Time to restore my 356 notchback

Share progress on your 356 related project or full restoration with others!
Message
Author
User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#46 Post by David Aronson » Mon Dec 11, 2017 8:08 pm

Well now I am well into this project. Metal work is done and waiting for Paint. Engine is in the process of the build. Walt from Competition Engineering worked all the kinks out of the engine. Crank case rebuild with a ton of work. Welding cracks, straightening out the crank bore, shaving the halves and line boring. Crank magnafluxed, ground, hardened, heads reworked with new and larger intake valves, new seats, new guides, etc. New cam, new followers, new rods, balanced throughout, re-surfaced flywheel, and more. Have finished the lower end, following all the Harry Pellow advice I never did when the engine was last rebuilt in the 70s. I may not end up with a broken crank this time...........
Attachments
0T0A0657.JPG
Crank ready
0T0A0657.JPG (23.65 KiB) Viewed 1977 times
0T0A0653.JPG
All surfaces gooped with Moly and special sauce. Ready to drop the crank
0T0A0653.JPG (24.23 KiB) Viewed 1977 times
0T0A0647.JPG
Applying Harry's special mystery sauce
0T0A0647.JPG (25.07 KiB) Viewed 1977 times
0T0A0645.JPG
making sure all oil passages are open
0T0A0645.JPG (22.79 KiB) Viewed 1977 times
0T0A0642.JPG
Installing the timing gear, spacer, distributor drive gear. A convection oven on the counter behind me. Slid right on.
0T0A0642.JPG (26.17 KiB) Viewed 1977 times
0T0A0635.JPG
Document the engine build date. Engine is matching.
0T0A0635.JPG (16.86 KiB) Viewed 1977 times
0T0A0631.JPG
torquing the rods. Don't forget the locktite
0T0A0631.JPG (27.33 KiB) Viewed 1977 times
0T0A0605.JPG
Parts back from Competition Engineering. thanks Walt!
0T0A0605.JPG (24.84 KiB) Viewed 1977 times
0T0A0596.JPG
parts back from the zinc plater
0T0A0586.JPG
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#47 Post by David Aronson » Mon Dec 11, 2017 8:13 pm

Continuing the engine build
Attachments
0T0A0679.JPG
Case is done. More pics in a couple days
0T0A0679.JPG (23.09 KiB) Viewed 1977 times
0T0A0676.JPG
Correct bolts
0T0A0676.JPG (19.19 KiB) Viewed 1977 times
0T0A0672.JPG
torquing the acorn case bolts. Yes, the seals and correct washers with bevel toward seal.
0T0A0672.JPG (25.47 KiB) Viewed 1977 times
0T0A0664.JPG
Timing varified
0T0A0664.JPG (21.84 KiB) Viewed 1977 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#48 Post by David Aronson » Mon Dec 11, 2017 8:23 pm

My metal man, John Holden, in Shingles Springs, advised me that he has had a stroke. He is OK, kind of...It did cause him some damage and he is not "back to 100%". He wanted me to know that all of his projects, concerning Porsche restorations, are now on hold for the foreseeable future. I am concerned but plan on sticking with John until more time for healing is allowed and a direction for his restoration side is known. In the meantime, do any of you have any suggestions for quality body work. Actually, the body work is done, now paint prep, painting and undersealing.
Any suggestions. I am not planning a move just now but need to get my alternative plan together.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

Neil Merrilees
356 Fan
Posts: 2
Joined: Sat Feb 04, 2012 11:49 am

Re: Time to restore my 356 notchback

#49 Post by Neil Merrilees » Fri Jan 12, 2018 5:54 pm

David

Before you move forward, talk to Brandon at Altissimo in Napa (close to American Canyon) Just a hop skip and a jump from you. I know he is busy right now, but he is a great guy, and just did a great job on my roadster. My roadster was also originally Condor Yellow, but after buying a quart and spraying it out (in 1988) I decided I didn't like it. I have some old single stage PPG condor yellow that may still be alive if you want to do a test (only one quart). If you have any overspray on your door hinge covers, that the place for a match.

