Porsche 914 Hell Hole rust and panel removal

1975 Porsche 914 restoration, part 9. Cutting rusted and rotted out metal from the area in the engine bay underneath the battery, otherwise known as the Hell Hole.
Music from: pixabay.com/us...

[@huissens]

Watching you trying to remove the axle nut brought back memories of doing brakes on my 69 type 1. My uncle was helping me and my dad do the work. While trying to get the last hub nut off, my uncle broke his Craftsman ratchet (very stout breaker bar used as well). No problem. Off to Sears for a no questions asked replacement. Within 3 minutes, the 2nd Craftsman ratchet was toast. Never got that nut off, and my Dad got the craftsman replacement the following week at a different store

[@superprettyko]

WOW so much rust. So glad you and not me. I would not know hoe to put it back together. Keep them coming please.

[@JF-4444]

Loving the restoration! You are going about things in the right way. Need to be really careful to replace the suspension consoles in the proper location. I've been through this on two other 914s and they are really worth saving because they are so much fun to drive. You don't have to go 100 miles an hour to have fun in a 914. Just driving around town at normal speeds is fun because they are so connected to the road.

[@AutoDIYdactic]

Thanks! I measured the other side before I locked down the console in to position and I think I'm at least within 1/16th". I figured that is probably pretty important.

[@Mr10usdad]

You are doing a great job! I like the detail.

[@normanjohnson4648]

Good to see someone else struggle through the rust repair on the hell hole and frame rails. Good luck.

[@lowreedman]

Love the detail. Enjoying the process here.

[@richarddamico9894]

I am enjoying watching this, but also with dread, since I have a 1972. I am sure will need a lot of this work done. 😢

[@Otto-AutoPilot]

You're nailing it in every regard. More of the same please.

[@r.arabian3056]

Good for you for saving another one!! I like the detail at how you are doing it. None of my 914's had that kind of rust, but I am always curious how you do it to this level. Keep em coming!! Thumbs up!

[@AutoDIYdactic]

Thanks 👍

[@randyross7339]

Greatly appreciate your videos im looking at doin the same project next fall . I can see what I am in for.

[@tommclaughlin5617]

Definitely detail, thanks

[@oOlolilolOo]

Loving the details too, very satisfaying

[@richardjones38]

Your 'hell hole' corrosion was remarkably similar to my Californian '75. I didn't have to remove the outside of the longitudinal, jacking point or suspension console, but did have to make a parts for the inside bottom of the longitudinal, the whole top of it below the battery, and patch a hole where the battery tray had been welded to the inner rear wing (fender). I managed to do it without cutting the bottom of the inner wing / fender off. It was unbelievably awkward to so, even with the shell on a rotisserie, so I'd think I agree, cutting bodywork away for better access makes a lot of sense if you have to repair more of the outer longitudinal than I did, especially if not using a rotisserie. I couldn't have done mine without my 2" air grinder and a very compact reciprocating saw. The rear of your floor and bottom of the bulkhead / firewall appears to have survived better them mine. I had virtually no metal left there, with someone having fibreglassed over it all, probably misleading the guy who imported it into the UK who I bought it from into thinking it was fairly solid.

[@AutoDIYdactic]

A rotisserie would be amazing. I can't believe people think fiberglass is a good idea to patch rusty holes.

[@christianm7220]

I like that you are showing your work, not just a before and after.

[@littlejohnny47]

Enjoy this level of detail. Also enjoying the project. Good to see a 914 getting some much needed attention!

[@DailyDriveA5]

Great video, love the project 914!

[@siliconinsect]

Professional content the algorithm gods bust be smiling upon -- pushed you to the front page. I'll keep watching to see the finished 914.

[@cybersurfer2010]

Major surgery being done… Looks good they way you tackle this hell hole!

[@AutoDIYdactic]

Thanks!

[@dudley7540]

15 years ago I saw a 914 for sale on someone's lawn. Bad place for any car. Looking in the car told me the lawn needed mowing. They were asking 7500. Oh well.

[@AircultBerlin]

good job, but why didn't you loosen the welding spots on the side panel and then remove the entire side panel? That's in good condition. then you would have saved yourself the seam on the outside surface.. Greetings Mark 🇩🇪

[@AutoDIYdactic]

Thanks! I considered that but it's one complete panel that wraps around the door jamb area and up in to the pillar. Door and trunk fitment issues could then be an even worse problem.

[@tt-rs1457]

Unfortunally the rust prevention of Karmann was as good as it should have be. Where did it drive ?

[@AutoDIYdactic]

I believe this one spent its whole life in the Pacific Northwest. I have the original manual and several maintenance receipts from around the Seattle area.

[@waxingchandler3895]

I bet my 74 looks a lot like that =(

[@Level_Up_Nation]

What bit are you using to remove those pinch welds so easily!

[@AutoDIYdactic]

I'm using spot weld cutting bits. I think these are 5/16" which is a little large for these welds.

[@danielprout8987]

Who is going to help me pay for therapy

[@iaia5368]

In my opinion, it's not worth it. Clearly the structure of the car is literally rotten, consumed by rust. Even if you work on removing the rust from the visible parts, you will still have a lot of rust inside the non-visible parts. IF I were you, I would have this entire structure melted down, and use the metal to make something else. Afterwards, I would rebuild the chassis based on the specifications or technical drawing, as it doesn't appear to be an extremely complex chassis. You're going to waste your work doing that.

[@AutoDIYdactic]

If you look around, people have done a lot more with a lot worse!