offensive, so he killed and replaced it

Image

Image

Image


At some point in the past, as mentioned earlier in this thread, someone decided that the simplest solution to letting water out of the inside of the car was to put a chisel through the floor at various points.

These modifications are clearly not factory options so need to go and here is a bit more detail on that

Image

Image

Image


One sill top flange was near perfect (RH) and the other was horrible. The horrible one was cut away, a new bit of metal was let in and then trimmed to the correct depth.

Image

Image

Image


The new inner sill had some side-moulding mounting recesses beaten out, and the panel prepped for later.

With reference to marks from the original, the new inner sill was screwed into place as a starting point for rebuilding the whole sill area in general.

Image

Image

Image

Image
Last edited by Dougieboy1 on Sat Sep 22, 2018 8:29 am, edited 3 times in total.
1972 911S
1944 VW Schwimmwagen (originally a Porsche typ128, eventually VW166)
A bunch of other crap (according to my wife)
sladey
Nurse, I think I need some assistance
Posts: 9372
Joined: Sat Apr 23, 2005 9:08 pm
Location: Nottingham, UK

Re: Shrek

Post by sladey »

Brilliant
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
911hillclimber
Nurse, I think I need some assistance
Posts: 20689
Joined: Mon Mar 10, 2008 6:26 pm
Location: West Midlands

Re: Shrek

Post by 911hillclimber »

You can scroll these 'Barry' threads for ever and a day and never get bored.

This shell is a bit grim, I am fortunate to have such a solid shell compared to the shells now being bought back from the dead, just wish mine had been rebuilt this well!
Barry MUST have the best Job Satisfaction feeling at the end of each day.
Looking at the base of the A post, looks like the outer sill was brazed to it originally?

Great update, thanks for taking the effort to post it all. :)
Pictures truly do say a 1000 words.
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
Post Reply