I did the body prep and priming myself. I was about to paint the car myself in my garage, but fortunately, I ran into a post on this forum recommending his shop, and am I very thankful. If I did it again, I would have him do the prep and priming, as his shop turns out really beautiful cars, and he is really honest and efficient in his work. This year he had a couple 356's on the grass at the rennsport reunion, and he usually has a 356 or two in his shop. He sprayed on two part Spies Hecker, and it turned out great. I can't recommend him highly enough.
My car is now Signal red, which is what I have always wanted. Its not going to be for sale, it's going to be driven. Putting the charcoal carpeting in now.

Neil
 

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#50 Post by David Aronson » Mon Feb 05, 2018 1:38 pm

HELP! My body guy, John Holden, has completely tooled down since a stroke a few months ago. He has asked me to pick-up my car. The car is about 90% done in the metal stage. Does anyone know of a high quality body/paint shop in the Northern California area. I dread carting it down to the south......
Thanks for any ideas.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#51 Post by David Aronson » Mon Feb 12, 2018 1:01 pm

HELP...I heard there is a metal man in Placerville, first name Lance. Anyone know of such a person?
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#52 Post by David Aronson » Wed Mar 28, 2018 2:14 pm

OK, I found a fellow that is willing to take on the notch. Moving it next week. Should be ready for assembly by November. Finishing up the engine. Sheet metal back from powder coating. Waiting for one piece, lost in the years since engine was disassembled. Have made a tool to remove the steering arm from the steering box. Will include pictures soon.
Attachments
IMG_1526.JPG
IMG_1528.JPG
IMG_1530.JPG
20180328_112151.jpg
20180328_112202.jpg
Tool to remobe pitman arm
20180328_112215.jpg
20180328_112226.jpg
dipstickmetal.jpg
the missing piece. Walt at Competition Engineering is sending one. Great guy!
dipstickmetal.jpg (3.76 KiB) Viewed 1538 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#53 Post by David Aronson » Thu Mar 29, 2018 2:24 pm

20180812_134155.jpg
Engine complete ready for first run
20180812_134155.jpg (207.47 KiB) Viewed 796 times
About ready to start notch normal engine on run up stand. The engine is 1720cc, lightened S90 flywheel, 40mm intake valves, ported and matched, 912 rods, 83.5 JE pistons in bored cast iron cylinders, All balanced, new cam with street grind, new oil pump gears, timing gears. Just a nicely updated normal engine. Should work well. All machine work by Walt at Competition Engineering. Waiting for a new exhaust system to arrive.
Last edited by David Aronson on Mon Mar 25, 2019 1:06 pm, edited 1 time in total.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#54 Post by David Aronson » Mon Mar 25, 2019 1:00 pm

20180928_104015.jpg
20180928_104015.jpg (2.75 MiB) Viewed 797 times
image1540179099251.jpeg
image1540179099251.jpeg (296.37 KiB) Viewed 797 times
image1540179140731.jpeg
image1540179140731.jpeg (231.35 KiB) Viewed 797 times
image1540432335836.jpeg
image1540432335836.jpeg (351.59 KiB) Viewed 797 times
image1540432345140.jpeg
image1540432345140.jpeg (281.07 KiB) Viewed 797 times
OK, back with updates. Engine finished, car back from paint shop. I have made a bit of progress in the past 90 days. After the car arrived from Lance Lighthall's I got right to work. I have included a few catch up photos of the end of metal work and paint.
Attachments
20181128_120854.jpg
20181128_120854.jpg (3.38 MiB) Viewed 797 times
Last edited by David Aronson on Mon Mar 25, 2019 1:16 pm, edited 1 time in total.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#55 Post by David Aronson » Mon Mar 25, 2019 1:03 pm

20181202_101350.jpg
20181202_101350.jpg (230.63 KiB) Viewed 795 times
More photos of car in paint and delivery
Attachments
20181202_122351.jpg
20181202_122351.jpg (205.71 KiB) Viewed 795 times
20181128_120915.jpg
20181128_120915.jpg (176.78 KiB) Viewed 795 times
20181128_120905.jpg
20181128_120905.jpg (166.46 KiB) Viewed 795 times
20181128_120859.jpg
20181128_120859.jpg (163.57 KiB) Viewed 795 times
20181128_120854.jpg
20181128_120854.jpg (197.12 KiB) Viewed 795 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#56 Post by David Aronson » Mon Mar 25, 2019 1:20 pm

