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PostPosted: Tue Feb 11, 2014 3:01 am 
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After about a 2 month back track I am finally just about back to even on this damn rear fender. My partial fix and repair patch did not turn out to my satisfaction so I had to scrap it entirely and replace most of this fender with an original donor from my coupster project. I created a lot of additional unnecessary work for myself but I had to grind through it to make this this fender right again or at least to the best of my ability so I could live with it. Below are the basic progress photos. More details and additional photos can be seen here:http://www.abcgt.com/forum/14-356-Restoration-Projects/34-58367-The-75-Junkyard-Carrera-coupe-restoration.html?limit=6&start=426 orABCGT.com


Attachments:
File comment: The more I fussed with the original repair the worse it became and before the session was over I put my fist in it out of frustration over all the time and effort lost. It was a done deal after that so I began fitting this new donor fender which was the original from my '56 coupster project. A ton of time to both prep and repair this new fender and to get the rest of the car ready to accept it.
carrera 1665.JPG
carrera 1665.JPG [ 698.19 KiB | Viewed 5587 times ]
File comment: I had cut this fender short years ago so it required both a profile and bottom extension to be welded on first.
carrera 1672.JPG
carrera 1672.JPG [ 704.14 KiB | Viewed 5587 times ]
File comment: It was tough to walk by this hole everyday for a few weeks.
carrera 1676.JPG
carrera 1676.JPG [ 688.74 KiB | Viewed 5587 times ]
File comment: Many, many test fits. Just about ready for a final trim here.
carrera 1677.JPG
carrera 1677.JPG [ 685.86 KiB | Viewed 5587 times ]
File comment: trimmed and tacked on here.
carrera 1695.JPG
carrera 1695.JPG [ 709.07 KiB | Viewed 5587 times ]
File comment: Of course I had to relead the entire jamb and rocker joint. Yet, more extra work...
carrera 1787.JPG
carrera 1787.JPG [ 708.6 KiB | Viewed 5587 times ]
File comment: I spent about 5 hours over several sessions ever so slowly stitching these two pieces together. Joint has been filed and plannished here.
carrera 1838.JPG
carrera 1838.JPG [ 720.75 KiB | Viewed 5587 times ]
File comment: Sealed in DP40 a few swatches of filler to catch the obvious stuff and a test coat to see where it was at.
carrera 1857.JPG
carrera 1857.JPG [ 747.73 KiB | Viewed 5587 times ]
File comment: First test coat last night. overall shape and reflection across the door gap is there but a bit more tweaking and block sanding yet to go. Just glad to be back at almost even at this point. Thanks for reading this! Justin
carrera 1859.JPG
carrera 1859.JPG [ 705.35 KiB | Viewed 5587 times ]
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PostPosted: Tue Feb 11, 2014 3:31 am 
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Location: Off Interstate 75 Midway between Chattanooga and Atlanta
Put your fist in it? Yes, that's exactly how I felt when right at the end I buffed through finish paint for the second time on the coupe. :x I had my foot reared back, and I thought,...I'll kick...you bastard!,..but I stopped, thankfully, set the buffer down, and walked away for a piece.
Saved me weeks of time, but if it had been metal work like you were facing, I might have done it knowing it was then coming out anyway. Must've been satisfying! I'll say there were many times I felt like doing the same thing.

What I like about you and your project is that you don't get disablingly discouraged. I mean, some folks do repairs, then aren't happy, then start the redo, and then basicaly peter out or give up. Not you! Always moving forward,..even if after a slight retreat.
This car OWES you! many many good miles...and soon it seems!


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PostPosted: Tue Feb 11, 2014 7:41 pm 
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Tag: Meanwhile, back at the farm...
Justin,
What welder are you using?

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'64 356 Signal-Red SC Coupe
'66 Early 3-Gauge 912
'65 VW Beetle
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PostPosted: Wed Mar 19, 2014 1:26 am 
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I sure did Steve, it was a culmination of the loss of time and effort I had spent on it previously and All the time I knew I had yet to commit to dig myself back out just to wind up even again! :x It was my period on the end of this sad attempt which I knew would close the door forcing me to install the replacement panel. Not to mention it just felt good to beat it since it pissed me off so badly..
Thanks for the nice words, What keeps me going at this point is that I am way too close to push it to the side now. Had I been further off a break may not have hurt but I am also 25 years behind schedule on it and more lost time is not a luxury I can afford to myself any more.

