1959 718 RSK number 006 metal work restoration.

We,at the Metal Surgeon have been commissioned to undertake the aluminum restoration of this original 1959 Rsk Porsche prototype built race car.
The car has been 'restored' in the early eighties ,and after much research we discovered many flaws both obvious and not so obvious.One of the notable modifications made was the larger cut outs in the rear arches for bigger clearance.After a lot of measuring from various datum points we also discovered the body was an inch lower on the right side compare to the left.

Here's a picture to start off showing the rear arch cut outs.

https://www.dropbox.com/s/ws6m2h16b3...5405.JPG?raw=1

https://www.dropbox.com/s/m552ww431p...5402.JPG?raw=1

https://www.dropbox.com/s/fxxta17nn2...5398.JPG?raw=1

https://www.dropbox.com/s/3djss5l96o...5397.JPG?raw=1

Making 'B' post tooling and panel

https://www.dropbox.com/s/mcech1rcb5...0290.JPG?raw=1

https://www.dropbox.com/s/0cmwrl7xut...0291.JPG?raw=1

https://www.dropbox.com/s/b5j3ebsuhk...0292.JPG?raw=1

https://www.dropbox.com/s/j4mxr95m2w...0295.JPG?raw=1

https://www.dropbox.com/s/gqftefngev...0297.JPG?raw=1

Jig chasing alum

https://www.dropbox.com/s/pcii28ckqa...0320.JPG?raw=1


https://www.dropbox.com/s/6xskgiahle...0322.JPG?raw=1

https://www.dropbox.com/s/2u5rz2eiy9...0326.JPG?raw=1

tools of the trade....

https://www.dropbox.com/s/g9i1ibpawi...0331.JPG?raw=1

https://www.dropbox.com/s/okwfcfwqds...0358.JPG?raw=1

https://www.dropbox.com/s/csiezkuwcc...0490.JPG?raw=1

comparing both removed 'B' post from the previous 80's restoration.

https://www.dropbox.com/s/0gatx35474...0079.JPG?raw=1

https://www.dropbox.com/s/mqdhspqo2t...0081.JPG?raw=1

Uuummmmmmmmmm . . .



. . . no pics

?



........

Quote:

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Originally Posted by LongRanger

Uuummmmmmmmmm . . .



. . . no pics

?



........

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I can see pics.....

I can see them also.
Chris

Yeah, I see'm….

They're REALLY big photo files, ya'got'ya wait a bit for them to load up.....

building the right hand body side,with a built jig aided fixture.

https://www.dropbox.com/s/pgpmbpvf0q...0118.JPG?raw=1

https://www.dropbox.com/s/joef6tkb06...0433.JPG?raw=1

https://www.dropbox.com/s/wo371odzr0...0436.JPG?raw=1

https://www.dropbox.com/s/kxhgygwea7...0437.JPG?raw=1

https://www.dropbox.com/s/e1ypxfizpj...0438.JPG?raw=1

https://www.dropbox.com/s/krq9oc8o95...0441.JPG?raw=1

Thank you for posting these pictures. What a great project. Nice to see the methodical craftsmanship.

Please update us with your progress.<script type="text/javascript" src="safari-extension://com.ebay.safari.myebaymanager-QYHMMGCMJR/8ace170b/background/helpers/prefilterHelper.js"></script><script type="text/javascript" src="safari-extension://com.ebay.safari.myebaymanager-QYHMMGCMJR/8ace170b/background/helpers/prefilterHelper.js"></script>

https://www.dropbox.com/s/m893r3dolt...0475.JPG?raw=1

https://www.dropbox.com/s/v3uj6hvext...0477.JPG?raw=1

https://www.dropbox.com/s/5tcokkl77y...0007.JPG?raw=1

https://www.dropbox.com/s/wf2h9p7im3...0074.JPG?raw=1

https://www.dropbox.com/s/y14zocmxxl...0075.JPG?raw=1

https://www.dropbox.com/s/hin8jv917n...0084.JPG?raw=1

template from correct original left hand side ,now on the right side show incorrect profile.

