Where do I start with this one… maybe start with a few statements to set the mood
I am the ultimate gluten for punishment and I don’t know why I keep doing it to myself
the Japanese w / are simply amazing (I’ll get into that later)
if a jobs worth doing, it’s worth doing properly.
I’ve had this vehicle a number of years now and is the longest period of time I’ve owned a daily hack. It’s been faultless and continues to do everything and more considering it’s shoestring maintenance budget and daily abuse from its owner. The only major mechanical issue over the last 5 years was a gearbox replacement due to a whining 5th gear back in 2016 (clearly the previous owner abused the car as much as I have)
So during my annual inspection preparing it for mot I discover the horror story lurking beneath…
The tin worms have had a buffet on the chassis… I hate rust.
It’s actually in a relatively accessible place towards the front but to do a proper repair requires better access and as we all know, rust spreads much further than the visual hole. So the difficult decision was made to take the body off. A decision made all the more difficult considering the car is basically worthless and I could buy another one for less than £2000 but what’s the fun in that??
I actually started this back in July but time is in short supply at the moment. Works commenced with removal of front components including hydraulics, steering, radiators, wiring and brings me onto the Japanese. The way this car has been assembled is amazingly intuitive. I’ve got a workshop manual but haven’t needed it. Everything is easily accessible and every fastener is still recognisable as a fastener, not a furry blob of rust. This includes the flare nuts on the brake and clutch system, every one undid without issue considering they haven’t been touched in 20 years. Obviously made of better stuff then newer vehicles.
so far I’ve had 7 hours stripping and took 3 further hours to get the body lifted due to lack of facilities at home on the drive…
Not the prettiest setup but its now about 4ft high and once I back off the torsion bar tension nuts the chassis will roll under the trestles so I don’t have to work under the suspended body. Trestles are nice and solid (75x150 channel and 100mm tubes 5mm wall) and now I know where the clearance is I can weld a coupe of braces but it doesn’t really need any.
overall the chassis other than the area in question is in good nick, it’ll be getting a good prod but nothing is jumping out. But also on the list is all four shock absorbers, all the hard pipe work front to rear and rear axle brake pipes so all nice and accessible now. Fancy doing the exhaust in stainless too but I doubt I’ll get time. Just need some time now!!!
I am the ultimate gluten for punishment and I don’t know why I keep doing it to myself
the Japanese w / are simply amazing (I’ll get into that later)
if a jobs worth doing, it’s worth doing properly.
I’ve had this vehicle a number of years now and is the longest period of time I’ve owned a daily hack. It’s been faultless and continues to do everything and more considering it’s shoestring maintenance budget and daily abuse from its owner. The only major mechanical issue over the last 5 years was a gearbox replacement due to a whining 5th gear back in 2016 (clearly the previous owner abused the car as much as I have)
So during my annual inspection preparing it for mot I discover the horror story lurking beneath…
The tin worms have had a buffet on the chassis… I hate rust.
It’s actually in a relatively accessible place towards the front but to do a proper repair requires better access and as we all know, rust spreads much further than the visual hole. So the difficult decision was made to take the body off. A decision made all the more difficult considering the car is basically worthless and I could buy another one for less than £2000 but what’s the fun in that??
I actually started this back in July but time is in short supply at the moment. Works commenced with removal of front components including hydraulics, steering, radiators, wiring and brings me onto the Japanese. The way this car has been assembled is amazingly intuitive. I’ve got a workshop manual but haven’t needed it. Everything is easily accessible and every fastener is still recognisable as a fastener, not a furry blob of rust. This includes the flare nuts on the brake and clutch system, every one undid without issue considering they haven’t been touched in 20 years. Obviously made of better stuff then newer vehicles.
so far I’ve had 7 hours stripping and took 3 further hours to get the body lifted due to lack of facilities at home on the drive…
Not the prettiest setup but its now about 4ft high and once I back off the torsion bar tension nuts the chassis will roll under the trestles so I don’t have to work under the suspended body. Trestles are nice and solid (75x150 channel and 100mm tubes 5mm wall) and now I know where the clearance is I can weld a coupe of braces but it doesn’t really need any.
overall the chassis other than the area in question is in good nick, it’ll be getting a good prod but nothing is jumping out. But also on the list is all four shock absorbers, all the hard pipe work front to rear and rear axle brake pipes so all nice and accessible now. Fancy doing the exhaust in stainless too but I doubt I’ll get time. Just need some time now!!!