JDHertz11

Poor "bastards"... we don't get much rust here in the U.S.!!!

NineMeister

As you can see from the photos, the problem arises because the heat shield is fitted to the shell before painting, thus the joint face between the two only has one layer of primer with no seam sealer around the joint. Of course it's obvious that water is going to seep into the joint so if you drive your 993 in the rain there is an inevitability to the rust taking hold eventually nomatter how well you clean it.

I suppose that by knowing that it will be a problem the best solution is to tackle it before it begins, remove the plate, properly paint the joint face or just lather it in waxoyl then clean up & refit the plate.

Wilder

Firstly, great work again Colin. Can't wait to follow this project.

First time I've heard of this problem. Thanks for the heads up. Great info for us in the rainy Northwest.

ironimages

This should be fun to watch... subscribed

zechunique

I'm in too.

You guys blow my mind.

AOW162435

This thread does not remind me of Pimp Your Ride.




Andreas

MDamen

It's sort of like "How It's Made."

NineMeister

How to fix a rusty bit of rear chassis leg:

1. Cut away rotten section
2. Unpick oversize repair section from donor chassis leg
3. Trim repair section to size on chassis, clamp & weld joint
4. Prime

NineMeister

Roll cage pretty much finished, now just waiting on the roof panel to arrive from the OPC so we can fit it and finish off the welding of the cage to the shell.

Owen has now welded in the RS front panel tow eye reinforcement, ABS ecu & RS cutout switch brackets & has now moved on to the seam welding, making a start with the strut tops.

H.H.Chinn

Beautiful splice Colin! You've identified an area that may prove to be a problem in the future for fellow owners including myself. Some sheet metal fabricator needs to get on board and produce replacement sections for those less fortunate not having a donor vehicle to take from.

NineMeister

Thanks Harlan.

In normal circumstances to repair this area you would just cut a smaller hole & weld in a section of flat plate, but when 9m does a Clubsport it has to be perfect which is why we did an invisible repair.

NineMeister

We managed a little bit more progress at the end of last week. Unfortunately our OPC has been a bit slow with deliveries recently, hence we're still waiting on the roof being delivered which is obviously holding up our aim to get the shell finished before Christmas. The good news is that we received the deposit from our customer so I can now confirm that 9m93RS #2 is going to be painted blue - but you will have to wait until it is painted before we reveal what shade!

As a result on the missing roof panel we're focusing on the other details of the conversion to keep some momentum on the project. The donor shell originally came fitted with airbags & thus had the airbag lower dash section which is completely different to the glovebox version which is fitted to the RS Clubsport. Since the panel is expensive to buy Marc & Owen took a trip out to our mates Neil & Kevin at Prestige Salvage (in Leeds) to cut out the required repair section from a damaged non-airbag 964 shell - which also conveniently donated the correct glovebox & dash panels which we will need later on in the build. The photo shows the set up part way through the installation where Owen has clamped the new panel in place and is about to trim the joints before he welds it in.

grahampeterm

"The donor shell originally came fitted with airbags & thus had the airbag lower dash section which is completely different to the glovebox version which is fitted to the RS Clubsport."

Attention to detail again - us mere mortals would have never known!

Graham

NineMeister

Helps when you work alongside someone who's dyslexic but who has been more than compensated with a photographic memory that has the the ability to 100% recall any detail he's ever seen.

clubsport1

Speak for yourself mate!

There is one significant incorrect detail on the car, which really makes sense though.

The 7 UK commisioned rhd M003 cars came with the Lhd matter cage fitted from the factory..I notice 9M have placed the roof protection bar over the Rhd driver position, where as the factory Rhd cars have this going over the head of the passenger.......I understand the change from a potential safety point of view.