https://www.dropbox.com/s/hzk7m0jxa5...0087.JPG?raw=1

https://www.dropbox.com/s/rwhunn72uo...0088.JPG?raw=1

https://www.dropbox.com/s/7a9vgrnt7l...0109.JPG?raw=1

https://www.dropbox.com/s/iwqze9gk0m...0110.JPG?raw=1

https://www.dropbox.com/s/0eabdv3uyq...0112.JPG?raw=1

https://www.dropbox.com/s/gwft4jwztk...N0136.JPG?raw1

https://www.dropbox.com/s/im026785gz...0140.JPG?raw=1

https://www.dropbox.com/s/nsdf1rx1es...0011.JPG?raw=1

https://www.dropbox.com/s/odcegj2cmz...0108.JPG?raw=1

https://www.dropbox.com/s/9e0g85xpyk...0114.JPG?raw=1

https://www.dropbox.com/s/t5m5jlery6...0116.JPG?raw=1

https://www.dropbox.com/s/ttvbywdz19...0006.JPG?raw=1

https://www.dropbox.com/s/s420j7fu9m...0007.JPG?raw=1

https://www.dropbox.com/s/v157vaia4d...0012.JPG?raw=1

https://www.dropbox.com/s/bfpjmb9ggx...0027.JPG?raw=1

https://www.dropbox.com/s/5ml0kajuev...0058.JPG?raw=1

Offer RH rocker to new body side .Place datum patterns.

https://www.dropbox.com/s/8z37omrzi7...0063.JPG?raw=1

https://www.dropbox.com/s/xozq43rt04...0064.JPG?raw=1

https://www.dropbox.com/s/eox5icyewp...0066.JPG?raw=1

offer up newly handcrafted 'B' post to Body side
https://www.dropbox.com/s/i316av4pyb...0300.JPG?raw=1

https://www.dropbox.com/s/1wkefhgdeu...0304.JPG?raw=1

https://www.dropbox.com/s/r4bk78sk60...0313.JPG?raw=1

https://www.dropbox.com/s/8baai6i21i...0761.JPG?raw=1

Back inside the Datum box for tuning in/setting

https://www.dropbox.com/s/l72m2bq21s...0764.JPG?raw=1

https://www.dropbox.com/s/e0ersfzy1u...1138.JPG?raw=1

https://www.dropbox.com/s/2jt8148w8z...1508.JPG?raw=1

https://www.dropbox.com/s/7y9zkxbavd...1543.JPG?raw=1

https://www.dropbox.com/s/xiecshx7ml...1566.JPG?raw=1

https://www.dropbox.com/s/hm5goqgend...1631.JPG?raw=1

https://www.dropbox.com/s/sn33vwo8b5...9554.JPG?raw=1

https://www.dropbox.com/s/2oetnw9eph...9556.JPG?raw=1

Awesome, fabulous, fantastic

Thanks for posting and keep posting please.

Such interestng work. Thank you for the progress pictures.

Right hand door build.

https://www.dropbox.com/s/c0o08tqj3b...9565.JPG?raw=1

https://www.dropbox.com/s/6j0ritl0ep...9569.JPG?raw=1

https://www.dropbox.com/s/18i00hd6w1...9571.JPG?raw=1

https://www.dropbox.com/s/jdsmw3ca31...0108.JPG?raw=1

https://www.dropbox.com/s/rbxa721tc0...0112.JPG?raw=1

https://www.dropbox.com/s/mg3ssc03g1...0113.JPG?raw=1

https://www.dropbox.com/s/ir2czizdz4...0124.JPG?raw=1

How much more are you charging to make it into the 4 door version?
Beautiful craftsmanship!
Attachment 459584

Quote:

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Originally Posted by ptrsbtrs

How much more are you charging to make it into the 4 door version?
Beautiful craftsmanship!
Attachment 459584

---

Actually, six doors total, we're doing the limo version.....

Thank you!

