1964 Porsche 356C metal work restoration

Very cool car. Looks like you have some work ahead of you with the "pre 70s" bodywork there.
She will be a beauty when done treat her well

 

Was gonna say... it's like an archaeological dig.

But C cabs are hot right now, so well worth doing right.

 

What is involved with metal finishing? In other words, once you cut out the rusted metal and weld in a patch, how do you make the fender look like it is one continuous piece of metal (i.e., like a brand new fender)?

 

Practice - Practice - Practice.

 

Okay, but what techniques, procedures, etc. are used during metal finishing?

 

I'm not a metal worker, but having a 356 Speedster restored now.

There's a very worthwhile article in the 356 Club magazine this month written by Mark Fuhrman, if you can get your hands on that. Credit to Mark (and the guys at California Porsche Restoration) for my education on this.

Some of the techniques, after butt-welding panels as needed and getting smooth welds:

Panel straightening -- first there's metal shaping, which is literally tapping and sometimes pounding the metal to flatten out the high spots or "brows". The better your metal guy is at this, the less filler is needed later. They can literally feel the highs and lows with their bare palm. The "easy" way is to trowel on loads of filler -- see the 275 GTB restoration thread on FChat in the Vintage section. My Speedster had that where it was race-bumped in the rear quarter panel, and Mark McCracken's 275 GTB had rhinoplasty done the same way.

Originally, the Reutter, D'Iteren or Karmann workers used lead to get smooth surfaces, but the modern substitute would be Bondo or similar. There's an argument that lead is more authentic, but also that technology has given us better materials. (The guys doing mine are trained in using lead, so we did that.)

After filler comes "glazing", which is supposed to be easier to sand, so you can get a near perfect surface.

Then you move on to primer, although there are several blocking/sanding steps in between. It's an iterative process, but an experienced Porsche bodyman should be able to minimize the amount of filler used, detect and fill the low spots and smooth the high spots, etc., with less iteration than we mortals would need.

Then it is sprayed with sealer, which you do not sand. Obviously this must be done uniformly, because it's the base for paint.

After that, you have to decide on single stage (as original) or two-stage with clear coat paint. Again, there are arguments either way, but the single stage requires color sanding afterward to get real lustre out of it. I doubt any modern cars use single stage, so you need someone who knows what he's doing when color sanding -- very easy to screw things up expensively.

 

I actually was trained to work with metal many years ago. My history includes several historic cars as well as muscle cars and vintage Porsche's. I have done substantial metal work that is very simular to what you see in the photos. When I state "practice-practice-practice" I dont say it lightheartedly.

Now I do this stuff for fun (just did some today in fact) and leave the difficult jobs up to the professionals - like what we see above.

As for metal work - Start with proper gauge metal, shape it with an English Wheel and a sheet metal break (I have that) or "do it old school" with a hammer & dolly. Masterfully weld the piece into place with minimum warpage & a ton of patience. Hand tool the panel after welding if needed then FILE (yes file) the metal/welds down by hand or a deft touch with the right air tool. Continue to file and fill with weld when needed. Work that spot to the bitter end or opt out of the hard stuff and apply lead for final touches. The lead may not be necessary - if you have that practice that I spoke about.

It looks to me like the fellow that did the work above has that practice I refer to.

Bravo to his or her craftsmanship.

 

Brings back memories as I just completed a 7 yr. restoration of my 2 owner 1965 356 C. I purchased it in 1999 from the second owner in Fl. Mine took so long as I lived in Co. and restoration took place in Fl. It was finally completed months ago when we moved back to Fl. Car is Silver, with red Leather and red carpets.

Docf

 

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Pete