June 25, 2004

Now that the tail opens and closes properly, the repair, perfect seams, and fit are still being conducted. Note the cool bolt with the welding wire.The left side was damaged in the crash, so while repair work is being done, it's little do dads like the bolt that help pulls panels in and out during repair work.

We used the inside brake duct to make molds, so they had to be removed from the tail. We did this because it's easier to repair the inside of this panel while the brake duct is not there.

These shots are cracks in the top center of the rear fenders. Jack has ground the cracks to nothing and will build them back up with a few layers of mat.

Both ducts were removed and now reinstalled for good.

This is the repair work on the two fenders.

Jack is now about to grind all the paint off the tail. One last look at the original AP,
(SCCA "A" Production) and the number 77. These have to be removed now. We wish we could save them, but they're just too old!

The inside of the fenders are being rebuilt.

These are the original hood latch receivers. They will be removed, restored and reinstalled.

Repair work on the left is ready for fiberglass. The picture on the right shows the repair finished.

Same in these two pictures, Jack used pattern paper for the shape, tapes it off, and glasses right over it. When the glass is cured, the paper and tape is removed easily.

This is the tail light area just before stripping.

This is some of the original hardware that came off the tail.

If you look close you can see where the Carrera GTS holes used to be.

On the inside, an end mill was used to relieve the area where the badge studs stuck through (fiberglass was too thick). This was common on a lot of 904's because there was no control on how thick the fiberglass was. A chopper-gun was used in making most of the parts on the 904. If the operator kept the gun in one area two seconds too long, you ended up with a panel 6 mm rather than 3-4 mm, which was what they shot for, no pun intended.

Peter Gregg probably had this duct tail installed when he owned the car. Who knows who put the intake grills on the deck lid.

Jack is doing the tedious work of hand grinding the tail light buckets.

Remember when you have old filler and paint on fiberglass
(especially glass that's been cracked up), you have to start all the way at the bottom.

If you don't go to bare glass and do the proper work on top, your restoration finish could be a nightmare when the car gets into the sun. The sun will shrink and expand the different layers of materials at a different rate, thus making the paint finish uneven in areas with maybe divots or blisters. This can be properly done using proven methods of repair. Even if you do all the right things, there will always be a spot or two that will show its ugly little face.

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