Porsche 911 Door Jamb Surprises & DIY Repair

Porsche 911 Door Jamb Surprises & DIY Repair

This week my Porsche 911 Door Jambs get lots of attention so that when they are painted they look somewhat decent. My door jambs were dented, the number plate looked bad, the door stop brackets were bent over and there is rust in the lower seal channel. Fun surprises!

Below is a table of contents of past episodes 1-35. Click the link below for the rest
www.ahhgaragetime.com/TOC

Intro
Stripped Shell Introduction
https://youtu.be/1Z7Jm7HLQmg

1
Drivers Fender Backdate, Unfold short hood edge, Make Signal Box Parts From Flat Sheet
https://youtu.be/Dt-QB1vDuQQ

2
Drivers Fender Signal Box, Shape Bottom Portion w/ Bead Roller
https://youtu.be/qI6Jj14psUs

3
Drivers Fender Side Patch Panel Hammerform, TIG Weld Signal Housing
https://youtu.be/YAhsOyKi-qg

4
Drivers Fender TIG Weld Side Patch Panel, Add signal housing triangle piece
https://youtu.be/6FXdx6kbFtk

5
Passenger Side Fender Backdate, Additional Content From Driver’s Side
https://youtu.be/TV_JqDXP0qA

6
Shorthood to Longhood Conversion, Form Outer Skin Edges And Weld On
https://youtu.be/GJvClolyh4Q

7
E Wheel and Form Longhood Inner Skin w/ Handormed Strength Rib
https://youtu.be/b9PtEoh8xoA

8
TIG Weld Outer and Inner Longhood Extension
https://youtu.be/GkpAp_jls0E

9
Longhood Front Seal Custom Bracket
https://youtu.be/49i-WCkMOCw

10
Rear Backdate, Remove Rear Impact Bumper and Valence
https://youtu.be/FiI65ZN7AGs

11
Lead Rear Valence Corners, Rear Latch Panel Backdate
https://youtu.be/1HLIKrwI9-0

12
Hybrid Steel License Plate panel & Fiberglass Rear Bumper, Custom Panel Brackets
https://youtu.be/FfJgTVLin6s

13
Custom Aluminum Rear Bumperettes, Solidworks Design, Cut on CNC machine, Rear Flare Trial Fit
https://youtu.be/-Cy4XhKmawU

14
Form and TIG Weld Custom Rear Aluminum Bumperettes, Rear Bumper Complete
https://youtu.be/-Cy4XhKmawU

15
SC to RS Flare Comparison, Photoshop & Sheetmetal Conversion to RS
https://youtu.be/XFu2nSJ9Pos

16
Tack Weld Passenger Side RS Rear Flare, Remove Undercoat, Align Flare
https://youtu.be/0-n4tyIfgsw

17
Weld Passenger Side Flare, TIG VS MIG, Planishing, Weld Distortion, TIG Arc shots
https://youtu.be/t2xomaxWhFc

18
Align Body Panels, Hood gaps, Adjust tub with dumbell, Repair Rocker, gap tool, Windshield fit check
https://youtu.be/6yWs9XshwOE

19
Fill 20+ Holes, Mirror, Washer Jets, Rockers, Gas Filler, Antenna,
https://youtu.be/-zsdmKKBBxc

20
Remove Rear Window without cutting seal, Kick Method
https://youtu.be/gb6fcoNMcjQ

21
Remove Decklid Bumps and adjust Gaps & Fit, Add Weld material to edge
https://youtu.be/xvqSVX80zJM

22
Weld Pssgr Fender Support Panel, Lead Hood to Fender Gap, Weld Fender Edge to Reduce Gap
https://youtu.be/ja6NWEv1h88

23
Build quality, Improve Panel Fit, Lead Passenger Door Gap, Lead Rocker to fender gap, Drivers Door
https://youtu.be/Tl3BLMtuYBQ

24
Drivers Door Alignment, Fill Rust Pits with TIG, Lead Drivers Door Gap, Adjust Front Fender Signal Fit,
https://youtu.be/y1Ty8GZcRuw

25
Discovered Rust in Suspension Pan, Spot Weld Drilling, Tram Guage Mounting Points, cut out pan
https://youtu.be/RHk3–W7V0w

26
Suspension Pan Repair, remove suspension, Cut Latch Panel for Oil Cooler, Check Squareness
https://youtu.be/5Prp3qBijiw

27
Align and Weld Suspension Pan, Spirit Level to remove twist, Kettle Bell Hits to Tweak Position, Rosette Welds
https://youtu.be/VkPx2kQlIb4

28
Re-Align Hood/Tub after Suspension Pan Install, Repair rust on gas tank panel,
https://youtu.be/Aug5is2oKIM

29
Gas Tank Support Welded In, De-rusted with Electrolysis Bath, Reshaped pan edge, Final welding
https://youtu.be/8_AHZu8f7ys

30
Simulate Factory Spot Welds, Rosette Plug Welds, Pencil eraser on primer
https://youtu.be/8_AHZu8f7ys

31
Convert Drivers Side Flare to RS Profile and Repair Rust Damage
https://youtu.be/fWmQFgF5hEo

32
TIG Weld Drivers Side Flare, Remove Failed Undercoating in Wheel Well, Planish and Metal Finishing
https://youtu.be/ThKgR91ce4Q

33
Strip Paint from Car and Prep for Epoxy Primer, Strip it disc and paint stripper
https://youtu.be/U3Cqdiywe54

34
Epoxy Prime, Project Review and Cost Reveal
https://youtu.be/pC7Qp-z0bIY

35
Rear Coilover Gussetts & X-member strengthening plates, Golf Ball Dimple Dies For Speed Holes,
https://youtu.be/OvwP5Iy0864

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Comments

Jay Wellwood says:

Adding my comment for the coveted recipe. 🙂

Mike D'Silva says:

Thanks for taking the time to make the video.. so much effort required in recording, documenting, planning and editing. Really appreciate it 🙂

Guylandia says:

When you're in for a penny your in for a pound! Honestly this is the only way, (outside of a Gunther racing or similar shop restoration at 150k cost or more) that a quality resto gets done. The way I see it, the biggest issue is this, if you don't do it, knowing you didn't eats at you after the fact. I have been working on mine for a long time and I have a rust spot on mine that didn't exist when I initially started, and it made itself evident years after the paint went on… Keep it up I'm stoked you put in time every day!

Nikos DIY says:

Merry Christmas Tom!
I hope this will not become a new "project Binky"… Can wait for Bahama.

dan noyes says:

Offer shirts with "SANDING !" in a loud script

asicerik says:

Ah – rust. Our favorite! Looks like we both got an early Christmas present this last week. Nice fix on the jamb. You are not alone though, I am doing body work on my jambs too.

Dave Boyer says:

Merry Christmas, and awesome as usual! I wish I was doing car stuff today, but I took a break between tiling the new basement bathroom I put in…and work tomorrow.

fg jf says:

Why did you do black epoxy? Are you going to go with black paint in the door jambs? Great progress, and thanks for taking the time to document the journey. I'm sure you would be moving a lot faster if you weren't recording every step of the way. But here you are, killing it, even while recording every step.

christopher peterson says:

Do you needle gun the rust and or weld locations to prep?

open highway productions says:

Merry Christmas Tom and family. Thanks for the video content. Maybe Santa will bring some big RSR wheels for Christmas.

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