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DeadSkunk  (Warren)
DeadSkunk (Warren) UltimaDork
8/15/21 2:36 p.m.

The hardest part of bending the windshield header is going to be trying to straighten the tubes inside the A-pillars without distorting the cowl area they're attached to. The area could well be bent already.

dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/16/21 1:13 p.m.

Tough to tell how much the A pillars have moved if at all if they moved a lot the doors wouldn't close too well because the mirror section would be crushed in. 

dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/16/21 1:14 p.m.

Looking at the drivers side maybe it moved some but the top of the frame is definitely the worst part. 

TurnerX19 UltraDork
8/16/21 3:55 p.m.

Looks like the "ultra high strength" steel did its job heresmiley

Woody (Forum Supportum)
Woody (Forum Supportum) MegaDork
8/16/21 4:57 p.m.

I've cut enough A-pillars with Hurst tools to know that if they are bent, you will never straighten them...certainly not enough to make a windshield fit without breaking. 

If the windshield frame is welded out of three pieces, I'd grind away the filler, drill out the spot welds and replace the top piece. There are epoxies that are approved (NHTSA or IIHS?) for roof replacement. 

RichardSIA Dork
8/16/21 10:53 p.m.

Put a 65 Corvair body on it. devil
Just to rile the purist of both tribes. laugh

Gammaboy New Reader
8/17/21 3:48 a.m.

I don't know what's wrong with the 01 that AAZCD is stripping, but I'd contemplate reshelling into that...

But I'd probably just go speedster. 

I recall reading an article that welding those high strength steels is not great, and OEMs generally spec adhesives for repair of them.

AAZCD (Forum Supporter)
AAZCD (Forum Supporter) Dork
8/17/21 6:50 a.m.
Gammaboy said:

I don't know what's wrong with the 01 that AAZCD is stripping, but I'd contemplate reshelling into that...

The '01 is structurally good, but was a flood car without a title. The shell is probably just good for a track car and even then, it had a Tiptronic (auto) transmission. Better to just get parts from it if it's useful at all in this case.

dherr (Forum Supporter)
dherr (Forum Supporter) Dork
8/17/21 7:50 a.m.

Yes, that is a crazy build to be sure. Sounds like Dan0 does not want go to that extreme, but great to read the build for those structure pictures for the repairs. I was deciding on what to do with my 914 and when this Boxster came up, it did cross my mind to use the drivetrain in the 914. But after seeing this, there is not much 914 left. From what I have read, the Boxster drivetrain is too wide for the 914 frame rails without extensive modifications, which I won't do to a solid 914.

dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/17/21 4:49 p.m.

I'm torn between fixing it up (to road legal) and going cart style. Both are interesting projects, 


Keith Tanner
Keith Tanner MegaDork
8/17/21 5:10 p.m.

I just want to say that this car should be called the Squashster.

slowbird UltraDork
8/17/21 5:33 p.m.

I have a better (worse) idea for the windshield: cut the existing pillars off, slap on the folding windshield assembly from an old Jeep. laugh

dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/17/21 6:42 p.m.
slowbird said:

I have a better (worse) idea for the windshield: cut the existing pillars off, slap on the folding windshield assembly from an old Jeep. laugh

I did have a somewhat similar idea. Clean up the rest of the body, cut the windshield frame off, cage it, and incorporate some sort of plastic "windshield" to the cage. I'm not in love with the full speedster look and super low shield. My feeling is if I'm going to get that much wind, rain, bugs, etc. in my face I might as well be wearing a helmet and riding a motorcycle.

In the meantime I'll start by pulling off the front fenders, bumper, rear bumper and get an idea if anything else is damaged and if I can fix them somewhat. Then clean up the remaining glass around the windshield and start looking closer at that.

What I really, really want to do, is just cut the section of the windshield frame blocking my vision and go rip on the thing.... I drove it a mile after removing the top and I was either trying to be out of the seat or scrunched down lower.

BrianC72gt (Forum Supporter)
BrianC72gt (Forum Supporter) Reader
8/18/21 12:48 a.m.

