Restoration of my 1962 Super 90 Sunroof Coupe

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NateRicheson
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#16 Post by NateRicheson » Wed Mar 27, 2013 8:48 pm

Looks great what type of MIG welder are you using for the metal work. I'll be in the same boat here very soon with a much worse looking car.

Kevin Wills
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#17 Post by Kevin Wills » Fri Mar 29, 2013 2:18 pm

Bill, I can't tell you how true that is...

Nate, I can't take credit for the welds in the pictures. They are from the previous restoration. They look like oxy-acetylene welds to me. We are putting my car back together with a Hobart Handler 175 and .025 Easy Grind wire. The 175 is a bit hot for the thin stuff, but it is working reasonably well.

-Kevin-

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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#18 Post by Kevin Wills » Fri Mar 29, 2013 9:50 pm

Got the rear window channel cleaned and metal prepped after coming home from work early and washing my daily driver. Tomorrow, work on the driver's side closing panel continues. Enjoying the momentum...gonna keep grinding and welding...

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Greg Bryan
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#19 Post by Greg Bryan » Fri Mar 29, 2013 10:57 pm

Easy grind wire - I didn't know there was such a thing. I know the mig welds I make are harder than the back of my head! What's the brand or is it readily available from various suppliers?
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Kevin Wills
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#20 Post by Kevin Wills » Sat Mar 30, 2013 8:12 am

Greg, the brand I have is ESAB. It is pricey and took 6 weeks to get to my door. I'm not sure anyone actually stocks it... Well worth the price and the wait.

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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#21 Post by Kevin Wills » Tue Apr 09, 2013 10:37 pm

Quick update. Slowly making progress on the metal work. Two small patches, one in front of the gas door, the other behind the passenger side door. Dent pull holes were filled in on the front end. Lastly, rebuild of the driver's side closing panel continues. I hope to get the driver's side closing panel in primer by this weekend and continue with the rebuild of the outer structure.
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Kevin Wills
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#22 Post by Kevin Wills » Sun May 05, 2013 10:41 pm

I spent Saturday getting my stepson moved back to our house to begin a new job for a couple of months. Today, I got almost a full day of welding on the car. I got the driver's side inner closing panel buttoned up, finish welded my patch on the passenger's side quarter window, and tacked in patches that will blank out the license plate lights on the rear bumper. A good solid day of work and I am pleased with the progress. Slow but steady, I'll get this mess ready for primer...

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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#23 Post by Kevin Wills » Fri Nov 01, 2013 5:10 pm

Thought I might post some pictures of my progress lately. Progress comes slowly with a full time job and a six year old. I guess also slow because I am just a guy in a garage with a welder.

The good news that metal is basically done coming out (with the exception of the battery box) and is being fitted to go back in. The inner closing panels have been reconstructed. A fender repair panel has gone in on the drivers side. The full rocker came out on the driver's side and an outer rocker came out on the passenger's side. The replacement door on the passenger's side didn't work out, so a door bottom and lower skin are being fitted. Sharp eyes will notice that a C bottom is being installed to match the C bottom on the driver's side door. There is still much fitting and finishing work to be done, but this is where things are at today.

Next steps are to complete the rocker/fender/door fitting to set up the starting gaps and then tackle the battery box. Once these milestones are passed, the metalwork phase will be close to the end.

Hope you enjoy looking at the photos. I know it is nothing that nobody has seen before. For a pro, this would all be just routine stuff, but I am happy the project continues to move forward and wanted to share.
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Vic Skirmants
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#24 Post by Vic Skirmants » Fri Nov 01, 2013 5:29 pm

Kevin,
Good job. Must be very satisfying as you complete each step.

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Phil Planck
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#25 Post by Phil Planck » Fri Nov 01, 2013 9:19 pm

Kevin

Looking good. I'm at about the same point on my 63 S90, even though retired and after 12 years. Get it done before you retire, because you won't be able to find the time after that.
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Kevin Wills
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#26 Post by Kevin Wills » Fri Nov 01, 2013 11:28 pm

Thanks Vic and Phil. I have a few hundred hours in this so far with many more to come. It is very rewarding to return this car to its former glory and I can hardly wait for the day I get to drive it again. Maybe by the east coast holiday next year. We'll see...

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C J Murray
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#27 Post by C J Murray » Sun Nov 03, 2013 7:48 am

300 hours X $125 shop rate = $37,500, so far

I would be curious to hear how many hours you have invested when the car is finished. If anybody else has done their own body restoration, how many hours of their labor was required?
'57 Speedster
'59 Sunroof
'60 Devin D Porsche Race Car - Finally Finished!
'63 GS 2133 coupe
'64 Elva Courier mk4T
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Kevin Wills
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#28 Post by Kevin Wills » Mon Nov 04, 2013 10:01 am

Hi, Cliff. I am far less efficient than a professional. If I sent that bill to someone for what I have done so far, I am pretty sure I would end up missing. Good point, though about tracking hours. I should start keeping track.

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C J Murray
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#29 Post by C J Murray » Mon Nov 04, 2013 11:58 am

Hi Kevin,
When you work on your own car you tend to gaze and enjoy the results too much, at least I do. It looks like you are doing a top notch job.
'57 Speedster
'59 Sunroof
'60 Devin D Porsche Race Car - Finally Finished!
'63 GS 2133 coupe
'64 Elva Courier mk4T
'67 911 S Original Owner

Kevin Wills
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Re: Restoration of my 1962 Super 90 Sunroof Coupe

#30 Post by Kevin Wills » Fri Dec 20, 2013 12:34 am

Still making progress putting new metal in. Much work left to do, but the rear fender replacement piece and front fender patch are in.
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