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g911omr
Spa-Francorchamps


Joined: 29 Sep 2009
Posts: 307



PostPosted: Thu Nov 14, 2019 9:55 am    Post subject: Reply with quote

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.
 
  
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TurboRob
Silverstone


Joined: 18 Feb 2019
Posts: 108



PostPosted: Thu Nov 14, 2019 11:43 am    Post subject: Reply with quote

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.
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 2:03 pm    Post subject: Reply with quote

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
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 2:12 pm    Post subject: Reply with quote

Template for arch
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 2:13 pm    Post subject: Reply with quote

Arch seem welded
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 2:14 pm    Post subject: Reply with quote

Inner arch/tub. Not easy getting a decent photo due to space
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 2:15 pm    Post subject: Reply with quote

Rear of arches rough on both sides
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 2:16 pm    Post subject: Reply with quote

Rear of quarter panel cut out
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NedHan79
Hockenheim


Joined: 08 Nov 2018
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PostPosted: Thu Nov 14, 2019 2:18 pm    Post subject: Reply with quote

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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rgracin
Newbie


Joined: 24 Jan 2014
Posts: 36



PostPosted: Thu Nov 14, 2019 6:07 pm    Post subject: Reply with quote

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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2000 986 Boxster S
 
  
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NedHan79
Hockenheim


Joined: 08 Nov 2018
Posts: 679



PostPosted: Thu Nov 14, 2019 6:41 pm    Post subject: Reply with quote

I’ll admit I was very nervous (for want of a better expression.lol) about cutting it all out. I was bricking it about cutting the arches out but found that it was a lot easier making them than the likes of the front of the sills.

A 911’s not the cheapest yoke to be learning on Floor
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