Subtle waves and ripples along the right side are still being eliminated. Two PIA's in particular on each side of the door but its ever so slowly taking shape but not without a fight of course. A few photos below with more details here: http://www.abcgt.com/forum/14-356-Restoration-Projects/34-58367-The-75-Junkyard-Carrera-coupe-restoration.html?limit=6&start=474

Also just finished having the mains on my POLO-motor machined and then hand polished for windage. A few shots below but I have started a dedicated thread for just this motor: http://www.abcgt.com/forum/6-Hot-Rod--Modified-356/13467-Polopolus-engine-build-for-junkyard-coupe-58367.html
Thanks for looking! Justin


Attachments:
File comment: Hey Tony I'm using my faithful old Miller 251 which I've had since I outfitted this shop. I'll give you a call, I have lots of scrap steel you can practice on.
540 465.jpg
540 465.jpg [ 122.5 KiB | Viewed 5085 times ]
File comment: Mains were machined first by my friend Bill and hand finished the rest of the way
A chassis 1159.JPG
A chassis 1159.JPG [ 703.23 KiB | Viewed 5085 times ]
File comment: Might be only good for 1-2 additional HP but every little bit helps...
A chassis 1157.JPG
A chassis 1157.JPG [ 747.4 KiB | Viewed 5085 times ]
File comment: One of my troubled areas is a slight peak at the fender edge distorting the reflection
carrera 1877.JPG
carrera 1877.JPG [ 704.02 KiB | Viewed 5085 times ]
File comment: Slight repeated tapping and follow up long boarding until its uniform.
carrera 1875.JPG
carrera 1875.JPG [ 694.83 KiB | Viewed 5085 times ]
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PostPosted: Tue Mar 25, 2014 11:39 pm 
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Location: Off Interstate 75 Midway between Chattanooga and Atlanta
Is that a Snap On Blue Point 8 oz? If not, it's a damned close approximation.
No finer "finish work" hammer in the world. I got mine my first year in aircraft mechanics school and dread the day I have to rehandle it. Being a part time hobby blacksmith I own over 30 hammers,...but when it counts,..and you've got to have the right feel,..that's the one I reach for.

You are indeed close on finishing. GOGOGO!
Yes, I am not above cheerleading, haha.

I also have to comment that I like your "third hand" shots where it appears you can hold the hammer, the wood buffer piece, and the camera,..all at once. I've had to do that myself at times for work progress pix and it's fun when it works out eh? The hammer clamps the wood piece in this one, and it's a nice action shot.


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snap on blue point.jpg
snap on blue point.jpg [ 86.24 KiB | Viewed 4930 times ]
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PostPosted: Thu Feb 19, 2015 11:28 am 
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Location: Beijing, PRC
Justin,

I have lost your email address - I hope you can assist me with some photos of the metal profile that accepts the rubber seal for the carrera motors. The metal profile (like a C with flat back) is located around the sides and back of the carrera engine tray in the engine compartment. I am looking for detailed photos of entire length of the profiel on the tray. You can reach me at the email on my profile. Thanks in advance for the help.

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#151489 59A Cab
#159176 64C Cab


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PostPosted: Wed Mar 25, 2015 2:33 am 
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Careful with that hammer Steve... that's final paint right? :) I looked at my hammer and its made by prototool. Though not a fancy snap-on version it was part of my old mentors collection so its very sentimental and still just as handy. Congratulations on actually finishing and driving your car, Well done! I watched your video the first time you fired her up.. very cool! Now, have you cut those extra-long exhaust tips back yet? If so how many times did you scob or burn your ankles/shins on them before you did?
Congratulations once again!

Bill, great catching up with you and thank you for all the suggestions and help recently. Appreciated!