Now the car is home, painted and ready for assembly. Where did I put all the stuff I took off of her 6 years ago...........Hmmm.
Attachments
20181202_122351.jpg
Car finally up on the lift, let's begin!
20181202_122351.jpg (205.71 KiB) Viewed 794 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#57 Post by David Aronson » Mon Mar 25, 2019 1:50 pm

First thing is to pull the wiring harness into all the tunnels. I used a new harness and kept the old, totally intact with switches and controls in their original configurations. It really helped me figure where the wires went.
Attachments
20181204_125457.jpg
Old harness laid out for reference. I do intend to sell this out or lend it out if anyone needs one for reference.
20181204_125457.jpg (216.41 KiB) Viewed 792 times
20181204_125447.jpg
20181204_125447.jpg (194.46 KiB) Viewed 792 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#58 Post by David Aronson » Mon Mar 25, 2019 2:20 pm

Once the harness was installed, I began on the sound proofing and under-layment restoration. I found some very early rug padding from a mom and pop flooring store in town. After visiting Ted Blake's restoration center in Sacramento, stealing with my eyes as I am known to do, I came back with some great tips. One, use Wurth stoneguard black as your media. it is water soluble so easy to clean up and is the correct black color. It is expensive though. Then find a good adhesive. The 3M Super 77 is a great adhesive. On sale at Stoddard for over 25 bucks. What a rip. Lowes has it for 8 bucks and change. Also, Weldwood contact cement is great for large surfaces that you can get to with a brush. Much cheaper. I then experimented and found that the rug padding and 50lb roofing paper worked perfect. I ordered the Stoddard kit and found it inappropriate as it did not match the standard material in thickness or texture. I did use some of it as templates for sizing initially. I gave up on that and made my own from pictures and the old materials removed from the car. I maintained that in storage. What a mess.....
20190325_110121.jpg
the three chemicals needed.
20190325_110121.jpg (176.72 KiB) Viewed 791 times
20190325_110144.jpg
The two hard materials. Rug padding and roofing felt
20190325_110144.jpg (167.03 KiB) Viewed 791 times
20190325_110154.jpg
The finished product. A close reproduction of the original sound proofing materials found in my car.
20190325_110154.jpg (163.06 KiB) Viewed 791 times
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#59 Post by David Aronson » Mon Mar 25, 2019 2:21 pm

Now to work, sound proofing the notchback like it was originally.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

User avatar
David Aronson
356 Fan
Posts: 136
Joined: Mon Nov 24, 2014 12:58 pm
Location: Vacaville, Ca
Contact:

Re: Time to restore my 356 notchback

#60 Post by David Aronson » Mon Mar 25, 2019 2:28 pm

More pictures on the soundproofing on the notchback. I tried to fit the panels prior to saturating with Wurth. Then I would apply the roofing felt and paint with the wurth, form the panel with heat and pressure, then apply to car with adhesive. I originally used the 3M 77 as it was easy but required masking. I used Weldwood on most of the work as it was easy to apply and did not require masking in most areas.
Attachments
20181219_121630.jpg
20181219_121630.jpg (184.17 KiB) Viewed 789 times
20181219_114623.jpg
Cutting and fabricating soundproofing panels. Tedious work.
20181219_114623.jpg (200.84 KiB) Viewed 789 times
20181218_142606.jpg
20181218_142606.jpg (234.44 KiB) Viewed 789 times
20181218_142550.jpg
20181218_142550.jpg (202.83 KiB) Viewed 790 times
20181218_135238.jpg
20181218_135238.jpg (211.05 KiB) Viewed 790 times
20181227_104159.jpg
20181227_104159.jpg (130.11 KiB) Viewed 791 times
20181227_103852.jpg
20181227_103852.jpg (201.36 KiB) Viewed 791 times
20181227_103834_006.jpg
Fabricating and forming out of car was a clean option and kept the overspray away from previously restored areas.
20181227_103834_006.jpg (133.69 KiB) Viewed 791 times
Last edited by David Aronson on Wed Mar 27, 2019 11:53 am, edited 1 time in total.
61 Karmann Notchback 200831
67 Karman 912 461567
74 911 Targa (3.0 SC motor)
83 911SC (Concours award winner, still)
64 VW coupe
Vacaville Ca.

Post Reply