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996.1 aero restoration

What gauge steel did you use for the repairs? Also did you buy new jacking points or just fab something up? I see the jack points s are all available from Porsche but ends up being about £500 for the 4x
 
I can't remember on the gauge. My local motor factors had a choice. 0.8 and 1.0mm iirc. I went for the thicker of the 2.

On the jacking points, I made them from 2mm. I work in a small engineering shop so I have access to plasmas and a brake press. Made things a lot easier. Measured the old ones, plasma cut and folded. Cost me nothing but 20 mins and a lick of paint. After welding them in, loaded the insides with seam sealer and then plenty of stone chip to keep the water out
 

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yep I was considering similar, hardly the most complex of shapes and end of the day as long as its strong enough to jack the car on I couldnt give two hoots if it looks slightly different to original. I bought my 996 to drive not to keep as a garage queen concourse investment.
 
Looks like some great work there.

I'd be interested in how you did the arch. Any more pictures?
 
arch repair.

I would love to see more photos of the arch repair aswell. Why did you step the panel instead of butt welding? Is that not just making a water trap?
 
I looked at a C2.2 with aerokit a few years back that looked like it was going rotten underneath. Mostly around where the covers are attached to the sills.
The trouble is that once it starts the rot just spreads out.
 
Interesting thread and great work Ned - love seeing proper fabricating skills.

When I was buying a 996 12 months ago I generally found the ones without aerokits were less rusty.
 
Thanks guys. I made the arches from scratch. I basically made a template from cardboard, them out of 1/2" ply (an old school desk). Cut steel to size, screw to the template and then basically hammer the edge over. I used a plastic bossing mallet and plannishing hammer and dolly's. Takes a while but patience is key for a better finish.

I joddled the step in to give me room to move the arch to get the best fit. It'd be very hard to get the edges right to but weld. Also this is my first go at this so I wasn't sure. I plug welded all holes and seem welded the complete arch so should be water tight. Everything has weld through primer so even if water did get in, it's at least painted. And cavity wax too of course.
The inner arch (tub) was also cut out and made. This was not easy on the floor. Everything would have been easier on a ramp.

I'll see what pictures I can dig out. Like I said it's a bit of a faff to get them on here
 
Template for arch
 

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Arch seem welded
 

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Inner arch/tub. Not easy getting a decent photo due to space
 

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Rear of arches rough on both sides
 

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Rear of quarter panel cut out
 

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New inner and outer pieces fitted and joined. Everything round the arches have yet to be properly buffed back and filled but have been primed to keep them good
 

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Thanks for those. Looks really good.

I need similar doing to one of the rear arches on mine. Did a bodywork restoration evening course a couple of years ago, but still haven't put it into practice. Not sure if I've got the balls for the this to be the first job!
 
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