Pain in the Rear! | Barn-Find Porsche 356 Restoration | Episode 19
Summary
TLDRIn this workshop episode, the team tackles the Porsche restoration project with renewed vigor, focusing on the engine bay area. Despite a busy week with no progress on the Porsche and the acquisition of a new project, the episode dives into correcting a mistake made in panel alignment. A detailed process of trial, error, and adjustment unfolds as they work to correctly fit and weld a new panel to the chassis, ensuring proper alignment with the engine lid. The session is filled with technical challenges, teamwork, and a blend of frustration and triumph as they aim to reassemble the rear of the car. The episode concludes with a call for assistance from the 356 community regarding specific vehicle parts, showcasing the collaborative spirit of the restoration community.
Takeaways
- 😊 The video is part of an ongoing Porsche 356 restoration project
- 😮 A mistake was made in previously welding a panel, so it needs to be redone
- 👷♂️ John has come to help work on getting the engine bay fully assembled
- 🛠 The rear engine panel is test fitted multiple times to get it aligned perfectly
- 🔧 The engine lid latch is repaired and reinstalled to help position the panel
- 🎯 The goal is to have the back of the car mostly reassembled by the end of the video
- 😊 A new project car (a 1990 something) is hinted at but details are left for later
- 😅 Installing the rear panel takes all day and over 30 attempts to get right
- ⚙️ Additional parts like the wheel arches will be positioned based on the rear panel
- ❓ Guidance is requested on the purpose of some tabs on the newly installed panel
Q & A
What is the main focus of the workshop session mentioned in the transcript?
-The main focus of the workshop session is to get the engine bay of a Porsche completely buttoned up, involving tasks such as removing the engine lid, rebuilding, and ensuring everything lines up correctly.
Who is John and what is his role in the workshop?
-John is an individual who has volunteered another day of his time to assist in the workshop activities, specifically in the tasks related to the Porsche's engine bay.
What mistake did the speaker make during the project?
-The speaker made a mistake by getting ahead of themselves and welding a new panel directly to the chassis leg without placing the rear engine bay panel in between, which was the correct order.
How does the speaker plan to correct their mistake?
-The speaker plans to correct their mistake by drilling out the spot welds with a Worth spot weld drill bit, peeling off the incorrectly welded panel, and then properly positioning the new panel before spot welding all three layers together.
What is the significance of the engine lid in the project?
-The engine lid is significant because it needs to be properly aligned and fitted into the aperture of the rear panel, which is crucial for the back of the car to be correctly reassembled.
How do the workshop participants ensure the proper alignment and fit of the panels?
-They ensure proper alignment and fit by repeatedly offering up the panels, trimming and adjusting as necessary, and using the original engine lid for alignment checks to ensure it fits in the aperture correctly.
What is the 'order of the lasagna' mentioned in the context of assembling the car's rear?
-The 'order of the lasagna' refers to the specific layering order of the car's rear panels during assembly, which should be chassis leg, inner panel, and then the outer panel.
What are the steps taken before finally spot welding the panel in place?
-Before spot welding the panel in place, they perform a 'pill test' to ensure the primer holds during welding, prep the surfaces with weld-through primer, and carefully position the panel to ensure correct alignment.
What is the purpose of the primer used before spot welding?
-The primer used before spot welding is a weld-through primer, which helps protect the metal from corrosion and ensures a strong and durable weld.
What request for help is made at the end of the transcript?
-At the end of the transcript, the speaker requests help in identifying the purpose of two heavy, substantial tabs located on the rear end panel of a 356, which they are unable to find a use for.
Outlines
🚗 Restoration Challenges and Progress on the Porsche Project
The episode opens with an enthusiastic greeting and sets the stage for a productive day working on the Porsche restoration project. Despite a busy week with limited progress on the Porsche, the host introduces a new project, promising to reveal it soon. The focus then shifts to correcting a minor but crucial mistake made in the restoration process. The host realizes that the order of assembly for the rear engine bay panel was incorrect, requiring the removal of a newly welded panel to correctly position it between the chassis leg and the inner panel. This setback involves drilling out spot welds and preparing for the correct reassembly, showcasing the meticulous attention to detail required in such restoration projects.
