AWD 964/911 Bus

Show off your pristine van, restoration, or daily driver.
Post Reply
User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

Offered up the doors today and at first it all seamed ok -

ImageDoggy Doors by Duke of Boots1966, on Flickr

....but then some issues started to raise their heads. I am sure this should close further....

ImageDoggy Doors by Duke of Boots1966, on Flickr

this seems ok

ImageDoggy Doors by Duke of Boots1966, on Flickr

ah rats, a good inch at the bottom which makes me think the door bottom is warped which given the crap welding and repairs that are down there is a distinct possibility.

ImageDoggy Doors by Duke of Boots1966, on Flickr

and the off-side is not much better.

ImageDouble door trouble by Duke of Boots1966, on Flickr

ImageDouble door trouble by Duke of Boots1966, on Flickr

ImageDouble door trouble by Duke of Boots1966, on Flickr

Looked online but CandC have stopped doing the bottom section frame repair and their correct fit replacement door is for 55-60 so has the wrong handle pressing. hmmmmmm :roll: :roll:

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

Nothing a bit of filler can't sort out.....

ImageAll straight and level by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

Cut the dash out of the bus today and got to the heater tubes. Hmmm some work required.

ImageDash it by Duke of Boots1966, on Flickr

ImageDash it by Duke of Boots1966, on Flickr

ImageDash it by Duke of Boots1966, on Flickr

ImageDash it by Duke of Boots1966, on Flickr

ImageDash it by Duke of Boots1966, on Flickr

ImageDash it by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

Started tackling the dash repairs today. could be a long job.

ImageDash 2 by Duke of Boots1966, on Flickr

Not much to weld to so out it comes

ImageDash 2 by Duke of Boots1966, on Flickr

ImageDash 2 by Duke of Boots1966, on Flickr

Hole gone

ImageFast 3 by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

There is something not quite right with my parcel shelf, answers on a postcard.........

ImageMishmash by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Purists look away now!

Post by john&hannah »

I resigned myself to resurrecting my worm ridden air box but purists should look away now!

ImageCheese by Duke of Boots1966, on Flickr

ImagePurists look away now! by Duke of Boots1966, on Flickr

ImagePurists look away now! by Duke of Boots1966, on Flickr

ImagePurists look away now! by Duke of Boots1966, on Flickr

dom_k
Registered user
Posts: 147
Joined: Mon May 02, 2011 8:06 am

Re: AWD 964/911 Bus

Post by dom_k »

Loving the previous parcel shelf ‘repair’ - the pressings in the plate nearly match the originals :lol:

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

:compress: The left hand side is fat lip pressing and the right hand side is thin lip pressing so it can be used on all years of bus :lol:

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Less ventilation more metal

Post by john&hannah »

Spent the day repairing the sidewall of my cab air box today. Tough finding any sort of metal to weld to and add the mig on such a low amperage it felt like soldering :cyclopsani:

Before -

ImageLess ventilation more metal by Duke of Boots1966, on Flickr

After -

ImageMore metal by Duke of Boots1966, on Flickr

ImageMore metal by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Left and Right stuff

Post by john&hannah »

Got the steering box and associated U/J's in today and fabricated the morning brackets.

ImageLeft and right stuff by Duke of Boots1966, on Flickr

ImageLeft and right stuff by Duke of Boots1966, on Flickr

Looking back towards the Porsche 964 steering rack

ImageLeft and right stuff by Duke of Boots1966, on Flickr

Steering box on the right bidding behind its mounting bracket

ImageLeft and right stuff by Duke of Boots1966, on Flickr

If you ever have to fit a top bearing then the order is

bearing, split washer, spring and not like this!

ImageLeft and right stuff by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Off to get sprayed

Post by john&hannah »

The chassis having its final prep before heading of for shot blasting and weld through primer. Hopefully the last time it is upside down.

ImageOn its head by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

AWD Porsche 911 Splitscreen

Post by john&hannah »

Today was all about fixing the cab door locking mechanism with a clothes peg.....

Original looking system with return spring for the latch intact -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

The clothes pegs who may provide the answer -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

The cut down clothes peg spring -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

and in situ plus a repair to the retaining rivet -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

Cargo door fixing day. Trying to make 2 good doors out of 4.

Off with the old -

ImageDoors and Stuff by Duke of Boots1966, on Flickr


On with the new skin -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

And a repair to the bottom frame -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

Not so 'perfect fit' repair panels (again!) -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

Cut out the original window aperture -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

Pulling out a bashed in bump stop with a metal bar, 2 nuts and a bolt -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

ImageDoors and Stuff by Duke of Boots1966, on Flickr

ImageDoors and Stuff by Duke of Boots1966, on Flickr

Donor window tacked in place -

ImageDoors and Stuff by Duke of Boots1966, on Flickr

ImageDoors and Stuff by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Re: AWD 964/911 Bus

Post by john&hannah »

The chassis waiting for its primer having been shot blasted

ImageChassis at spray shop by Duke of Boots1966, on Flickr

User avatar
john&hannah
Registered user
Posts: 398
Joined: Tue Apr 14, 2009 2:59 pm

Cab door stops

Post by john&hannah »

So I was mildly surprised to find that the correct fit A pillar does not have the door stop fitted into it so there is no other option than to cut a new post and retro fit the old piece. Given that when they came from the factory the door stay was weld into the A frame and sandwiched between the 2 parts then it would have made sense to do this with repro parts but rant over.

Sooooooooooo.....

Cutting a new post :evil:

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

Fitting the old door stay

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

Cutting the inside of the A frame and welding in the reinforcing leg. Originally it was sandwiched between the 2 parts that make up the A frame but I bent the leg so it would pop out the cut i made and could be butt welded.

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

and making good -

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

And fitting the door to check alignment (doors don't come with the door stay hole either :bounce:

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

ImagePerfect (ish) fit by Duke of Boots1966, on Flickr

Post Reply