NineMeister

Hi, it's me again, back with another Ninemeister build thread which I think you will all enjoy. Well, when I say build thread, what I actually mean is build threads plural because I'm going to post two takes on the same theme, the 9m11RS, which in simple terms is Ninemeister's interpretation of how to build the perfect 2.7RS homage. Now I realise that when it comes to RS look-alike projects there is probably nothing that hasn't been done or seen before, however what we learned from these two projects is how the customer's interpretations of their perfect "RS" can result in radically different results and secondly how much the choice of donor car affects the work required to achieve their goals. I hope you enjoy the journeys as much as we have.

This thread is Part 1 which I have titled "The Regeneration". It follows the story of a 911SC from the moment it was driven into our shop as a recently converted 2.7RS replica, during the strip down to the discovery of the problems which lay beneath its shiny paint and then through subsequent ground up restoration to the finished 9m11RS. As with most things 9m, this one is probably the most thorough and extensive SC body restorations that you will ever see. Enjoy.

NineMeister

This is where it all began.

The owner Dave had recently purchased his 2.7RS replica, based on a UK registered RHD 1981 911SC. Safe in the knowledge that he had an invoice from the supplying dealer describing the car as a "911 2.7RS conversion .... freshly converted ... all rust dealt with...", Dave had concerns over the closure and fit of the doors so brought it down to Ninemeister's Bank Quay premises for a quick inspection and for us to evaluate whether we could correct the panel fits through adjustment. Suffice to say, the poor old SC needed a lot more than adjustment as you are about to witness.

NineMeister

A quick walk-around with the camera pointed out a few of the more immediately noticeable issues:

NineMeister

It was immediately apparent that the door adjustment issue required a lot more than the adjustment that the owner was hoping for, in fact we doubt that he expected our quotation of £10,000 per side to sort it out. What he could not see at the time was that repairing this SC was going to take some intensive body surgery to remove the rot that remained in the shell. Fortunately he trusted our judgement much more than that of the garage he purchased it from and after a few months deliberating decided to let us loose on the repair.

NineMeister

Initial strip down revealed a few more of the SC's hidden secrets:

NineMeister

As with most 9m jobs, loading the bare shell onto our Celette bracket jig is the first stage of the process, whether for full restoration or an more straightforward RS conversion. No point in spending hundreds of hours building a bent bodyshell, is there?

Working on a clean shell pays dividends maintaining a clean working environment, so out came the steam cleaner to rid the underside of road grime and salt. We had a clue to what to expect next when Robin blew steam through the inner wing....

Amber Gramps

Wow. Anyone that is so willingly blind as to purchase that car deserves the pain of an expensive redux. Fortunately it's in very capable hands. Keep 'em coming.

09mageec

Definitely keeping an eye on this thread. Can't wait to see the finished product.

What were the miles on this shell?

NineMeister

The SC had clocked 174,000 miles at this point.

NineMeister

Quarter panels and wings removed did not improve our opinion of the previous "restoration".

Suffice to say that armed with these photos, an engineers report from myself and the help from a solicitor friend, the owner sought and received suitable compensation from the dealer who sold him the car, very much to the dealer's credit I must say.

09mageec

This is starting to scare me lol.

AP997S

To quote somebody . . . . . "Rust Never Sleeps"

09mageec

Question. How is rust able to progress when these bodies are galvanized? Does the zinc coating break down over time?

Amber Gramps

LOLzzz Time to buy stock in Restoration Design Inc.

NineMeister

The zinc galvanising is a sacrificial anode that erodes to protect the steel once electrolytic corrosion starts, usually due to the presence of water which has penetrated the under body paint or sealant. Since the sealant is bonded to the zinc, once the zinc starts to erode away the sealant forms a hollow cavity that collects more water which continues the corrosion and eventually begins attacking the steel. Some areas (like the front edge of the kidney bowls) are masked from the factory sealant gun, hence they have nominal paint coverage and begin erosion/corrosion earlier in the life of the car.