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oh my god help

Colin,

Thanks for the tip I'll have a good poke around there... next weekend I'm planning to take the door off and then remove what remains of the sill. I got a new sill panel from OPC cambridge (apparently they are selling like hot cakes at the moment... only a couple left!). I see what you mean about the sill, going to be tricky to get the mig welder into the shape at the bottom.

Rob
 
I found the way to do it was to drill a line of holes in the sill, get the car as high as you can on that side and plug weld it.Leave the side your not working on on the floor and get the side your doing as high as poss.Also do all the other welds first and the bottom edge last.

Hope this helps
 
When I did mine couple of weeks back, I did some of the welds from the underside of the car - i.e. I drilled through the seam on the car (before I put the new panel on) and welded onto the new sill panel, much easier access.

Good call on the genuine Porsche Sill - I made a repair section for the Driver's side and it was a right pain, then the ebay panel I bought for the passenger side wasn't a great fit either!
 
Sill almost off! It was crusty along the whole length, even though it was a way off rusting all the way through.

IMG-20130907-00377_zps51ef3374.jpg


Very satisfying but I'm sick to death of drilling out spot-welds.
 
Your really lucky Rob your intermediate panel looks really good. Just give it a clean and a paint with some zinc paint. Job looks like it's going to be really good repair.
 
Colin,

Thanks, yes I'm very lucky with the intermediate panel especially since the outer sill was in a very bad state. No point doing half a job I want it to be good for the next 25 years. Treated myself to a joddler/punch to get the panels and plug welds just right.

Planning on wire brushing the intermediate panel and giving it a good load of weld-through primer.

Rob
 
Nice Rob.
I found it easier to do the bottom of the back quarter and all the bits and bobs at that end first and then put the sill on last.
 
Looking really good, I thought you needed 2 brace the door. Looks too be going very well. Top job
 
Colin,
Sill not welded on yet, I like to get all my repair panels made up before welding anything, just had to clamp it there to see what it looked like! Don't have a plan of action yet but putting the sill on last makes sense.

Getting the rear quarter right is going to be tricky...

T3rra... hope I wasn't supposed to brace the door! I saw plenty of photos of 944's with sills missing and no bracing, and I assumed that the remaining inner sill and roof would hold everything together. Pretty sure nothing has moved around because the new sill is a perfect fit. I left the car on it's wheels to try and stop things moving.

Rob

 
Thanks all for the encouragement... had a real slog of an afternoon re-making this really tricky inner section. My first attempt just wasn't right, this time I made it out of two pieces to get the shape right and have some adjustment.

IMG-20130914-00389_zps70ce883f.jpg


IMG-20130914-00388_zps512e2f2b.jpg


I've invested in a shrinker/stretcher because I need to make some more wheel arch repair sections for the rear quarter, the outer piece is made with that (plus some cuts to do the really deep curves) and then the inner piece is just a shaped flat bit of steel.

Just tack welded in for now, it will all be seam welded and then dressed down... will look like a work of art then, shame it can't be seen!
 
Some more progress in a couple of hours this weekend (was supposed to be decorating the spare room, managed to sneak out to the garage!)

All the repair pieces clamped into place or temporarily secured with self tappers
20130921_180447_zps281a11d7.jpg


Getting these curves 'right' was a nightmare with nothing to work to. The rear quarter repair panel is from Elliot, the shape was bang on but needed some fettling with the shrinker/stretcher to get the curve right. On the back side the curve follow the wheel arch and the front side it follows the sill.
20130921_180516_zpsdfb108c6.jpg


Much better view down the door shut hole now!
20130921_180601_zpsbd86a6dd.jpg


Feeling buoyed now it's starting to take shape...
 
Looks really good Rob. Now get the metal sticky together machine out and stick it together!!!!!

[:D][:D][:D][:D][:D][:D]
 
Yes sir!! Next weekend hopefully!

Any ideas how to get a good seam across the rear quarter? At the moment it's joddled but hard to get enoigh clamping force on it to get a flush joint. Wondering if I should just cut it across and do a butt joint.
 
I did like you a joggled edge then hammer shaft in through vent hole and push the panel flush then tack. I them seam welded it and dressed the weld down with a flap pad. Just go slow and dot dash the seem weld in order to not get too much heat into it.
 
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