906-138
September 23, 2002

Now we're working on the front brake air ducts. They are original, but like the rest of the car, not bad enough to throw away and not good enough to just leave in the state of disrepair.

We'll show you a lot of detailed photos so you can see the steps in repairing these two hunks of shit!

The piece on the upper right is the area in the nose, which we cut out in order to save what was left of the flange on the duct itself. Then, we separate it on the workbench where we can see the whole part.

Just another picture of all the garbage from years of crashes.

Same part, different picture.

Same

Now we're dissecting the part. The piece at the top is the nose, the three pieces in the middle are what's left when all the trash (lower right) is painstakingly removed.

This is the other side (brake duct).

The before shot

You can see if you look close that the condition isn't that good!

In the next step, we'll split the duct into two pieces (which is how it's made originally).

More of the same

Now the crap has been removed.

Different shot

You can see where we cut the ducts out. We will glue the brake duct surrounding material back in the holes minus the ducts.

Now the part is replaced by glassing it on the outside and we'll be ready to finish it on the inside when this repair is cured.

The part is installed and held in position with tape for a perfect fit. When the outside is cured, we will match the surface area with a matt layup.

The inside is now finished and you can't even tell where the brake ducts will be installed (we do this later).

Now the outside is sanded and ready for bodywork. The duct will be installed after it's rebuilt and after the inside of the nose is reskined in 10oz. "S" weave glass (this will be the original texture).

Here a picture of the inside of the front right fender. You will notice two different shades of resin. This is because the car was probably crashed when it was near new. The green represents the construction of the rest of the car and the amber color is a factory piece more than likely installed at Porsche. Nobody in those days took the time and detail to do such a great job in splicing the two pieces together. Later we will tell you how and why this car got the special attention that it did (this car is full of titanium, get the hint?).

These are the gas tanks which are being stripped so we can see if they are savable or not.

The gas tanks are aluminum and in very bad condition.

The finished mold will be six layers of matt.

Jack is removing the mold from the headlight plug and will be making new parts in the morning.

 

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