Late 1959 S/R coupe project # 108625

Share progress on your 356 related project or full restoration with others!
Post Reply
Message
Author
User avatar
Martin Benade
356 Fan
Posts: 9533
Joined: Wed Nov 23, 2011 10:52 am
Location: Cleveland, Ohio

Re: Late 1959 S/R coupe project # 108625

#121 Post by Martin Benade »

More great work. You accomplish so much- do you work on this full time, or is this all done after coming home from a job?
Cleveland Ohio
62 Cabriolet
56 VW
02 IS 300
04 Sienna

Justin Rio
356 Fan
Posts: 891
Joined: Mon Aug 25, 2008 6:45 pm
Contact:

Re: Late 1959 S/R coupe project # 108625

#122 Post by Justin Rio »

Thank you Martin, on the contrary I'm slow as sh%t but I'm thorough and steady as she goes. These entries are a few years old and I'm just trying to catch this thread up to where the project stands today. I'm trying to convey as best as I can what actually goes into rebuilding a severely rusty car but these entries can still make the process seem deceptively easy. It is not and certainly nothing like assembling Ikea furniture. Nothing goes in without a fight and there are many hours of test fits, refits and frustration in between each posted progress photo. It might be too detailed for some but when the car is finished there will be a couple of detailed records on line as to what exactly is going on under all of its Shiny red paint ,new upholstery and fresh undercoating. The next custodian and its current one can have full confidence in this finished car they're looking at. As I've told friends before there is nothing I'd trust less than a freshly painted/"restored" 356 that's emerged from the shadows without a build history. Anyway, I'm rambling, thanks again Martin.


Fitting the old tube end into its new home.
IMG_7440.JPG
Aligning the tube. Close but the forward shoulder needs more rolling to allow the angle to drop in evenly.
IMG_7441.JPG
After some adjustment I finally got that tube section pretty much where it was before.
IMG_7442.JPG
New section is set into its final position. These two tube ends do come in at different angles which is probably why they remained separated like this.
IMG_7447.JPG
Tube tacked into final position.
IMG_7444.JPG
The tubes approach angle did put up a bit of a fight against that relief collar before I got all to align.
IMG_7449.JPG
Removed one last time to weld up the tube end as originally done.
IMG_7451.JPG
Seam welded the tube end to the opening of the shoulder as found.
IMG_7453.JPG
Only way to do it BTW as you'll never laydown a nice clean bead way down in here.
IMG_7455.JPG
Another test to check my fit and alignment after all that heat.
IMG_7454.JPG
Everything still in there and good to go. Time for the last detail. Heeling the bottom flange over. Getting close...
Thanks for looking.

Justin

Justin Rio
356 Fan
Posts: 891
Joined: Mon Aug 25, 2008 6:45 pm
Contact:

Re: Late 1959 S/R coupe project # 108625

#123 Post by Justin Rio »

IMG_7457.JPG
Flange added, plug weld holes in and at long last I have this final piece of this particular puzzle completed.
IMG_7456.JPG
Time now to get these inside surfaces treated and coated so I can close this up for good.
IMG_7458.JPG
Best I can do with the remaining surface rust was to treat it with converter.
IMG_7459.JPG
Then the inner cavities where slopped heavy with some epoxy sealer. A lot of heat still to come so I don't know how much of this will survive but it will offer at least some additional protection.
IMG_7461.JPG
Mounted back on... For good this time.
IMG_7460.JPG
Ready for the first few plug welds and tacks next.
IMG_7462.JPG
End of this tube at the elbow is literally within a wisp of where it was originally. As close as I could hope for.
IMG_7463.JPG
Commitment time. Plug welds and tacks added.
IMG_7464.JPG
Elbow joint tacked and set as well. Looks close though not an exact copy but it is proper 18 gauge and one piece. I can live with it. Welding it in the rest of the way next.
Thanks for looking.
Justin

DaveErickson
356 Fan
Posts: 1463
Joined: Sat Oct 26, 2013 9:34 pm
Location: Monterey, CA

Re: Late 1959 S/R coupe project # 108625

#124 Post by DaveErickson »

Justin, it looks very cool. Too bad it will all be hidden. There was a lot of work in there.

Justin Rio
356 Fan
Posts: 891
Joined: Mon Aug 25, 2008 6:45 pm
Contact:

Re: Late 1959 S/R coupe project # 108625

#125 Post by Justin Rio »

Thanks a lot Dave, Yes, a ton of work to copy and layer as it was found but most importantly it had to be strong and able to perform its job under load when its all finished. True it won't be seen again but we these old photos to show exactly what's going on under its longitudinal closing panels. Justin

Tying up loose ends in prep for closure of this cavity.
IMG_7494.JPG
Time to finish stitching up this long run.
IMG_7497.JPG
All welded and dressed.
IMG_7496.JPG
Welded the elbow joint back up next. Gas welded as originally. Very tough and tricky getting the blind side of the tube stitched in. Having it on a rotisserie made that possible.
IMG_7511.JPG
All that is left on this corner is the inner closing wall. 100% solid steel down in this junction once again.
IMG_7492.JPG
By the time this final inner wall is repaired there will be 4 layers of 18 gauge in this corner. Then when the floor is added that will make this flange 5 layers thick... then a 20 gauge(should be 18) longitudinal closing panel on top of that. This area ahead of the torsion housing will be very stout once again.
IMG_7512.JPG
Finished out the weld joint in and around the new flanged opening.
IMG_7513.JPG
Looking at this completed corner made for a very pleasant session...
IMG_7514.JPG
Just a couple more loose ends to go and I'll be fitting the closing panel.
IMG_7516.JPG
Right side just about ready to accept a new floor.

Thanks for looking.

Justin

Post Reply