I've decided to follow Bill's lead a bit and build a Faux-cam out of my Polo-motor for my car. Just recently purchased the entire 4-cam generator assembly complete minus the shroud tin from Peter Hofmann at classic parts in Germany. Below are a few shots of that. More photos and details of it can be seen here: http://www.abcgt.com/forum/6-Hot-Rod--M ... 6&start=24

Final paint beginning with the bumpers started this week and though I am several years behind schedule its all the more satisfying to be at this stage officially. More updates as painting and motor work slowly continues. Thanks for looking! Justin


Attachments:
File comment: Since I can't shoot metallic on with satisfactory results my neighbor and buddy Rick pictured here has generously volunteered is time and talent to help me. getting ready to shoot the bumpers here.
carrera 2149.JPG
carrera 2149.JPG [ 774.24 KiB | Viewed 3102 times ]
File comment: They turned as best as I could hope for with a uniform pattern and not a "tiger strip" to be seen. BUT we missed a lower corner on each bumper at the tip as they turn inward. The base was just fogged there without solid coverage. The clear was already on at discovery so no choice but to sand and try again.
carrera 2153.JPG
carrera 2153.JPG [ 702.2 KiB | Viewed 3102 times ]
File comment: Beautiful and accurate reproduction complete right down the rebuilt 12V generator.
carrera 2138.JPG
carrera 2138.JPG [ 733.77 KiB | Viewed 3102 times ]
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PostPosted: Wed May 20, 2015 1:36 am 
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Getting small nagging parts into final coat of silver.


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File comment: Dash now in final color. This allows me to seal the cabin off in anticipation for the final painting of the body.
carrera 2199.JPG
carrera 2199.JPG [ 756.61 KiB | Viewed 2874 times ]
File comment: My buddy Rick really laid down the flake nicely and could not be happier with it.
carrera 2202.JPG
carrera 2202.JPG [ 727.82 KiB | Viewed 2874 times ]
File comment: Another run of parts is off to Victor Miles as well. The pile of parts to be restored is really dwindling at this point.
carrera 2207.JPG
carrera 2207.JPG [ 714.35 KiB | Viewed 2874 times ]
File comment: Finished this batch out a couple of weeks ago. Only the body plugs and steering box access cover remain; then its just the big stuff like doors, lids and the body skin.
carrera 2219.JPG
carrera 2219.JPG [ 720.93 KiB | Viewed 2874 times ]
File comment: Now in process of thinning out the bodywork as much as possible without destroying the established body line in prep for the sealer.
Thanks for looking! Justin

A chassis 3629.JPG
A chassis 3629.JPG [ 725.93 KiB | Viewed 2874 times ]
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PostPosted: Wed Jun 03, 2015 10:37 am 
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Location: Montana
love it Justin. even has a few parts that were orginally on my cab..

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PostPosted: Sat Jun 27, 2015 3:53 pm 
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Justin,
Coupe line up and gabs looking better than factory...if factory spend the time you have ...They would have gone broke....:-)
Lovely work....

On the Carrera shroud ,please make sure #3&4 cylinder side will have different angle on 911 engines and 616 356 engines
and #1&2 cylinder section will have longer air guide wing ( Original Carrera Shrouds are short and different angle, will loose air force )
These modifications we do in our Carrera Shrouds we build. Each Engines have different length and angle of air guide wings to get the air
with max force to the cylinders and cylinder heads. Just a note for you.
Best,
Ibrahim Kuzu
4 Cam Cooling Parts
Dallas,TX

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PostPosted: Sat Aug 22, 2015 2:46 am 
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Thank you very much Robert! You must be talking about the gravel screen/fender brace with your chassis number on it. Tell you what, I'm all for getting bits and pieces back together with the car they originally came from. If you have or can round up another original tank screen I'll be happy to trade with you. Again, I just need it to be original and in like condition.

Hi Ibrahim, Thanks a lot! I also appreciate the tip concerning the internal veins. Its going to be a real work in progress as it goes but I will most certainly keep what you said in mind. Thanks again you guys! Justin

This coupe should have been painted months ago but my side job Coupe into Speedster project eats a lot of my off time now but I do try to set at least an hour a day so it continues to crawl forward. I'm just finishing up the last bit of back masking and will have it sealer hopefully by next week. I'd like to get it into finally paint soon as the motor for this project is beginning to really move forward and will most certainly be taking up a lot more of my attention. Below are a few updated shots and links to each if you'd like to see more. Thanks for stopping by! Justin

Polopolus Engine build for this car: http://www.abcgt.com/forum/6-Hot-Rod--M ... 6&start=66

Coupe into Speedster project: http://www.abcgt.com/forum/14-356-Resto ... =846#29417


