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Tank support panel

R

RugbyBodders

PCGB Member
Member
So i have a small area of corrosion near the Offside front suspension mount. not stripped back the under seal in the area yet to fully establish to extent, but will need to buy a front floor section to complete the repair.

My car’s completely original, so I’m wandering whether I should have the smallest possible area cut out and replaced, or replace the entire front floor and tank support.

I’m thinking I want to keep as much of the original car as possible and therefore limit the extent of repair, but would welcome everyone thoughts?
 
Hi Craig, On my 911E I usually buy a replacement panel and cut out the bit I need to replace. Depends upon what the rest of the metal is like.
This way I keep as much of the original metal which is nice.
Rich
 
I think that’s the route I want to go down. Obviously depends on the condition of the material either side of the corrosion, guess I won’t really know until the car is stripped.
 
I think you need to establish exactly how far the corrosion has spread before you can decide what to do.
Doing the job properly means not having do do it again later. I would replace the complete panel.
These are old cars and cutting out a small area to weld in a patch means it is no longer an original part.
 
The tank support is a common corrosion area. As a hollow part they often rot from the inside out. I would suggest breaking through where you have found the rusted through area and using a borescope inspect the inside of the tank support. Cheap borescopes to attached to a mobile phone are available.
If the supports is repairable it needs to be injected with cavity wax or some rust inhibitor of some kind.
 
Thanks all.

Car is booked in for mid-April with Carrera Performance near Horsham.

I’ve insisted that I’m present whilst the car is stripped so that we can decide the extent of the repair.

Obviously it’s in a structural area, so need to be mindful that the repair will be under load, and your point Robin regarding doing it correctly once is very valid.


Will keep you posted on how it goes.
 
I'm with Robin, top and bottom panels.
The 'edges' of the sections (sort of the front chassis legs by the battery boxes ) can get thin too so some work there possibly.
I did my 911T ('73) myself in 1988 using real Porsche panels. Still solid, all welded and cavity sprayed back then, still there perfect now after 32 years on the road and 70K miles.
Good idea to be there when uncovering the area(s) that are/could be rusty.
Good luck!
 
So we opened up the car today. Cut open from within the trunk, which showed that the battery support panel was in really good condition, considering it was 52 years old.

What it did show was that offside front suspension mount was heavily corroded as suspected and there was a lot of rust flakes in the cavity between the upper tank support panel and the lower front suspension panel. Nearside support was in reasonable condition, but had surface rust. Was unable to verify the remaining steel thickness.

Both battery boxes, front panel, inner wings are all in really good solid condition along with the mid to rear section of the tank compartment floor.

We pretty much stripped the front end mechanics and removed the offending rusted panels by drilling out the spot welds, so has been a busy day!

So decision made to replace the entire front section of the tank compartment floor from the front panel back to just beyond the suspension mounts. New Tank/battery support panel and suspension reinforcing brackets.

Going to get the suspension subframe and steering rack protective plate powder-coated whilst it’s off the car and replace the rubber bushes.

Hopefully the car should be back on the road in 2-3 weeks.

 
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