AE86 booter project

[Myles1970]

A few more little jobs done:-



Bonnet adjusters released and blasted



Boot lid fitted, rear spoiler - I like the “option drift” decal, but it may have to go if I decide to repaint the spoiler



Before and after



….. herself didn’t miss her electric toothbrush for an hour or two, hopefully the smell of petrol will go soon

 

[Myles1970]

So my eyebrows arrived
…. No longer available from Toyota a guy in Sweden has been scanning various plastic parts that are no more, and 3d printing them.





I’m well impressed and they fit perfectly





Finally finished off the wheel well, filling and sanding was an ‘orrible job





And that’s the repair patch on the driver side wing nearly sorted…

 

[choco]

What material are they printed in ?

 

[Myles1970]

What material are they printed in ?

I’m not sure….

 

[Myles1970]

I’ve been scuffing the inside of one of the wings in preparation for 2k ep, then either top coat or gravitex followed by top coat…. as I don’t have any wing liners (they’re rare as rocking horse poo) - they wouldn’t work with flares anyway…





Prepping the three wing brackets is a PITA, I’m tempted to drill them off, but I’d be afraid of welding them back on crooked. I did drill one of them off as is was a bit scabby, so I blasted it and painted it off the wing

 

[Myles1970]

I’ve been away from the garage for a few weeks; day and night sun zero temperatures followed by family time over Christmas are my excuses. Headed back in yesterday and today and got a bit done:




Stiffer springs, short stroke shocks and not much weight in the shell made things a little challenging



It’d be nice to have some wheels on before 2023



Happy New Year everyone!

 

[Wedg1e]

Good effort, can't fault the dedication!
I used to get over to Monaghan a couple of times a year, servicing x-ray kit for a company in Clones that made tankers (well, the tank bit).

 

[Myles1970]

The collar for the steering column/firewall boot was corroded from the leaking master cylinder….


…, so a repair was done (it won’t be seen)



Below is my efforts at zinc plating …. Horrible, isn’t it. The dull grey was replaced by brown from the Trifin y passivate. Disappointing, I may need to make the two 3 hour round trips to the platers again.




I thought I’d give them a blast on the (recently acquired) Lidl bench polisher, and thankfully they turned out alright.

 

[Myles1970]

Steering rack painted up, new boots, tie rods and ends….




…. And front subframe built and offered up. The 4 bolts for the subframe itself dropped right in happily, the others not so much. Will have to loosen everything up and spend some time at it. Also need to order new bearings/seals etc

 

[Myles1970]

Steering column reassembled:





….. imagine my surprise when the stub axles turned left as I steered right

… turns out the manual rack was out of an LHD car. Oh well, these things are sent to try us



Meanwhile, some of my zinc plating…





The above pieces show the results of the trifin y passivate from youplate.Co.uk. They look dark and dull initially, but they polish up well…if a little more “antique brass” than bright yellow, hopefully they should resist corrosion a while longer



Above: spot the diy repair

 

[atomant48]

imagine my surprise when the stub axles turned left as I steered right

Ive just watched a doco on the MP4/4 and they had the same concern….so you are in good company!

 

[Nick DV]

Nice work, still enjoying the build

 

[Cosantoir]

What material are they printed in ?

Usually car stuff in good quality is printed in nylon but PETG will work too.

I’m not sure….

Actually nabbed a scanner myself a few weeks back for the exact same thing so handy!!!!


Great to see this continuing to progress so well

 

[Myles1970]

Progress Report:- New Myles-stone Achieved
Hubs overhauled with new races, bearings, seals etc.

Front brake Calipers refurbished with new seals, pistons and rubbers







….but best of all, I got to properly test fit all four wheels! This is the first time I’ve ever seen this car with wheels on. Not yet truly rolling as the quick rack (rhd this time) has yet to be fitted, and the front wheels foul the struts so I’ll be needing spacers. But thanks to @Cosantoir I’ll be able to test fit various thicknesses before committing to buy

 

[Cosantoir]

Body work looking fresh!!!
Delighted to be able to help

 

[Nick DV]

Coming along very nicely. Always seems a giant step has been made once the wheels go on

 

[Myles1970]

Ok, all wheels and axle off again . Hindsight is a wonderful thing, but the axle was making running the brake/fuel pipes more difficult, so back on its side it went….





… it also gives much better access to the captive nuts whose threads needed cleaning. My method of replicating the original front-to-rear brake pipe, fuel feed, return and breather pipes by using cable ties and masking tape to mark where the clips would go proved painfully difficult and only mildly successful. As I’d rescued the original clips and rubbers, I was weary of work-hardening them by repeatedly opening and closing them and seeing them break, so I didn’t run the pipes one by one. Rather, I made up each pipe and started at a point which would have them roughly centred, and am working outward from there. As you can see I’m not quite finished, but getting there..



I managed to get a repair kit with a similar i.d. as my master cylinder, so I’ve glass blasted and painted it ready for a rebuild. The servo was crusty from the leaking brake-fluid, and had a rattle when shaken so I’ve opened it up.





…. the diaphragm is in good shape, so I’ll blast the corrosion off and hit it with some epoxy when the weather warms up a little…..

….that’s all for now

 

[Myles1970]

I’m starting to flag now lol. I’ve been hoping to get the underside finished so I can concentrate on getting it rolling and get it off the rotisserie for good. But exhaustion is catching up on me…. 2-3hrs after getting home from work at 9ish, in bed by 12 or 1am before getting up for work at 540am ready for the 1hr and 40 minute drive to work again…. So I’ve been slacking off for a while. Couple that with the main dealer being unusually slow with getting parts (parking brake clips, seals, nuts etc), means there’s not much to update with….

Anyway, enough of my whinging, here’s what I got up to today



Exhaust heat shields after several hours alternating between the wire wheel on the bench grinder and the phosphoric acid treatment. I eventually gave in and hit some of the more stubborn scales bits with a flap disc. Of course I forgot to take any before pics, but they’re well improved….. there was no clean metal to be seen when I started.

Any suggestions as to what paint to use? Obviously finish isn’t terribly important….. 2k epoxy primer followed by 2k? Zinc plating? Epoxy mastic?

Answers on a postcard please

 

[Dcal]

Cerakote.

 

[Myles1970]

Cerakote.

Really? Doesn’t that need to be baked on?