🔧 Fine-Tuning and Fitting Panels with Precision
In the meticulous process of fitting the rear panel, the hosts demonstrate the iterative nature of restoration. They engage in a series of trials, cutting, and adjustments to ensure the panel fits perfectly. The focus on precision is evident as they carefully measure and trim the panel, ensuring it aligns correctly, particularly around the engine lid latch. The hosts display a mix of determination and light-hearted banter, reflecting the challenges and camaraderie found in collaborative restoration projects. Despite the repetitive nature of the task, their commitment to achieving a flawless fit highlights the dedication required in automotive restoration.
🔩 Final Adjustments and Spot Welding for Durability
The third segment illustrates the culmination of the painstaking restoration process. The hosts prepare for the final assembly by priming the surfaces and conducting a rigorous test to ensure the durability of the spot welds. They demonstrate a cautious approach, spot welding the cross piece that ties the chassis legs together, mindful of the possibility of needing adjustments. The meticulous attention to detail is evident as they carefully spot weld the back panel, ensuring it aligns perfectly with the car's structure. The segment encapsulates the blend of precision, patience, and a hint of humor that characterizes the project, emphasizing the satisfaction derived from committing to quality craftsmanship.
🎉 Celebratory Conclusion and a Call for Community Input
The final paragraph captures the triumph and relief of successfully integrating the rear panel. The hosts take a moment to celebrate the milestone, reflecting on the day's challenges and the precision required to reach this point. They meticulously verify the alignment and operation of the engine lid, emphasizing the importance of each component's placement. In a moment of community engagement, the hosts seek assistance regarding the purpose of specific tabs on the rear end, inviting viewers with knowledge or experience with 356 models to share insights. The segment concludes on a light-hearted note, highlighting the camaraderie and collective effort that defines the project, and hinting at the ongoing journey of restoration.
Mindmap
Keywords
💡restoration
💡engine bay
💡spot welding
💡measurements
💡original parts
💡step-by-step
💡patience
💡customization
💡challenges
💡satisfaction
Highlights
Welding a new rear engine panel onto the chassis
Made a mistake by welding the panel before fitting the inner panel
Test welding primered steel to ensure good adhesion
Panel fit is extremely close after much trimming
Fitting the original engine lid to locate the panel aperture
Bolting on the original engine lid latch mechanism
Final tweaks before commiting to welding the panel permanently
First spot welds to permanently attach the panel
Panel alignment checked thoroughly before welding
Celebrating getting a very difficult panel fully fitted
Additional panels located based on new rear panel position
Seek help identifying tabs on panel from 356 owners
Much work still needed to complete all rear panels and bumper
Taking time and care with alignment before permanent welding
Step backwards to fix incorrectly welded panel
Transcripts
hello everyone welcome to the workshop
welcome back thank you so much for
joining us we're back on the Porsche and
today is going to be a good day it's
Friday and I'm very grateful that John
has given up another day of his time to
come up here and give me a hand and
today in this episode we are going to
get that engine bait completely buttoned
up that's going to involve getting the
engine lid off the shelves off the
racking rebuilding having a look at the
engine lid catch getting that installed
uh to make sure everything lines up so
by the end of this video most of the
back of the car is going to be back in
place it's a big day um I have had a
busy week so unfortunately all week I've
not been able to actually do anything on
the Porsche um I have got a new project
though I've just bought a
19 you're going to have to wait a little
bit longer to see that um but I promise
I'll introduce it to the channel very
soon time to get on with this one
because actually the start of the
process is taking a little step
backwards because I've made a a mistake
a small one but I've I've done something
wrong have a look so you can see this
new panel that I've welded on here on
the back I got carried away basically
I've welded it on spot welded it to the
to the chassis leg um and then hammered
over under the lip at the bottom there I
shouldn't have done that I was running a
little a bit ahead of myself because
this new panel the rear engine bay panel
has to fit inside that uh and go in
between that and the Chassy leg so the
order of the lasagna on the back would