https://www.dropbox.com/s/be03jn508n...0199.JPG?raw=1

https://www.dropbox.com/s/03h2u82i37...0242.JPG?raw=1

https://www.dropbox.com/s/vspd1lq00z...0381.JPG?raw=1

https://www.dropbox.com/s/dbsrjynxzi...0383.JPG?raw=1

https://www.dropbox.com/s/jefn50kj1l...0390.JPG?raw=1

https://www.dropbox.com/s/jefn50kj1l...0390.JPG?raw=1


https://www.dropbox.com/s/edonxscvwi...0422.JPG?raw=1


https://www.dropbox.com/s/0z7cgmfpau...0430.JPG?raw=1

https://www.dropbox.com/s/enh1hed2y7...0437.JPG?raw=1

https://www.dropbox.com/s/op75e8z76i...0446.JPG?raw=1

https://www.dropbox.com/s/g3p2tckqb6...0445.JPG?raw=1

https://www.dropbox.com/s/iycwjt92pu...0507.JPG?raw=1

https://www.dropbox.com/s/4odupkvza9...0515.JPG?raw=1

https://www.dropbox.com/s/7fbosr9p66...0538.JPG?raw=1

https://www.dropbox.com/s/xrqu37vkc6...0545.JPG?raw=1

https://www.dropbox.com/s/0ezgj8848o...0596.JPG?raw=1

https://www.dropbox.com/s/xryucvo8c2...0677.JPG?raw=1

https://www.dropbox.com/s/w1jpv86x87...0675.JPG?raw=1

Just incredible attention to detail and craftsmanship... thanks for the continued flow of pictures... I would love to see your workshop and watch some of this work...

Quote:

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Originally Posted by StephenAcworth

Just incredible attention to detail and craftsmanship... thanks for the continued flow of pictures... I would love to see your workshop and watch some of this work...

---

Thank you for following along Stephen.Tons more photos to post.Welcome to the workshop anytime !

Left hand door build.

https://www.dropbox.com/s/hsu8tmkkjd...9875.JPG?raw=1

https://www.dropbox.com/s/rcbkgzscvu...9857.JPG?raw=1

https://www.dropbox.com/s/xfcast4paj...0029.JPG?raw=1

https://www.dropbox.com/s/qmlqptboq1...0056.JPG?raw=1



https://www.dropbox.com/s/qav8e7bcdb...0088.JPG?raw=1

LH 'A' Post build

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

http://forums.pelicanparts.com/uploa...1538326769.JPG

and for RH 'A' post

http://forums.pelicanparts.com/uploa...1538484410.JPG

http://forums.pelicanparts.com/uploa...1538484410.JPG

http://forums.pelicanparts.com/uploa...1538484410.JPG

http://forums.pelicanparts.com/uploa...1538484410.JPG

B post build and developement

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

http://forums.pelicanparts.com/uploa...1538948207.JPG

B post cont.

http://forums.pelicanparts.com/uploa...1538966865.JPG

http://forums.pelicanparts.com/uploa...1538966865.JPG

http://forums.pelicanparts.com/uploa...1538966865.JPG

http://forums.pelicanparts.com/uploa...1538966865.JPG

http://forums.pelicanparts.com/uploa...1538966865.JPG

http://forums.pelicanparts.com/uploa...1538966865.JPG

B post build cont.

http://forums.pelicanparts.com/uploa...1539967598.JPG

http://forums.pelicanparts.com/uploa...1539967598.JPG

http://forums.pelicanparts.com/uploa...1539967598.JPG

http://forums.pelicanparts.com/uploa...1539967598.JPG

Jig chasing in the B post and tools used to form the panel

http://forums.pelicanparts.com/uploa...1540145948.JPG

http://forums.pelicanparts.com/uploa...1540145948.JPG

http://forums.pelicanparts.com/uploa...1540145948.JPG

http://forums.pelicanparts.com/uploa...1540145948.JPG

Metal finishing

http://forums.pelicanparts.com/uploa...1540163019.JPG

http://forums.pelicanparts.com/uploa...1540162735.JPG

http://forums.pelicanparts.com/uploa...1540162735.JPG

http://forums.pelicanparts.com/uploa...1540162735.JPG

B post offered upto bodyside

http://forums.pelicanparts.com/uploa...1540212573.JPG


http://forums.pelicanparts.com/uploa...1540213023.JPG

Making the LH door inner structure from a basic jig made.


hinge wall panel chase in.

http://forums.pelicanparts.com/uploa...1540214610.JPG

http://forums.pelicanparts.com/uploa...1540214610.JPG

roughed in

http://forums.pelicanparts.com/uploa...1540214610.JPG

making skin to inner

http://forums.pelicanparts.com/uploa...1540214610.JPG

What will be left if the original body, if there was something from the previous restoration?

How do you manage to find the right dimensions and shapes?

Impressive work and thank you for the update.