I would jack the bent section up while also applying pressure across with a port-o-power between the A pillars, pushing them apart.  Even if you are going to cut those pieces out and replace them, it is better to get the mangled pieces close to right, then cut them out.  This will help ensure that the adjacent metal that you leave alone is close to where it should be.  How do the side windows mate to the A-pillar? 

Also, you might want to get your hands on some technical data as to which kind of metal is used in which location.  I'm guessing it is all one of the many variants of  high strength steel (HSS) which losses it's strength when heated and should be tossed out when folded or torn.  And there are also approved attachment points.  And newer vehicles with structural damage are becoming more and more unrepairable.  My next project is a 91 Toyota MR2 with a light side impact to the sill, door and floor.  It's all mild steel, so heat, grind, bash, flatten, pull, hammer, remove-straighten-and splice back to your heart's content.  However, with all of the exotic HSS in newer vehicles, you have to remove/replace complete assemblies at approved attachment points and weld /glue back.

This is why late model vehicles with seemingly light damage get totaled so easily.  The HSS saves weight & adds strength for OEMs squeezing every ounce of weight for fuel economy, etc., but to get it back to an insurable OEM spec requires lots of work, no more cutting out and re-sectioning pieces of critical structures like chassis legs, or convertible top windshield headers.  Sorry for pissing on the parade, but a speedster treatment with cut down lexan or triplex would be neat.

2Girlsracing (Steffi)
2Girlsracing (Steffi) Reader
8/18/21 3:47 a.m.

Duvall hot rod windscreen or speedster. Or both!

dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/18/21 7:33 p.m.

Busy with work this week, but dreaming all day about it.

Weekend goals

1. Look for exhaust leak 

2. Pull door panels to vacuum broken glass (spent a bunch last week cleaning it up in the rest of the car)

3. Remove remaining windshield glass and windshield trim for a better look. 

4. Pull off front bumper, rear bumper, possibly front fenders to look for other damage. Plus to see what underneath looks like to see how a cart style would look


dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/19/21 5:16 p.m.

Today's couple minutes before dinner. Took the stick jack and tried using it to lift the rear section of the quarters. It's space limited but I think it did make a difference. 

Having the right tools and techniques would likely fix it better but considering my thoughts are replacing panels or BoxsterCart what does it matter. 

If I can make things fit again. I may just drive it as a "survivor"


dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/28/21 7:53 p.m.


Removed the last bit of the windshield today. Pulled door panels and got the broken window glass out of there. 

californiamilleghia SuperDork
8/28/21 8:05 p.m.

can you use a 4 post lift to pull up the quarter  panels and windshield frame ?

Rotaryracer Reader
8/29/21 9:39 a.m.
dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/29/21 6:57 p.m.
californiamilleghia said:

can you use a 4 post lift to pull up the quarter  panels and windshield frame ?

I don't have access to one. I'll be trying a floor or bottle jack with a 2x4 as previously suggested or lifting it with a engine hoist. 

dan0 (Forum Supporter)
dan0 (Forum Supporter) Reader
8/29/21 7:02 p.m.
Rotaryracer said:

Granted, just a *little* more work than BoxsterKart, but...



When I have a shop I want to build something like this. For now I just have a garage with enough space to store it. 

TED_fiestaHP HalfDork
8/29/21 8:27 p.m.

  Harbor freight sells a hydraulic ram tool, has lots of adapters and stuff.  For what it can be used for, it is really cheap.  I have one, it's really handy.

  I also bought the tool they have, that welds little sticks to the dent, then you use a slide hammer on the little sticks.  Takes a little practice, you start at the edges of the dent, and keep making the dent smaller.

demnted New Reader
8/29/21 11:20 p.m.

nylon strap and engine hoist?


AAZCD (Forum Supporter)
AAZCD (Forum Supporter) Dork
8/29/21 11:51 p.m.

If using the jack & 2x4 method make sure that the surface that you are pushing from is reinforced so that it doesn't deform as the other end is corrected. -Push from a wide base to a focused point.

You may have success in some areas using lots of hot glue and a wooden lever & fulcrum. Here's what one of the 986Forum guys did a while back. I've done similar on my Beetles. http://986forum.com/forums/diy-project-guides/64150-pdr-your-own.html

One of the pics:

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