be chassis leg inner panel then the
outer panel as a free all stacked up and
I've gone and spot welded the outer
panel straight to the chassis leg
without the rear panel in between so I
need to go and get my worth spot well
drill bit drill out these spot Wells
peel this back off probably put a new
piece in and leave it loose so I can
slot the new panel in then spot world
all three together idiot just getting
too carried away when
M that was a long long good afternoon
John
hey Friday
traffic that's on the outside that's
what I was getting confused
with we
need
fers onest J
oh where am I boy what what you want me
to
do make
[Music]
lunch we're refreshing our memories from
last week and we're about to offer this
back on and see how how sneaky sneak up
on it we can be how many times are we
going to be offering this up today I I
reckon it's going to be about
50 take
one yeah okay yeah so a
look a
look we're
learning need end up wearing it then
we're not high enough
I just want to cut that it might even
cut D me might lose that I think we can
safely lose at least that
what
this spoken it's
off hey
well they are move out n of this is
safe see that's nice
oh oh hold it if I do it on side I can
transpose it oh you got loads I just
want you got load have
you
[Music]
I need a
clicker if you do that line then we go
sort of 4 in outside of it well I about
you give yourself a generous inch on
that like literally in
parallel
that was very slow
yeah oh my God yeah at least enough two
Ines you can have out of that no yes I
draw I car acoss the line look have a
[Music]
look take
off
these worth cutting discs it's lasting
well it's the first one it is lasting
well is
it righty yeah like see um back off
again whoa
look you how much we got to cut off from
the oversized panel look a little bit
we'll weld that in somewhere else yeah
we'll keep that we make another panel
out of that bit make front panel out of
that yeah
here we go first time you're going in
I'm going in W you're going
out are you in or you out you in
in come on come
on oh thanks thanks a lot put yours in
here you get that's
[Music]
Jesus it's quite emotional the rear
panel is very close to fitting it's
getting closer and closer we're trimming
and trimming and trimming and sort of
sneaking up and it's getting closer and
further in it's needs a little bit of a
trim here and there the whd on the back
needs a little bit of kind of relief and
manipulating to get it to fit just
right but we need to make sure it's
centered because in the middle of the
panel is the ledge the L latch for the
engine lid for the engine
lid and we also need to make sure the
aperture is by moving it in and in and
in we're actually making the aperture
smaller so we need to make sure that the
engine lid is actually going to fit in
the hole which luckily I've got it's
matching numbers to the car original to
the car still in original paint so I
think it's time to me to go up the
ladder and ramage around up there and
find the engine lid Bolt the latch to it
hang it on the freshly restored hinges
and see and that will help us know where
yeah where the middle is right let's do
it I'll get my hard hat right I'm going
up John found another pen going shopping
be careful up there can you put the
brake on huh
hey oh
look prestine SS heavy it's worse than I
remember it's worse than you
remember oh oh my God I have it notori
all right there you go stick the box in
there very nice this is
exciting free free bolts very
strange oh my
God don't you
cry when you
bleed
it's what you and I both
[Music]
need this is the latch for the engine
lid look at that original
paint original isn't it beautiful color
it is a beautiful color fed green it's
actually blue
it's going to end up on
there right let's get it screwed on
then was preventing I think we're still
on that though I
think did I not take enough off yeah
nowhere near no near I we're making this
panel fit this panel
what number are we on now this panel's
coming back off for another little trim
I got to be honest I think we're well
we're getting well in the 20s now yeah
we're get we're getting late
20s need all day to fit one
panel one simple
[Music]
panel
29 no this is 30
30
[Music]
like that up put it back
down hello that's latched when spring
compression
was become part of the process that
hasn't latched for many a
year okay have we been trying to latch
the Bonnet the boot to it and it the
latch doesn't work the latch was
actually broken I'm not saying that no
no this is
potentially and I will say
potentially the last time this panel is
coming off uh so all the
areas that are are going to be
sandwiched between each other are
getting
primed in a well through cler we're
about to spot world this on so we we
need to do a pill test so we got two
bits of the Tim we're going to use and