Door builds cont.

http://forums.pelicanparts.com/uploa...1540224568.JPG

http://forums.pelicanparts.com/uploa...1540224568.JPG

http://forums.pelicanparts.com/uploa...1540224568.JPG

http://forums.pelicanparts.com/uploa...1540224568.JPG

Door lock refurbish and install.

http://forums.pelicanparts.com/uploa...1540400581.JPG


http://forums.pelicanparts.com/uploa...1540400581.JPG

RH side build process and checking fixture ,patterned from the correct LH side


http://forums.pelicanparts.com/uploa...1540403174.JPG

http://forums.pelicanparts.com/uploa...1540403174.JPG

http://forums.pelicanparts.com/uploa...1540403174.JPG

http://forums.pelicanparts.com/uploa...1540403174.JPG

http://forums.pelicanparts.com/uploa...1540403174.JPG

Knocking over the interior corner flange with aided jig.


http://forums.pelicanparts.com/uploa...1540681628.JPG


http://forums.pelicanparts.com/uploa...1540681107.JPG

http://forums.pelicanparts.com/uploa...1540681107.JPG

offering up the windshield and side window

http://forums.pelicanparts.com/uploa...1540681107.JPG

Dry fitting and tuning as we go along to keep everything in check.

http://forums.pelicanparts.com/uploa...1540681905.JPG

http://forums.pelicanparts.com/uploa...1540681905.JPG

http://forums.pelicanparts.com/uploa...1540681905.JPG

http://forums.pelicanparts.com/uploa...1540681905.JPG

Flange tooling to rear body.


http://forums.pelicanparts.com/uploa...1541287606.JPG

Anneal and knock in

http://forums.pelicanparts.com/uploa...1541287606.JPG

rear body set on flange for fitment check.

http://forums.pelicanparts.com/uploa...1541287606.JPG

Flange detail

http://forums.pelicanparts.com/uploa...1541287606.JPG



http://forums.pelicanparts.com/uploa...1541287606.JPG

NOW HIRING

Fully skilled metal workers
Entry level metal workers

apply to Jon@themetalsurgeon.com
or Valerie@themetalsurgeon.com

Benefits including Health Care

thank you!

A Post with glue ready to bond

http://forums.pelicanparts.com/uploa...1541735472.JPG

Open A Post area ,ready to take A post

http://forums.pelicanparts.com/uploa...1541735472.JPG

Overview

http://forums.pelicanparts.com/uploa...1541735472.JPG


Setting in position / Angle finder

http://forums.pelicanparts.com/uploa...1541735472.JPG

Inner A post frame structure


http://forums.pelicanparts.com/uploa...1541857745.JPG

LH A post glue in

http://forums.pelicanparts.com/uploa...1541857745.JPG

http://forums.pelicanparts.com/uploa...1541857745.JPG

Making new inner rocker sections ,both LH and RH sides from the originals as they were overworked and made thin from previous attempted restoration in the 80's.

As inner rockers are the backbone of vehicles ,these need to be structurally sound.

http://forums.pelicanparts.com/uploa...1541951994.JPG

http://forums.pelicanparts.com/uploa...1541951994.JPG

http://forums.pelicanparts.com/uploa...1541951994.JPG

http://forums.pelicanparts.com/uploa...1541951994.JPG

http://forums.pelicanparts.com/uploa...1541951994.JPG

http://forums.pelicanparts.com/uploa...1541951994.JPG

http://forums.pelicanparts.com/uploa...1541951994.JPG

Rocker inner assembly to bodyside


http://forums.pelicanparts.com/uploa...1542564884.JPG

Alum opening,flange made

http://forums.pelicanparts.com/uploa...1542564884.JPG

incorrect positioning/to inner rocker

http://forums.pelicanparts.com/uploa...1542564884.JPG

http://forums.pelicanparts.com/uploa...1542564884.JPG

oil cooler housing (original)

http://forums.pelicanparts.com/uploa...1542564884.JPG

grafted in

http://forums.pelicanparts.com/uploa...1542564884.JPG

air intake fitted

http://forums.pelicanparts.com/uploa...1542564884.JPG

Cleco 'ing together

http://forums.pelicanparts.com/uploa...1542564884.JPG

http://forums.pelicanparts.com/uploa...1542564884.JPG

thanks for sharing your work....inspiring and elevating.