911 Suspension Pan Welding 👍Align Then Weld…

911 Suspension Pan Welding 👍Align Then Weld…


today I’m determined to finish the
install on my 911 suspension panel come on let’s do this the ranch dad welcome to garage time you know this
channel and this community is all about sharing tips and tricks so you can build
something cool in your garage come on let’s do this
okay last week’s episode I got the new suspension pan roughly to fit in place
and it’s in its correct position so now I just need to do its final trim and
mark it very carefully get it in its in its position so I can weld it in place
okay I’m getting ready to cut the suspension pan so it fits the gas tank
support and I just marked a couple lines here in addition to having a clamp
alright guys I’ve done enough measuring I think it’s time to get the first cut
in I’m going to be cutting right along here where the gas tank support is I’m
gonna use the air saw to just you know get a conservative cut on that and see
how it lines up I’ve gone through a few cycles now of
trial Fitz and I have it trimmed and looking good it’s it’s it’s in position
still using the jack to hold the diagonal but I have a screw right there
in the middle of the screen and then over here I have it trimmed on this side
and it’s it’s fitting really well against the flanges let me show you from
the bottom okay I just have a couple clamps holding it in place right here
here you can see that screw is a screw is sticking through and then I have to
push it up right here but I just need another clamp it’ll it’ll push up into
there this is the driver side and it has some good alignment too it’s just that
the flanges are a little bit offset so I’m gonna have to devise a method to
just pull this down when the pan is out I can pull it down by hand but I’m gonna
have to probably weld some tabs on here and be able to pull this down but right
now I’m done trimming and cutting so I’m gonna go inside and rebuild the flanges
that I had to cut earlier let me show you let me show you what I’m gonna do I
thought I would take a template of the original flange and then make the new
flange really to fit the new pan the driver’s side needs that same flange I’m gonna put some relief cuts in here
just because it’s just gonna go faster and I’ll weld up the cuts on in the end
if this was an external part or something that was going to be seen I
would spend the time to form these around
it doesn’t fit at all need to make a little moon shape around this this bolt yeah I’m just getting ready to attack
weld this in place it’s it’s close enough I completely messed up on this
section right here I I cut it the wrong angle you can see it’s like a like a
pizza I should have cut it the other way just cut it upside down and messed it up
so I’m gonna have to probably splice a little piece in there just fill it up
with plug weld I’m not sure yet so I’m going to tack this in right now and move
to the other side I know it’s very uncharacteristic for me
to use a MIG welder but in this case I’m I’m just doing it for speed this does
not require any planishing any metal finishing this is purely done just to
for speed alright I just wired brushed this well just to kind of show off a
little bit you can get good results with a MIG weld or two okay I couldn’t actually finish the
welding on this side because that the bolt boss there is kind of in the way of
the weld seam since this weld seems lower on this side so I’m gonna remove
the pan and finish up this this weld now that I know that it fits and also over
here there is a flange I need to fix so you can see there’s a hole right here
there you go there’s a hole right here that was created when I was grinding the
old pan out so I need to repair that flange too I’m gonna do that right now all right I did get the the flanges are
real nice and solid there’s a you know no pinholes underneath you look at the
light below here I did have to touch it up with the TIG welder but this is
definitely better than it was nice and strong the same is true for this side it
is you know fully welded end and once again from the backside there are no
holes to be seen through the through there I also fixed this flange here in
the corner flange here in the corner has that hole is now removed I just filled
it up with weld so I’m now ready to wire brush clean this metal really well and
start to rust proof it so I can get the whole thing welded back together all
right I’m in the process of cleaning out the underside of this cavity right here
and what I’m I’m finding is I’m finding a bunch of this cotton material it’s
like it’s like a nest probably a mouse nest I don’t think I don’t think the
factory put this stuff in there so I’m just digging this out so I can clean
this cavity and get it ready for rust treatment hope I don’t find a little
critter inside all right it never ceases to amaze me
what I what I find in this car in the rear shelf
I found a bird’s nest and now this is like a mouse nest here in the front so
you know this car has had an interesting life it’s been you know animal sanctuary
it’s been in a rack it’s been who knows where when it was new and now it’s kind
of getting a new life kind of one step at a time
so this is just an interesting kind of part of the process just wanted to show
you guys what I found it’s really important that I clean out these empty
cavities when I have access to them so I can prevent rust from getting in there
in the future and hopefully this car is driven enough now to where any critters
are gonna stay away came here under the car I’ve just
cleaned out this section and I got all the original rust out of here this is
the factory paint right here this is this is original I’m going to scuff it
up with some scotch brite and add a little bit more you know rust-oleum kind
of type paint this is the cavity right inside here where I found all the the
mouse the mouse nest and then on these seams right here where it’s going to get
spot welded I’m gonna coat this with well weld through primer well any spots
that gets welded is gonna have well through primer okay while I’m waiting
for the paint to dry I’m working on this gas tank bolt the threads on this bolt
