1986 Porsche 911 - with added E46 M3

just amazing fabrication once again Mr Teaboy

...That's tidier than the few remaining standard panels on my car.
"Not too mad on the finish" Pfft.
Show off.
;D I kid. Nice work as always.

Tonight I had a go at fitting the kidney and there was a small rib in the inner wing pressing preventing it going on properly, so I chopped it out.




Got a bit cut out to fill the hole


but couldn't weld it in though, as I have run out of gas.
This was not a major surprise as the gauge has been showing zero bottle pressure for about a week and a half.

I thought if I get the kidney bowl on and fix it in place with self tappers,


it will mean I can start to get the jack tube cut out, as the kidney will give me a datum for fitting the new one.
Like this


The jack tube is fixed in with a large plug weld up through the floor, which you could deal with using a hole saw.


There is also a longer plug weld inside the doorstep which takes two large holes which you link up with the dremmel


This caused my dremmel to make a pffft type noise and issue a small amount of smoke, it had run it's last.

I want to get the remainder of the inner sill out.
This is sandwiched between the rear inner wing and the floor, the jack tube runs through the inner wing and inner sill, which is why I wanted it out now.

The bottom bit of the inner wing below the jack tube was a bit crusty anyway, so I cut it off.
Drilled through the spotwelds and I was able to pull the last bit of the inner sill out.


I think some people would have cut the new inner sill short and welded it together to the remaining old bit, and not bothered to remove this piece.
I briefly considered that but it didn't seem like the right thing to do.

Hoping to get some gas tomorrow, if all goes to plan. ;D

Cheers Tony, appreciate it mate.

Cheers, Keefy.

I got a new bottle of gas on Thursday and was itching to use it but today what with working up the scaffold, and standing to attention in my union jack regalia in front of the tv, I only managed to sneak a quick hour this evening.

I got that piece welded in


and fettled


I am getting ready to fit the inner sill now so I need to get the flange repaired on the bottom edge of the floor.


I stuck that bit of wood there for the picture to make it more visible.

I got it fettled smooth


and trimmed off


There are another couple of smaller bits still to do on the flange but I had had enough by then.

I agree great job chap keep it coming!

Thanks mate.
Love your Herald BTW ;D



Thanks.
I know where you can get oversize 944 pistons if you need them



Thanks

Yes, just trimming the weld down.
Try not to keep the flap disc in the same place for too long to prevent it overheating.
I do it in much the same way as Tonybmw, but with not quite as much skill.
See here

Great work as always. Yours and Tony's work is a joy to behold.

Things are a bit slow as I am recovering from a bit of minor surgery.

I had a very steady day in the shed and I got my inner sill on today.
Luckily I remembered to put the heater silencer back in first.
Note the two jacks supporting the car in place whilst the side is cut off.


The jack tube is just loose at the moment.
I had to put it in now because the inner end of the tube is wider than the hole it sticks through and I wanted to close off the bottom of the rear inner wing.
I used part of that repair piece I made before.


I slapped a bit of zinc primer on it.
I also managed to lean my elbow into the paint tin lid
It is reassuring that I can't get the paint off my skin.

I need to drill loads of holes in the kidney bowl to fit that next.

This is it.


For anyone who does not know why this is called a kidney bowl, here is a picture of an old type one which they used for about the first twenty years of 911 production.


From about '85ish they changed to ones like mine to strengthen that area.