1971 911 TE - New Chapter


Disassembling and inspect all components
Repair of some rust areas, and Modifications - page 1
Repair of some rust areas, and Modifications - page 2
Repair of some rust areas, and Modifications - page 3
Restoration of components
Fitting Suspension and body work
Assembly after Painting
Interior
Implementing the GT3 Muffler

Repair of some rust areas, and Modifications - Page 2

I started with the right side of the door lock support. I got new pieces for both sides. I also removed carefully the outer rocker panel, since I want to reuse it.

Here is some work needed.

I removed the inner rocker section, this will be replaced with a new piece. Also I get better access to see what's going on in there.

I removed the bottom section of the door post, As well a section of the inner wall.

I made a new piece and welded it in.

Then I made a new piece for the bottom of the door post.

I found some rust at the top section of the door post. So I started to look into that.

And before you know it you are deep in it, LOL. So I just cut out bad sections, made new pieces and welded it back in.

And finally done with that section.

So back to the rocker. After spraying the inside with some green stuff from Eastwood, I installed the heating tube.

Primed the inside of the inner rocker panel. And welded it in.

Next, a new rocker support and test fitting the outer rocker.

I started on the driver side with the rocker area. The old door lock support, outer and inner rocker is removed.

I checked out the lower section of the door post, and decided it must be removed.

I cut out a piece of the inner wall behind the door post bottom section.

I made a new piece and welded it in.

Also made a new bottom section and welded it in.

The rear section of the inner rocker needed also a new piece where the inner rocker ends.

The top section of the rear quarter needed some repair.

The heater tube end plastic pieces were falling apart, so I made some new ends with the 3D printer.

I also replaced the jack support in the left side and welded the inner rocker panel.

Here is it all finish welded.

Here with the outer rocker support and some primer.

I mounted the doors, fenders and hood, to make sure all lines up.

Here I found something I didn't like. The right door was worse then I expected.

There was a lot of body filler and the sheet metal under it was really bad. So I decided to use another door I had. The good thing is that it already has the mounting hole for the right mirror.

So now that it all fits, I can finish the outer rockers and the door lock supports.

Now I started with the fenders. There was some repair needed where they bolt to the body. Here are pictures of the section I welded in new pieces.

I also closed the antenna hole.

The right side fender was pretty good, but the left one had some repair many years ago. Someone filled in a big gap with fiberglass filler. I removed all this stuff so I can fix this section. I want to make this correct, so I ordered new turn signal housings seals to make sure at the end all fits nice. I will continue on the fender when the seals come in.

I also ordered a few weeks ago 2 sleeves for the rear torsion bar sections. Since the sleeves are in I can start with that. I started on the left side and made 2 opening so I have access for cutting and welding.

I welded some braces in, so the tube will not move when I cut the old sleeve out.

I removed all the old section and cleaned up as good as possible. Ready to fit in the new sleeve.

Making a template for the inner section.

Inner section welded in.

Now lining up the new sleeve with the t-bar and spring plate in place, so it will line up OK. Tack weld the sleeve to the tube.

Fitting the outer sheet metal. I had to make it in 2 pieces.

This should be good for another 50 years.

Closed the access holes and this side is done.

The same procedure for the right side.

Next on the list was to cut out the old rear shelf on the 71 911, and fit in the new piece.

On the left side there was some rust and I had to cut out some old metal and made some new pieces to weld in.

I also needed a new section for the fire wall.

At the right side, I removed the reinforcement piece for the roll bar mounting plate. This is what happen after 10 + years in between the 2 sheet metal pieces.

It was only surface rust, and I was able to clean it up.

I opted for the later model shelf since it's a bit higher and will give some extra space in the engine bay.

Cleaning up the original hinge mounts for the deck lid.

When I had the rough position, I drilled some larger holes in the shelf, so I could move them a bit to make sure they were in the right position for the deck lid hinges.

A few adjustments and the lid did actually fit nice. I had also to make small piece for the section at the left between the self and the window frame.

Here it is all finish welded in.

Here is my collection so far what I have removed. It should not much be added at this point.

1971 911 TE - New Chapter


Disassembling and inspect all components
Repair of some rust areas, and Modifications - page 1
Repair of some rust areas, and Modifications - page 2
Repair of some rust areas, and Modifications - page 3
Restoration of components
Fitting Suspension and body work
Assembly after Painting
Interior
Implementing the GT3 Muffler