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Gazc2
Barcelona


Joined: 08 Nov 2003
Posts: 1397
Location: Scotland


PostPosted: Mon Oct 03, 2016 4:13 pm    Post subject: Reply with quote

Ive never tried that before holding the car up with the handle on the trolley jack Very Happy
_________________
2007 997 Turbo & 924s in progress
1990 964 C2
1989 3.2 targa
1987 3.2 Cab
1986 3.3 Turbo
1986 944 2.5 (later fitted with a 2.7 after wife went scuba diving in a flood and popped a piston through the block)
 



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dommorton
Shanghai


Joined: 16 Mar 2008
Posts: 4999


1998 Porsche 993 Carrera 4S

PostPosted: Mon Oct 03, 2016 6:24 pm    Post subject: Reply with quote

Oh Car-o-liner

I'll get my coat Get Me Coat
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Good cars can get you from point A to point B. And great cars? Well, they'll just get you into trouble.
 
  
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Cameltoe & Heel
Österreich


Joined: 26 Jan 2009
Posts: 957
Location: Preston - Lancs


PostPosted: Wed Apr 19, 2017 2:56 pm    Post subject: Reply with quote

Folks,
some more progress made recently so I thought I'd post some pics:

Car loaded and ready for trip to the garage:

Work is being done at CrashUK in Bolton, you can judge the workmanship for yourselves.







Being winched onto the jig:



Sat on jig but still on trolley:



Car now secured to jig with custom welded brackets, N/S rear leg was 4mm (due to wheel impact) out of factory dimensions where the side panel bolts to the chassis leg, so pulled straight.

Trick here was that it was only out in one spot so had to hold the remainder of the leg solid hence chain and bracket being held from O/S, and RAM from N/S.



Rear view:



Ram setup on O/S now ready to pull small indent from chassis leg due to wheel impact, chassis leg this side was spot on and well within factory tolerance:



Here you can see how Colin has welded two plated onto the chassis to pull out the O/S indent damage:



A clearer shot:



After pulling straight, removing plates and cleaning up:



Now fill the area:



It's always best to pull the damage in the panel back to where it was to ensure the best fit when installing new panels:



Same on N/S, impact pulled back on panel, not to save panel just to ensure everything goes back to where it should be:



All engine aperture measurements taken and compared to factory, rear quarters now removed on both sides as well as the top scuttle panel.

And with those panels goes the inherent Targa rust beneath roof problems Smile. New panels will receive plenty of layers of protection along the top edges of the panels to ensure rust will not return.



O/S without rear quarter:



N/S without rear quarter, notice how the sill has been cut ready for new panel, this juncture will butt to new panel and be braise welded to ensure reduced distortion compared to Mig, braised welds are also much better for rust prevention.



Rear quarters clamped on for mockup purposes at this stage. The quarters will be spot welded as per the originals however Colin is going to use additional special panel bonding which conducts allowing you to spot weld through. this should help give the panels more rigidity and hopefully the chassis. Spot weld locations noted to ensure perfect match to original panels.



Rear quarters are now primed on the inside and will be seam sealed:



Checking door gaps on mockup:



Much more to come within next few weeks, paint is booked in for 2nd May.

Trev
 
  
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Millomboy
Suzuka


Joined: 10 Dec 2012
Posts: 1007
Location: Hampshire

1997 Porsche 993 Targa

PostPosted: Wed Apr 19, 2017 4:52 pm    Post subject: Reply with quote

Epic. Bow
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Ocean blue targa.
The only true freedom, is freedom from the heart's desires. And the only true happiness, this way lies.
 
  
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NottsRS
Barcelona


Joined: 11 Jan 2009
Posts: 1301



PostPosted: Wed Apr 19, 2017 4:57 pm    Post subject: Reply with quote

Good work Trev. Get stuck in there boy thumbsup
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993 RS | Riviera Blue | Lightweight
964 RS | GP White | Lightweight
993 4S | Viola Metallic | Factory Non Sunroof | [Jan'09-Mar'16]
 
  
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MilSub
Spa-Francorchamps


Joined: 10 Jun 2014
Posts: 274
Location: Hampshire


PostPosted: Wed Apr 19, 2017 5:21 pm    Post subject: Reply with quote

Incredible work Trev - have just read the whole thread worship I had no idea that machinery like the car-o-liner existed - amazing pictures, amazing story!
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1996 Carrera 4
 
  
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Cameltoe & Heel
Österreich


Joined: 26 Jan 2009
Posts: 957
Location: Preston - Lancs


PostPosted: Wed Apr 19, 2017 6:49 pm    Post subject: Reply with quote

Thanks guys, glad you enjoy the story so far, long way to go yet but it should start coming together soon.

Colin did my Mitsubishi Shogun 4 Work which I bought with a smashed in front end, did a great job on that and I've been using that for the last three years and serves as my work horse for parts runs, tip runs and often as my daily commuter if the mrs has the Range.

His usual work is on top end sports cars, repairing Lambo's, Bentley's, Fezza's etc which have real damage so this is nothing to him. He's a real enthusiast of his trade, and it comes across when you talk to him. The tools he has are just amazing.

Colin's really enjoying working on the 993, says the build quality is amazing and very rust free for a 20yr old beast.

