My Attempt at a metal wide body build

[Kongsodoken]

Not had much time recently but now things are calming down I’ve had chance to do some more work on the car so thought it about time to document the process!

so the plan
new sills
rust repairs
widen the car so I can use early offset wheels
complete bare metal respray DIY
sunroof delete

never done any body work before never painted a car before but thought I would give it a go
end of the day it’s only paint -I can sand off and do it again.
Ive had several quotes for the experts to do this 8K for the wide body and sills (plus sills) and 12K for the bare metal respray.
for me this is more about the challenge and the doing than the end result.

to start I brought an EBay £400 mig welder now I have done some welding when I was an apprentice but that was 40years ago so I know what a good weld is but took a bit of practice to get there.

started on the sills - so of this I may have posted before

sills off and everything painted in epoxy

 

[Kongsodoken]

The drivers side I removed the whole sill which was then a pain to grind back under the door hinges so on the passenger side I cut the sill short much easier to fit and weld

 

[Kongsodoken]

I always thought that my 944 was rust free -how wrong was I these cars hide rust so well this is behind the rear wheel - evidence of a previous repair just filled with filler

 

[Kongsodoken]

Rust repairs so far have been the hardest part of this build
watch a few youtube videos and made a tape template then started bending the metal

 

[Kongsodoken]

After a lot of hammering and test fitting I finally got a good fit and just a slim coating on 3m epoxy metal I’m very happy

 

[Kongsodoken]

Welded the sill up my welding is getting better

 

[Kongsodoken]

More rust repairs

 

[Kongsodoken]

Now the fun starts thought long and hard about taking an angle grinder to my car but what’s the worst that can happen

 

[Kongsodoken]

And a few more pictures starting to cut the steel to fill the gaps

 

[russmw]

Totally admire your determination and “give it a go” attitude especially after giving body work/painting a try and failed horrendously (bringing dead paint back to life, electric, mechanics and interior stuff I’m good with but not bodywork).

Looking forward to seeing more updates.

 

[scam75]

Jeezo Ken, talk about a change of direction! Good luck, I am sure you will enjoy the process! Awesome work so far, puts my handbrake shoes job into perspective!!

 

[AnotherPITA]

Fair play, you need some guts to take a grinder to your car. What is your end goal - hopefully a usable street car with it's own identity?

 

[dlknight]

I nervously looked at those pictures of the front and rear wings with the cut down them! Great work though!

 

[blade7]

I've mentioned before that I did an apprenticeship as a fabricator welder, when I left school. So I used to be fairly handy with sheet metal work and welding. But panelling up, and painting a whole car, and a curvy one at that is something I never fancied. Not so bad if you have access to a modern spray booth I suppose, even that Tim fella on car SOS managed to paint a white Manta.

 

[Kongsodoken]

A little more progress
lots of hammer and dolly work and a thin skim of 3m epoxy and it’s taking shape

 

[Kongsodoken]

hardest bit by far welding upside down in the wheel arches but it’s done forgot to photograph it before the epoxy went on

 

[Kongsodoken]

I've mentioned before that I did an apprenticeship as a fabricator welder, when I left school. So I used to be fairly handy with sheet metal work and welding. But panelling up, and painting a whole car, and a curvy one at that is something I never fancied. Not so bad if you have access to a modern spray booth I suppose, even that Tim fella on car SOS managed to paint a white Manta.

I’m just very patient so do a little at a time and do it until it’s perfect
I think it’s an easy car to paint it’s solid colour and except for rear panels can be painted separately if needs be.
if It’s not good sand it off and try again -

 

[Kongsodoken]

I nervously looked at those pictures of the front and rear wings with the cut down them! Great work though!

Sorry should have added a 18+ certificate in thread title

 

[Kongsodoken]

Fair play, you need some guts to take a grinder to your car. What is your end goal - hopefully a usable street car with its own identity?

Guts or a few screws loose - just a bit of fun really see if I can do it
looking for a “singer” 944 a car that looks original but with a little something extra but you would need to know your onions to spot what the extra is

 

[Kongsodoken]

Jeezo Ken, talk about a change of direction! Good luck, I am sure you will enjoy the process! Awesome work so far, puts my handbrake shoes job into perspective!!

thanks - actually I felt well chuffed when I got my handbrake working