January 31, 2011

Late January - The Big Clip

Well, after getting about 90% of the small rust damage fixed, it was time to address the 900 pound gorilla in the room. The rear C-pillar. This was an extremely difficult clip for me. The clip went across the rear window, the trunk, the parcel shelf, and the drip rail. All very unforgiving with the slightest mis-alignment. 

I marked out the cuts to bypass factory welds, and inner bracing so that there was access to the welds from the inside as well. 



Below is the section all cut out. 


Here's the old section with the lighter yellow donor section. It still needs to be trimmed down to size, taking all kinds of care not to cut to much. This was a pretty tough clip to track down as most all unrestored early 911's and 912's have rust in this area. In fact the clip that I have has a lot of rust right below this in the parcel shelf, which I'll replace from yet another donor vehicle. 


A quick fitting and final trimming before welding.



And here with the section welded in. This took almost 3 hours due to extra time cooling the sheet metal to prevent warping and distorting the panel.  


Here's the donor clips lined up. Parcel shelf from the white one, c-pillar from the yellow one. 


And now you see why I've started calling her the "Quilt". Well, I've managed get the toughest of the rust work behind me. Some time is needed on the front fender rails, and a little time behind the drivers rocker panel, and then it's paint prep time. 

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