This is a great project as well. We are taking a solid 914 and combining it with an ’84 3.2 liter 911 Targa. Fabson Engineering is doing all of the mechanical work and upgrades in this swap. Steel GT flares are butt welded to the body as well as reshaping the steel bumpers to work better with the fiberglass valances and provide proper crash protection. Fiberglass bumper tops have also been sourced to eliminate the wavy look of the stock rubber tops. The front bumper has also been altered to accommodate an oil cooler ducted through the front trunk. There will be numerous small custom details done as we move through the process.
This is sure to be a fun car to drive when completed.
(Click on any image below to view larger size.)
Here we are preparing to fit both flares to the rocker panels.
Here is one of the small issues that was found.
The area is cut away until there is good metal.
The area is prepared for some replacement sheet metal.
The metal is formed to fit. The two oval holes are where the oil cooler lines will run to go to the front of the car.
A patch is made to fit.
The fit after trimming.
A line of tape is laid out to define where the bumper top will be trimmed to.
This is the fit at the front before welding.
The front flare fastened in place. Notice how it compares to the stock opening.
Cutting the body away to start welding the flare on.
The front valance fits great.
The stock steel bumper is altered to create an opening that matches the lower valance for the oil cooler.
The finished metal work.
This shot shows how the flare compares to the original wheel opening.
The rear flare and lower valance fit is checked throughout the welding process.
A little more work and it will be perfect.
This is one of four pieces per side that were added to reinforce the rear of the car.
This illustrates how poorly the fiberglass rocker panels are made.
The body is trimmed one section at a time and tack welded in place. Hammer and dolly work is done throughout this process.
Here the flares are TIG welded together and the welds are ground smooth.
With some blue fine line tape as a guide, the fender edge is trimmed as the final part of adding flares.
After evaluating the door fit, it was determined that someone put body filler on that was not needed. This is more common than you think. After some sanding and checking, we are on our way.
The collapsible spare from the 911 donor car provides plenty of clearance for the oil cooler shroud to be placed in front.
This is a very simple way to relocate the spare tire. Rubber pads will be glued to the back wall after painting.
At the same time as the priming process is being done, the inner wheel wells are epoxied and topcoated.
The flares are painted with epoxy and high build primers.
The painting process begins. The first round is all of the bumper pieces and rockers. The rockers got an application of chip guard before color was applied.
Targa top, trunk and engine lids are next with everything being color sanded the next day.
With the wiring harness still in the car, special care is taken to mask it and hold it out of the way.
The bottom is covered in undercoating to make it a uniform surface.
The same treatment is done in the rear trunk.
Two good coats of epoxy primer are applied.
The yellow is applied with a single stage paint with flattener added to reduce the number of coats needed to achieve the desired look.
After the body is finish sanded and remasked, the base/clear finish is applied.
After polishing, it is re-assembled.
The car is now ready to go out and get the new drive train. It will come back for carpet, trim and finishing touches. It is due back here in spring. Stay tuned.
With the drive train, suspension and brakes complete, it is time for the interior. Some cosmetic repairs were needed on the dash.
A new set of carpets, door panels and seats.
The roll bar has been repainted with all new hardware as well.