My SC coupe project. Made by hand…again.

[Michael Doyle]

You’re doing a fantastic job on your restoration. When interior time comes, I make the proper recreated Reutter Headliner for your car. The material is color matched very light grey with the elongated Diamond hole perforation pattern. Contact me for more info if interested. best/Michael

[Tom Perazzo]

Thanks Michael, My car is a karmann. Is that pattern different?

[Tom Perazzo]

Did ZF make replacement boxes with a slightly different casting?
I have one that has a metal tag on it with a date code of 566
Was that made is 66?
Just curious, I have a few other boxes too dated 63 and they are slightly different.

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More details in this video:
https://youtu.be/24YhU9gHm3A

[Tom Perazzo]

Steering box now installed, adjusted, and looking good. Will add the locking plate tabs when doing final torque on the entire front suspension.

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Full YouTube video here showing steering box rebuild and how I measured the tight spot torque

https://youtu.be/4XFIendCXH8

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[Tom Perazzo]

Ever wonder what the inside of the tunnel in the tunnel look like? I snuck a boroscope camera in there to check for sharp edges.

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Here's the full video and wire harness install.
https://youtu.be/1pj-OBDK6X4

Cheers
Tom

[DaveErickson]

My 356 is back home in my garage!

356 on trailer.jpg
356 back in garage.jpg

I bet you didn't know this would be a life long project did you?

Tom, I’ve enjoyed this thread for all the detail and beautiful work you have done. Did you post the work on the cowl or the exterior body in another forum? I have some damage to the interior cowl on my D, not quite sure how it got there, but it looks like fatigue cracks in the opening under the dash where the hinge comes through, so I would really enjoy seeing what you did to repair your cowl.

Also, you refer to the use of osphoric acid several times. I am familiar with phosphoric acid, what is the difference? Are both acids readily available? I’ve used a metal etch product that contains dilute phosphoric acid that leaves a coating that stops flash rust.

[Tom Perazzo]

I had a heck of a time installing the OEM asphalt based tap paper. Here is the second attempt.

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Tough to do on a cold day, so I ended making a makeshift disposable oven.

Here's the install video:
https://youtu.be/ilNYn2x2mss

[Tom Perazzo]

Moving on to the rear now.
I hate to cover up this cleanly painted engine bay.

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Here's the rear firewall pieces in position. The lower one gets glued and the upper one does not.

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I put some temporary push nuts in, but I'll replace with round once the interior is in.

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Still need to add the rear latch and shelf pieces and of course screw the side panels down.

Full YouTube vid here:
https://youtu.be/eEbxiw2Srrw

[Tom Perazzo]

Front sound insulation now installed.

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Kinda hard to work with this authentic material, but it does look original.

Full install video here:
https://youtu.be/KxUYWKWN6Ds

[Tom Perazzo]

This car is finally back on four wheels again albeit temporarily.
I decided to inspect the transaxle and found a worn bearing, so the car has a temporary trans installed for now, but the assembly continues.

Most of my work is covered in video format these days if your interested. It's a weekly vlog style.
https://youtu.be/37zLL8A8qwM

[Phil Planck]

Looks great Tom. I think your going to beat me to the finish line.