Attachments:
File comment: A lot of free time for my car lost between this side project and my day job.
A chassis 4103.JPG
A chassis 4103.JPG [ 697.04 KiB | Viewed 2383 times ]
File comment: test fitting New 4-cam fan shroud from Germany on my 2.7 liter 964 polopolus motor build for this project.
carrera 2311.JPG
carrera 2311.JPG [ 751.08 KiB | Viewed 2383 times ]
File comment: Final masking almost complete and ready to go to sealer then.....Final paint. Finally.
carrera 2289.JPG
carrera 2289.JPG [ 732.92 KiB | Viewed 2383 times ]
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PostPosted: Thu Oct 22, 2015 10:22 pm 
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Bodywork and final paint job Completed. :D A couple of years behind schedule but this big milestone finally reached as of last week. Had to enlist the help of a good friend a fellow car builder-painter to ensure the new Silver paint went on like its supposed to. He did not disappoint, I'd realistically still be wrestling with the metal flake with mixed results at best. Turns out I'm more suited to a sanding block than a spray-gun; at least in dealing with metallic paint. Its certainly not perfect by any stretch but the car is at least to a level that I can stand to look at on a daily basis. The job of course did not go smoothly or as planned but perseverance eventually put it to bed. This long and sorted journey begins here: http://www.abcgt.com/forum/14-356-Resto ... &start=690

If you care to see more photos and details. The actual fun part of putting this car back together can actually begin. The next logical step will be a new headliner and or wiring harness installation.
Thanks for looking! Justin


Attachments:
File comment: Sealed, prepped and ready to go into the booth
carrera 2439.JPG
carrera 2439.JPG [ 738.69 KiB | Viewed 2179 times ]
File comment: In silver base
carrera 2457.JPG
carrera 2457.JPG [ 719.88 KiB | Viewed 2179 times ]
File comment: Clear coated and finally finished.
carrera 2501.JPG
carrera 2501.JPG [ 378.72 KiB | Viewed 2179 times ]
File comment: The true test of this paint job, direct sunlight. Couldn't have been happier with it.
carrera 2525.JPG
carrera 2525.JPG [ 453.39 KiB | Viewed 2179 times ]
File comment: All ready to come back home.
carrera 2519.JPG
carrera 2519.JPG [ 568.21 KiB | Viewed 2179 times ]
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PostPosted: Fri Oct 23, 2015 2:12 pm 
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Location: salton city
hi justin i'm trying to think of good words to compliment your project. pleasing might be an understated word. bitchin also comes to mind . seems like it's a milestone reached. congratulations fits. thanks for sharing

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PostPosted: Fri Jan 22, 2016 5:18 am 
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Thank you Ryan, I really appreciate that! Getting it in final color was a major miles stone as it means the corner has finally been turned to where I can actually begin assembling car after all these years. Not to mention the fact that I am just totally burned out on block sanding on this body; it was more than time to move on. Though I'm still in process of color sanding it :? but I can at least see the end of it coming. Thanks again! Justin

1/22/16

Slowly color sanding the finish and to break up that monotony assembling and installing what I can. New headliner has been installed and am just getting the front suspension set. More photos and details of that work here:
http://www.abcgt.com/forum/14-356-Resto ... =864#32062
Thanks for looking! Justin


Attachments:
File comment: Slowly color sanding a section at a time.
carrera 2677.JPG
carrera 2677.JPG [ 411.48 KiB | Viewed 1768 times ]
File comment: New headliner from AI installed.
carrera 2894.JPG
carrera 2894.JPG [ 3.28 MiB | Viewed 1768 times ]
File comment: Sail panels proved tricky to keep wrinkle free so being my first headliner it took me a bit longer than it would a pro.
carrera 2893.JPG
carrera 2893.JPG [ 3.39 MiB | Viewed 1768 times ]
File comment: New arms and spindles set with initial installment of the brakes.
A chassis 4693.JPG
A chassis 4693.JPG [ 3.5 MiB | Viewed 1768 times ]
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PostPosted: Fri Jan 22, 2016 9:29 am 
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Justin Rio wrote:
Bodywork and final paint job Completed. :D A couple of years behind schedule but this big milestone finally reached as of last week. Had to enlist the help of a good friend a fellow car builder-painter to ensure the new Silver paint went on like its supposed to. He did not disappoint, I'd realistically still be wrestling with the metal flake with mixed results at best. Turns out I'm more suited to a sanding block than a spray-gun; at least in dealing with metallic paint.
Thanks for looking! Justin


It's always good to follow the code of Clint, "A man's got to know his limitations."

The car looks great.

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