we primered it and we spot weld it
together can't peel it off D can't peel
it off
d d peel it off John I can't come on no
the world through primer is holding it I
think we can safely say that's got it
that's one and we've put about 50 in
there on each side million I could twist
it off that
still don't want to let
go I think I think we got it Dom look
one spot world that's crazy isn't that
amazing that's the one yeah I'm tearing
the world out now I can see look yeah
look yeah yeah the Steel's actually giv
up yeah spot world still on there
complete multiply that by 400 yeah
should be pretty good panel's not going
in yet the panel before is going in so
this cross piece that's tying the two
chassis legs together is going to get
welded in place that is going in now
first first thing this morning we've
been here and it's taken all day we had
a small break for some lunch little meal
deal from SSB
John he's out of control he's out of
control oh my have you
actually I'm glad he thinks it's funny
brilliant can tell it's not his machine
can't
you done a handful of worlds on this
back panel because we can get to it from
underneath even once the back panel's on
that's enough to hold it in position for
now just in case we change our minds we
change our minds which we we have done
we've been known to do a few times today
no we're being a little bit indecisive
uh that's it back panel back on now for
the last time and then we can actually
get that spot welded along this back
Edge and be part of the car woohoo
[Music]
it I'm down the top B not
this no it's fine don't keep touching it
cuz then you're going to move something
else but that's how it works it's fine
there are you happy about
this that looks good look at that in
there right going to draw this is it
we're spot welding it in it's not coming
out again I'm literally going to spot
weld it in now before John touches
something else and moves something
else just one there just
there yeah like that yeah
yeah oh on your on your hair on your
hair on the
clamp your hair yeah we're done
here yeah keep it Square sure yeah do
it oh it's on that's it well wow what a
day you
committed
yeah oh when you hold this it's quite
scary
[Music]
it's not higher there happy do it there
do it sure do
it a myir ah this not in here do you
want one more for luck just to hold it
on the go on the other panel the
receiving end where' you want to go on
the Ed of the panel there the original
spot wheel area is that
ready oh my
God ready
yeah four spot Wheels on the side three
or four down the back it needs a lot
more it's in the right place it's
completely we've checked every single
measurement possible left and right on
the select table front and back we've
got the engine lid actually hanging and
hinging and opening and closing and
latching perfect
really really good I just need to spend
some time now just hammer and dollying
little areas and committing with a lot
more spot worlds really but celebratory
chocolate muff no it's not chocolate no
Sicilian lemon Sicilian lemon quarter to
five now and we've done about 10 spot
worlds it just shows how long this takes
it's we're not rushing and we're taking
our time we're probably taking we're
being overly cautious overly cautious I
imagine but we only want to do it once
yeah it's true yeah well we've done it
about 50 times today but ultimately yeah
we don't want to be unpicking it to it's
nice knowing that that's all in the
exactly the right place we just need to
now add more spot worlds all the body
panels the rear skin the two wheel
arches all the bumper even everything is
dictated by that panel that we've just
put on pretty much because we've set
where the aperture is for the engine bay
spend some time now just tidy bits up
welding a few bits on few little bits
here and there and we're good John's got
a long drive home now so before I turn
all the lights off we'll say goodbye
goodbye we'll see you next time I hope
you've enjoyed it oh hang on before I go
have a quick look at this panel anyone
out there that's got a 356 we need your
help this is the the rear end that we've
just put on and we've got two quite
heavy substantial tab that's a 2 mil
there yeah and there just inside of
those
holes you don't see them on the outside
of the car comes out and over and almost
touches it but it doesn't touch it there
is a brace in the middle that ties back
to the outer skin we know that but these
I can't find a use for that is a bit of
homework for everybody uh anybody out
there that's got a 356 or knows anybody
that works on them or works on them
themsel what are those little tabs for
let me know neither of us have got a
clue right say goodbye John goodbye
John don't you
cry when you
bleed it's what you now both
need I came to take you to the
[Music]
light
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