I'm going to pick up two new check straps from Porsche Bolton tomorrow lunch so will pop in and see the work in the flesh

Just wait to you see his welds Smile

Trev
 
  
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h2no
Newbie


Joined: 04 Aug 2015
Posts: 32
Location: Newport, South Wales

1995 Porsche 993 Carrera 2

PostPosted: Wed Apr 19, 2017 9:32 pm    Post subject: Reply with quote

Loving your thread, will be interested in the door straps tomorrow, as I need mine done too.
 
  
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Jet Jock
Nürburgring


Joined: 18 Jul 2005
Posts: 484
Location: Dublin


PostPosted: Wed Apr 19, 2017 10:18 pm    Post subject: Reply with quote

Thread just gets better. Thanks.
_________________
993 C2, RSR's, Cargraphic 100 Cell Cat, Turbo Twist Hollows, Brembo Big Reds Turbo Brakes, Big Ovals, Wayne Schofield Remap, KW Supersport set up by Chris Franklin, RS engine and transmission mounts, Fabspeed induction kit, HID conversion...
 
  
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AP90
Spa-Francorchamps


Joined: 25 Sep 2004
Posts: 282
Location: Cornwall UK


PostPosted: Thu Apr 20, 2017 9:05 pm    Post subject: Reply with quote

Thank you for taking the time to shoot and post, very interesting
 
  
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Cameltoe & Heel
Österreich


Joined: 26 Jan 2009
Posts: 957
Location: Preston - Lancs


PostPosted: Fri Apr 21, 2017 1:17 pm    Post subject: Reply with quote

Ok chaps, hope you don't mind picture overload:

This was inside O/S rear quarter, great protection applied at the factory which we've looked to replicate where we can:



Inside the new quarter which has been primed and seam sealed in the appropriate areas, including right down to the sill, all done prior to fitting to ensure access:



Method used here was to use a brush initially and then a spreader with a course sponge attached to get the correct texture.



And again:





Tops of the inner wings were dirty but also showing some small rust spots which needed to be remediated correctly:





O/S not as bad:



Down to bare metal:



Now upper inner wings treated with this 2k high build primer brushed on nice and thick.





Rear quarters are being spot welded on today, Colin asked which pattern I would like, his regular or follow Porsche?, i said to follow the Porsche pattern although it doesn't really matter as the roof sits here and hides all welds. It's inside the rear engine compartment where the visible welds are Smile



Will post pics of the welds v.soon.

Trev
 
  
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BHZ661
Österreich


Joined: 03 Feb 2015
Posts: 976
Location: Milton Keynes


PostPosted: Fri Apr 21, 2017 3:16 pm    Post subject: Reply with quote

Fantastic read and looking forward to updates thumbsup
 
  
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Cameltoe & Heel
Österreich


Joined: 26 Jan 2009
Posts: 957
Location: Preston - Lancs


PostPosted: Mon Apr 24, 2017 8:42 pm    Post subject: Reply with quote

Right chaps a few more updates......


Prepped with black panel bond ready for new quarter, have to be quick as the bond goes off.



Rear quarter fitted and sill now ready for welding, decided to go with mig welding in the end for strength.



Trying a few test spots:



Sill now welded and prepared:



Quarter spot welded and panel bonded along top edge following the original pattern of spots:



Along the door seam here was tricky due to a small lip on the rear:



Along the engine bay aperture is very important as it can be seen when opening the engine lid, Porsche pattern and precise copy of original weld made here:



Just some of the equipment used, never underestimate what investment it takes to perform works on a car if you're going to do it right:



Rear quarter now in place, you can see the seam of black panel bond from within the wheel arch, this will be cleaned up a little and another line of dealer applied to keep out any nasties:



Engine aperture now with both rear quarters fitted:

 
  
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Cameltoe & Heel
Österreich


Joined: 26 Jan 2009
Posts: 957
Location: Preston - Lancs


PostPosted: Fri Apr 28, 2017 4:50 pm    Post subject: Reply with quote

OK so whilst the car was at the bodyshop it was time to fix the check strap arresters. Mine was making the dreaded clicking sound on both sides which just wouldn't do.

Anybody who's looked into this will know there's a few ways to do the job,

1) Quick blob of weld on the outside to hopefully hold it
2) Cut window into the A post and re-weld the joints properly
3) Install new Porsche A post which have modified welds and additional strength so I believe?.

I've opted for option 2 as it seems somewhat less intrusive than replacing the full pillar.

We can see the state of the welds here on the A post, not good:



After a cleanup:



Whole section required cutting out:



New steel sections making for both sides:





Section offered up with two holes for the weld:



And primed:



Ready for welding:



Welded and made good, now just needs some primer before going to the paint shop:



Lots of work but the job needs doing right.

Trev
 
  
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ballcock
Sepang


Joined: 22 Jul 2008
Posts: 2812
Location: Dublin

1996 Porsche 993 Carrera 2

PostPosted: Sat Apr 29, 2017 3:33 am    Post subject: Reply with quote

Fab thread Trev, really enjoying the detail and the many pics..
Rgds
Barney.
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'96 Iris C2 vario manual coupe, Koni FZD's/M033's RSR's and HID's.
'83 W460 LWB G Wagen updated with OM602 engine and 6 speed 'box ...My daily driver

Ex. '99 996 C2 manual coupe.
 
  
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