. . . no filler on a butt-welded panel -- just metal. (Compare this repair to the lap-welded bit above.)
And the panel 'fits,' now, too . . .
. . . no filler on a butt-welded panel -- just metal. (Compare this repair to the lap-welded bit above.)
And the panel 'fits,' now, too . . .
When the shop in North Carolina had replaced the rockers . . . they cut off a particular 'tab' . . .
1) and 2) Repair One of the passenger side rocker; the 'tab' that mounts the front upper edge of the outer rocker is missing
3) Top part of replacement rocker removed to provide access; notice the oil lines
4) Here's the missing tab, removed from the original rocker --- this is why I save just about everything that comes off my cars
5) Missing tab back in place
1) John's fabricated patch panel . . .
2) . . . spliced into place . . .
3) and 4) . . . and dressed.
I know that these panels are no longer virgin original . . . but I love all the craftsmanship --- all the art --- that John puts into these repairs. I mean, even though everything looks stock ---- John’s work is as careful and custom as anything I’ve ever seen.
And I’ll never look at any of these panels the same way.
After the driver’s side front quarters came off, turns out that 1059 had been in some kind of minor collision at some point.
Remember those funky after-market air horns that turned-up in the PPI, with one of the trumpets chipped? Turns out that there were some other things going on there, at that corner of the car. A support bracket that mounts to the battery-box and attaches to the fender and the bumper ---- was bent and missing a chunk. And the box itself had some braze repairs on it. Not good; as John explains it, the flux used to do the brazing is corrosive and, if it isn’t completely cleaned-off, will cause problems over time. It looked like a tab had been brazed-on to the damaged battery box, probably to pull out the damage. Brazing is not a modern technique so this repair was probably done quite some time ago --- early ‘70s, maybe?
Anyway, John fixed everything . . . .
1) Here’s the box, as found
2) The bracket that attaches to the fender has been NLA for a while --- so John fabricated a replacement
3) and 4) More views of the crumply battery box
5) The actual damaged portion removed . . .
1) Here’s where John started from
2) The replacement piece welded in . . .
3) . . . . and blended
1) 'Box-top' fabricated . . .
2) . . . placed . . .
3) . . . welded and blended . . .
4) . . . primed . . .
5) . . . and re-finished
I love these shots. 1059 is just a good old car --- nothing shiny or showy --- but still intact, more or less. I mean, everything here is basically 40-years-old.
And all of John's handiwork? It'll live anonymously behind the fender . . . no one's ever gonna see this stuff.
Except here.
John is great to work with. Between my 69S, the current TLG project ST and your car we are getting to see his full range. If I was undertaking another project of magnitude I would send John my car..... from the east coast!
86 Sport Purpose Carrera "O4"
You did not mention it, but it looks like he cleaned up the fender to trunk joint and applied new seam sealer tape? Any recommendations on what seam sealer brand to use, or are the all pretty much the same? Beautiful work by the way.
Mark Erbesfield
2018 911 Carrera T 7spd manual 😊
1973 911S #9113301282
1957 356A #58648
1966 Toyota Land Cruiser FJ45LV
1982 Toyota Land Cruiser FJ40
1977 Toyota Land Cruiser FJ40
1972 Toyota Land Cruiser FJ40 FST (Factory Soft Top)
1971 Toyota Land Cruiser FJ40 “Patina Queen”
1979 MB 450SL "Dad's old car"
2019 Cayenne "Wife's car"
The whole fender/apron area was always in pretty good shape, but has been tidied-up, then primed. The seam sealer is just the 'regular' Porsche product --- a two-sided putty-like material that conforms/distorts when the fenders are bolted up --- applied in the usual way. John's only modification was using some 993-type silicon sealer on the vertical portions, the way the factory did on the later cars, to keep water out of the join.Originally Posted by merbesfield
John's pretty picky --- and adamant --- about the quality and integrity of the whole fender-join area because of the complications (rust) that can take hold here if any corners get cut. Amen to that.
Rick Kreiskott
The only other rust that John found on his tear-down was the front apron seal channel. Nose looked fine, trunk looked fine, pan looked fine, hood, etc . . . but for some reason that apron seal channel was pretty crispy.
For a while, John thought he might have to buy a whole apron panel, just to get the channel. But it turns-out that Stoddard sells the channel by itself so that's what John got.
1) Channel at tear down . . .
2) . . . and as removed
3) Front apron panel with channel removed
4) and 5) . . . then prepped
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