are okay but it’s coming unattached from the surrounding metal
this was bulged out like a volcano and I’ve kind of hammered it flat just a
little bit but I need to go through and kind of reweld the nut to the to the
surface of the plate so it doesn’t come loose in the future okay i weld it
around the hole most of it anyways so it’s going to hold the nut in place but
now I need to tap out the hole so the bolt will still work okay I got all those flanges with the
another coat of paint on them I got the weld through primer on them and I’m
ready to weld the pan in but I gotta air on my welding helmet so the batteries
are low when I was fixing that that little bolt area for the gas tank filler
so I had to take a break and go to the store and grab those batteries so I’ve
gotta do what you got to do okay the low battery indicator says I’m
good to go okay before I weld this in I I’m
probably gonna overkill this it’s probably not required but what I’m what
I’m seeing is this is where the bulk of the suspension loads are and I got one
two three four spot welds and maybe it you know about the same on this side so
I’m gonna edge weld this here only because I’m you know kind of paranoid
and and I just want to make it a little stronger the worst thing that could ever
happen is that this becomes detached from the pan you know why you’re driving
and I’m not blaming the quality of this at all I’m just going the extra mile now I feel better Portia did this to
some of their race cars I think they called it seem welding not particularly
in this area I don’t know but along gas tank supports and all the spot welded
structures all this pinch welds all those can get seam welded like this or
lap welded and that that increases the strength of the structure believe it or
not okay earlier I mentioned I wanted to keep the
front end relaxed without having this jack in place but what I found out is
that the front section of this this car is super weak when it doesn’t have the
tappan installed it’s basically just a hollow it’s just like a hollow square
and there’s nothing to keep it in position so what happens is I over
stretch it and it’ll move like an inch or more of two inches and then it just
kind of springs back so without any strength given by the pan it’s just not
able to hold its position so what I’m gonna have to do is realign the pan it’s
in now for its final time I’m gonna check all the suspension points for like
the third time and I’m gonna have to overshoot a little bit on the diagonal
and then do some welding and then let it relax back into position so I’m just
gonna have to keep monitoring it and and strategically weld it in the corners so
that it holds its position all right I have a little bit of good news the
diagonal jack is gone and I’ve just been able to get a few tack welds in there’s
one right there a couple right here there’s some here in
the corner and I’ve done some on the outside as well moving over here a
couple tack welds here here in the front I’m trying to hold this diagonal
position there’s a few tack welds down underneath here as well just holding
things in place so I’ve been using this tram gauge over and over again to make
sure that the position of these suspension points are the correct
distance from front to rear they’re also the correct distance from
diagonal and so the position of these are correct
you know this direction and this direction and now I’m trying to
determine if they’re in the right place in terms of height so I’m gonna get the
spirit level back out like I did before and just measure the height relative to
the rear torsion bar if you remember a few episodes back I leveled the entire
car based on the rear torsion bar using a custom seat channel kind of a spirit
level technique and so I’m confident the car is sitting horizontal or flat and I
just want to make sure that the suspension points in the front are also
flat with respect to the torsion bar in the back so that means there’s no
there’s no tweak in the chassis and I’m not going to use the garage floor I’m
going to use the water level to know that it is definitely flat ok so I’m
down here with this this height gauge and this channel full of liquid has been
completely leveled it’s actually level with the floor
no shims are required so I’m trying to fit this underneath here okay that’s
touching on the driver’s side so the height here is is fixed by this rod so
check the other side and it is it’s it’s off this side is off by about you try to
get an idea ok the distance between the bar and the channel here is about three
or four millimeters so there’s a there’s a twist going like this in the pan that
I need to take care of so I think what I’ll do is I’ll support the car by this
front side and then I’ll just hammer this side down try to level it out
before it’s all the way welded in a little bit of bad news little bit of brute force let’s see if
it’s closer okay just so you know the car is supported by a jack stand in the
center of the car right where the tunnel meets the front bulkhead so it’s a
strong enough area to support the weight of the car and I have the tires on
either side just in case it does fall off the jack stand or whatever but so
there’s no weight of the car adjusting the heights of this thing
everything is supported in the center so it’s free to twist without the weight of
the car which I think is the most accurate way to do it so this side is
what it was before this side is still too loose okay now it is within two
millimeters so I guess we went from four to about two or three to about two so
believe it or not that only moved it like a millimeter and a half which is
kind of surprising how strong this gets with only a few tack welds in place so
like I do it again let me show you guys what I’m hitting against inside here so
this is just a solid round bar and then I’m aiming here in the corner and this
is a just a big half-inch piece of steel to spread the load so I’m lining this up
in the corner to kind of give it some support and then I’m coming straight
down and pushing on this area right here I’ve also moved it kind of over into
this area a little bit to just pushing down on the pan and you can see it’s
