Saturday I decided it was time to tackle the front fenders to get started on making them wider to clear the wheels. In order for that to happen I needed to get the lower fenders mounted. I decided to extent the outer rocker and start the flair with that. I bought a repop outer rocker to save myself some time making the bends hoping it would line up easier. To get started with everything I marked the fender and made my first cut into very expensive fenders.
As you can tell from the picture below the repop rocker wasn't even close to the same size, bend angles, or dimensions as a stock rocker.
With the top part of the rocker the only thing remotely close to right I took the rocker sections and rolled them with a very flat wheel in the english wheel.
After bending the correct dimensions into the rocker I ran it through the stretcher and again through the english wheel to give it a little curve by the door area and it was enough to flow with the body and gain me 1.5" of flair. And yes, I know the body line doesn't line up. I have some more trimming to do on the bottom of the fender, but its easier to remove then it is to add.
With the passenger side tacked mostly welded in I moved onto the driver side.
With the new extensions mostly welded in I went back to the passenger side to start finishing it out. I started with the end cap so I could tie into the frame rail and make sure nothing moved. I left the top and bottom open as I need to install Rivnuts to mount the wheel well liner when I get that made and I need to weld in tubed so I can run bolts up into the fender. The back side of the fender will have aluminum L channel bonded to it on the back side.
I also checked fitment of the trans tunnel plate as well. I made it 3.5" longer because of the wheel base change and cut it out of 1/8" aluminum. This is more than likely going to be made out of carbon fiber as well.
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Hi AJ. Wonder your thoughts. After getting my extended rockers and the inners completed... I sort of regret that capped the rocker in front of the tire such that the tire would kick debris towards metal that will be body color. I did think about this while I was building it but didn't worry about it because I had intended on clear wrapping the entire bottom of my car...that was until the PPG guy advised not to do that as it could cause the paint to fail (and the skim coat of filler), since it wouldn't be heat cured.
Saturday I got the driver rocker capped off. I'm still waiting on some parts I ordered to finish things off before I can finish boxing in the extensions.
So with the stand still on the fenders I moved to the hood. I got everything measured out and then cut a big hole in the carbon fiber to start mounting the hood vent.
With that out of the way I decided to finish up the metal work on the roof. Some hammer and dolly work to get things banged into place then the shrinking disk to finish things off. I'm going to have my body guy check it out and if its acceptable then I'll weld the inner structure and roof supports back in.
With time to kill still I got the front and back of the spoiler marked to follow the stock spoiler curve and ready to cut out. My band saw blade broke so I'm gonna try and get a new one today.
With the little time I had left I started messing with the hood latch. I didn't buy the cheap knock off one that everyone is selling. I found a clean original Porsche latch on ebay pretty cheap.
Then out in the sun loading up. The rocker being black is hard to get pictures of inside.
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Saturday I wasn't planning on working on the car as I was supposed to work. Another guy asked me to swap weekends with him so I wasn't really prepared to get anything done on the car. I did have the wicker bill trimmed up and filed to shape and got that installed. Now it follows the body lines.
Then I moved onto the hood latch. I forgot to cut the adapter plate out so I couldn't finish it up.
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After that I got started on mounting the HVAC module. I got two of the 3 or 4 mounts done. Some dimple die work and bead rolling to keep it strong and lose some weight.
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Ok guys, I kinda slack with the updated on the car on the message boards. Its just kinda a hassle since I don't have the internet and I have to pair to my phone and transfer all the pics to the computer, resize, and convert them to a format I can upload. Anyways I've been busy so lets hop in.
Picking up where I left off last time I got the car stripped down with the craptastic epoxy that the blaster applied that was flaking off and then into sealer. Also the bare metal was sealed to stop the surface rust.
With that out of the way I was able to get the driver quarter metal finished by pick and file and with the stud gun on areas with no back access.
The passenger side was the same process. Final fit, zip screw, trim, weld, metal finish, seal.
With the quarters in place I needed to finish up retucking the bumper. Since I did the wide body on the car I needed to modify the pockets to be a little deeper and trim the bumper ends accordingly. I didn't get great pictures when I did the driver side so I'll run down the passenger side. With the bumper bolted in place I tapped off the metal around to make a template. Transferring that to some sheet metal I got everything cut out and clamped into place before welding and metal finishing everything.
Now with the bumper squared away I moved onto the door handles. I'm running C6 style release buttons so I needed a pocket to get my fingers into. Starting with a shape the same angle as the stock gills and not the NACA duct I made a tape pattern to get me in the ball park. It took some work and time, but I like how they came out.
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