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Bodywork

Then the first 'constructive' work was started: the bodywork. Since i am a computer programmer, not a welder, i had to apply for some help here. Most (well, almost all) work you see on this page has been done by Mr. Jan van der Heiden from Eersel, Holland, who does this for a living, and is something of a wizard with a welding torch. He has done an excellent job, and if you like what you see here, he does all kinds of restoration work, just send me an e-mail for his address.
While working on the body of this car, i was pleasantly surprised by the availability of parts. Almost everything you need is directly available, either original parts from Porsche, or a somewhat more affordable imitation from other manufacturers. Considering that this car is older than i am there must be a lot of them still running!
body5.JPG (18270 bytes) So, this is where we started. The body cleaned and all parts removed. At this point i had found so much holes in it, and worse, very badly done repairs, that i had almost given up hope.  
body7.JPG (25571 bytes) Here a very peculiar Porsche characteristic is unveiled: The heating system. There are two heat exchangers around the exhausts, and from there hot air is blown into the frame, through tubes ending up just before the seats in the passenger compartment. Because these tubes are inside the frame, and get quite hot, they rust away sooner than the rest of the frame. Repairing requires cutting open almost everything. The thicker part of the tube you see here is a silencer.
body6.JPG (19593 bytes) Here is a better view of the pipes, with the new silencer in place. Remember this if you are ever thinking of buying an early model Porsche. If the heaters don't work, this probably means that these tubes have been filled up, instead of repaired. Stay away of such 'restorations', the covered up rust will very soon pop up again!
body2.JPG (18067 bytes) The front of the car. These parts were again patched up badly. If this car would have been finished, it would have broken in two at the first bump.
body4.JPG (18264 bytes) The hole you see is where the fuel tank goes. The black metal part is a complete replacement part. This sure made the work easier.
body8.JPG (18621 bytes) The same part photographed from the front...
body3.JPG (18236 bytes) With the silencers in place, the underside could be welded in.
body1.JPG (17133 bytes) Here the doors are being fitted. If there is any misalignment in the car, it can be corrected here. Then, the all new rear wings can be welded in place.
The rest of the bodywork has already been primered in this picture. One very important job had to be done before the body was finished, the alignment. Several sizes of the car have to be within certain well defined limits. If this is not checked carefully, the car will never steer straight,or worse, it will not qualify for a registration. Luckily everything was in order.
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