it’s changing the gap a little bit so I will have to come back and Hammer these
flanges flat as it as it goes down it’s it’s starting to
you know distort as it should all right now it’s moment of truth
take two okay got contact on the right side and
contact on the left side so I think it’s I think it’s right but I’m gonna get the
square and square up this height gauge to the floor or to the channel just to
make sure I’m not measuring in a wonky way but I think the hardest part might
be done okay I don’t know if you can see that
but I was able to confirm that the the channel is located you know directly
below the pickup points and that it’s square from front to rear and square
from left to right so this is no longer tweaked it looks great I’m gonna I’m
gonna double check a couple of these other measurement points just to make
sure I didn’t for some reason only affect the front so everything is as
planar with respect to the rear of the car
so one other thing I’m gonna show you inside I’m just gonna use the old
straight edge method right there at the gas tank and make sure that things are
looking flat there too if I hold the straight edge across the the gas tank
floor it’s it’s nice and flat so if I get into an area where there’s no weld
yeah right here this is looking really good the the driver’s side is the same
situation no daylight underneath here so I have a feeling the the pan is in its
final position and you know the the intimidating part is over so now it’s
just a matter of finishing a ton of plug welds and really locking this thing into
position the heat shouldn’t distort this too much I am going to double-check as I
go just to make sure that things aren’t getting really out of hand but I really
don’t see anything moving at this point considering how hard I had to hit it
just to move three millimeters okay here’s a cool little little trick
for you guys so I’m having I’m having trouble with this flange being offset so
I need to pull this this part of the car I need to pull it down so I’ve welded on
this little little eye bolt you see there it’s just I bolt and it’s welded
on to the outside of that flange and then I put this s hook through there and
then I put a bar okay there’s a bar through there like that and now I can
see I could pull this flange down to where I want it
once it’s where I want it I can see clamp it and then finish welding this
this is the passenger side gas tank support and it’s about I’d say 80%
finished are welded in see all the plug welds there there’s the weld there in
the corner continually going up to the front bulkhead here’s the driver side
plug welds still a few more to do in this corner and also there’s a butt weld
there to finish in a big hole to fill okay this is the driver side lower area
and I was able to get that seam to meet with the other seam there’s still some
to be trimmed a little trimming needs to be done right here this this flange on
the new pan is just a little too long but I did bring this down like I showed
you on the other side with that special eye hook technique and these these are
just raw welds not ground down not finished I’m gonna be doing a lot more
work on this to kind of make it look prettier but the good news is it’s this
in place and it’s not moving okay here’s the passenger side again these are just
raw welds plug welds not looking very pretty at the moment but definitely
secure you can see that I hook there that’s definitely gonna be cut off I
still need to pull down a little bit more to get these these flanges here to
line up a little bit better alright so that was a struggle you know I’m not
gonna lie plan a didn’t work out as like I wanted it to you know I had to use the
diagonal jack longer than I wanted but I didn’t just slap it in there and I
didn’t rush to get the job finished I took a lot of time measuring that’s why
the video is probably a little longer this week I tried to explain all the
steps even though some of them are off camera in terms of lining up and
realigning up measuring measuring measuring so thanks for sticking with me
to the end next time I’m going to install that cover that goes over the
top of the suspension pan tidying up the welds and treating them a little bit
more with rust I like to use a 3m cavity wax on all the internal cavities that
have already been welded just in case some of that some of that paint that was
put on there and the weld through primer you know a lot of that gets burnt when
you do welding especially as hot as I did the plug welds so I want to use the
next best thing which is either epoxy primer or cavity wax in those in those
cavities but I will also let you know that I’m going to go to Rennsport next
week it’s a four-day event Thursday Friday Saturday Sunday I will be there
all four days for those of you that don’t know rents for reunions held in
Monterey Laguna Seca it’s a famous track they’re gonna be reuniting you know old
racecars with old racecar drivers modern Porsches on the track car show car
Corral it’s gonna be a big event Porsches 70th anniversary I’m gonna be
there all four days if you happen to be going please let me know I will leave my
email in the About section on YouTube or you can find me on Instagram and
Facebook under aa garage time I’d love to meet up with you and share some
stories so thanks again see you soon

8 thoughts on “911 Suspension Pan Welding 👍Align Then Weld…

  1. thanks great series
    my e mail [email protected]
    will be at rennsport love to meet up

    btw did you modify both rear flares?
    alos i know you need front turnsignal houaing i got my 911 and 356 parts from jim at EASY BUT I THINK HE SOLD HIS INVENTORY TO GARY EMORY GIVE THEM A CALL

  2. My A-arm on the drivers side is distorted, pushed up into suspension pan a little and is not a good reference point. The passenger side looks fine with no rust or holes. Should I just use the passenger side as the reference for the height from garage floor?

  3. Another great video. I have a wonky garage floor so I’m wondering whether to make a jig first. I need to address this before I start pulling mine apart.

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