Today will go down in the annals of history as a great one. For the first time in a decade, Zip's halves are fastened back together with every fastener intended by Mr. Porsche. It wasn't an easy road to travel but it can be checked off.
First, let me say I should have chased the mount threads prior to bringing the body down. I had to lift it back off and run a tap through all 6 in the back. All were boogered with paint and rust but one must have been tapped an incorrect thread because it was a fight all the way through, at points making me fear the tap would break.
The first day's attempt at lining up the seal and getting the holes to match up ended up being a complete waste. I'm now so blind in both near and far distances, I can no longer use my bifocals to work because I can't tilt my head to look when on a creeper or sandwiched in a tight space so I'm now relegated to using readers and being blind for anything but extremely closeup.
I pulled the wheels and put the bug on the lift using the front and rear suspension as mount points so I could use carpentry shims to separate the pan from the channels to get the seal in place and to use a die grinder to wallow out holes for alignment, sometimes extreme cutting being required.
The witches hat mounting holes had to be wallowed the most due to the channel nuts no longer being captured floaters but fixed nuts welded in place. I wallowed it so much I needed larger washers to keep the stockers from being swallowed up.
but two dremel tools later, success!