AE86 booter project

[Myles1970]

Ouch.....

It must be nice to be able to do sections like this big and relitively easy pieces to fit always feel like great success.

This area is quite complicated as there's a lot missing (rotted away) so I'm having to be creative....

The blank (?) for the end of the sill:




.....^^^ the above will be plug welded to the inner and sill membrane, and will be butt welded to the inner arch as well as the inner wheel well...


.... repair section for the inner sill:



....and cutting out the rot from the quarter panel sill end:



The cheapie air saw is great, but the replacement blades (from china) aren't so hot

 

[Dcal]

Just use decent hacksaw blades broken to size
If you want, you can grind them to thin the shape.
I don't bother unless I'm cutting some very tight radius or starting in a small hole.

 

[Myles1970]

Got a little more done tonight:



...also, these were here when I got home





.... that's it, no more spending for a while €€€

 

[Dieselman 63]

Enjoy watching this build. My sister has an AE111 Levin, it’s a zippy little thing even with the 4afe.

 

[Cosantoir]

View attachment 308841

.... that's it, no more spending for a while €€€

Send a pic of the top down

 

[Myles1970]

@Cosantoir ?

 

[Cosantoir]

Sorry was supposed to have the pic of the headlights. Just looking at how you would mount the light brows

 

[Myles1970]

Sorry was supposed to have the pic of the headlights. Just looking at how you would mount the light brows

Ah! I'll take a pic tomorrow. From memory, I think there's two holes in the grey plastic on the top, and two on the bottom of each

 

[Myles1970]

@Cosantoir there we are, one from the top:



....and one from underneath:



....HTH

 

[Myles1970]

Got a little bit done today.... Started on the captive nut for the bonnet hinge that had been ripped off:



Straight cuts this time, and the obligatory spot welds....

....hey presto!


Surface rust underneath mostly, I had been expecting worse as it the run-off for the windscreen... It was well sealed though so I've just treated it ....



And finally, found the original bolt and tacked it in:

 

[Myles1970]

Also, trying to repair the passenger side rear wheel arch/sill area:



I'd say a shrinker would come in handy to shrink the flange...

I decided to leave it for now .... Skipped lunch and my concentration was going. I'm half tempted to try one of these repair sections:

 

[Cosantoir]

what is this science??

Those two sections on the headlights where a screw goes into would be a decent mounting point for eyebrows

 

[Myles1970]

View attachment 309348what is this science??

Those two sections on the headlights where a screw goes into would be a decent mounting point for eyebrows

Yes, I suspect that is what they are for

 

[Myles1970]

....I suppose the best thing I can say about this, is that it's below the swage line and will be mostly covered by sideskirt



.... this, will also be covered, and will allow me to bolt-on the bonnet hinge securely

 

[Myles1970]

And that's that.

Also removed the passenger seat mounting at the sill; one of the spot-welds had come apart and the inner sill was torn.... Managed to make a few more tears (must order some more spot-weld bits) before welding up the tears and blobbing the holes. I'll finish cleaning up the mounting and mount it ( ) next time

 

[Myles1970]

.....I didn't , although I did fill in the holes left in the floor.

Instead I carried on with the quarter panel:



De-rusted, primered and...

...the same for the inside.



The batteries on my mask and head torch are on the way out, so I'll return to that horizontal seam and a few plug welds along the bottom tomorrow or the next day



Above and below, the forward end of the wheel arch closed-up/sill capped off.

 

[Myles1970]

One major faut-pas (pardon my french) averted today, I inadvertently introduced a concave crown - I can't think of the correct term - between the arch and the b pillar. I think I have it sorted after some more french, some cutting/grinding and some hammer off dolly...


^^^ hopefully not too bad now. There are two horizontal seams here, so some filler action is inevitable



^^^ the silver primer creates an illusion in the pic

 

[Myles1970]

So flares are back in fashion (in my house anyway )

 

[Myles1970]

.....I'm not sure how well they go with these skirts though...



The standard skirts are much more understated, and iirc go up at an angle from the bottom corner of the door.

I think I'll leave the proper test fitting of these until the car is fully in primer and off the rotisserie so I can refit the bumper

 

[Myles1970]

Back to hammering sheet metal...



... this surely must be one of the most satisfying aspects to a car restoration project. Even if the shape isn't perfect, at least I know I'm not putting rusty metal back on



Again here I've chickened out and made the wheel arch repair in two pieces which I'll weld together...