AE86 booter project

[Myles1970]

So, there I was... Heat lamps on and wiping down with panel wipe and what did I spot:



Circled is a hole that had been hiding under some stonechip/scutchcoat (?).... Oh well, as you can see I wasn't for turning , and on went two coats of Spraymaxx 2k epoxy primer/sealer (aerosols).



...I used a full painters suit (we use them at work for tending to our dirtier unpleasant guests), visor and organic/vapour filters in my mask. Overkill maybe as there's no isocyanates in the primer.

I've yet to see how it goes off, but the Spraymaxx aerosols were quite good though they don't go far. One can did one coat of one inner wing (both sides) and the firewall.... Gives quite a good fan, even if it's hard on the index finger

 

[Cosantoir]

Wow the lick if paint really brings it all together

Were each pannel completely rust free or did you have to get any bits with a rust converter or similar product before painting?

 

[Myles1970]

Wow the lick if paint really brings it all together

Were each pannel completely rust free or did you have to get any bits with a rust converter or similar product before painting?

The whole front end had been stripped when I got the shell, so the first thing I did was treat it with phosphoric acid before tackling anything that was past treating. It was in a poor state, and I'd say the material on the apron is a fair bit less than 0.8mm. I'd been coating everything in upol weld thru primer to preserve while I tackled various repairs, but evidently it's quite porous as it seemed to flash over with rust again. It mustn't have been too bad though as it looked good after keying and wiping over with thinners.

Anything that cleans off easily I'm just treating with phosphoric acid and primering. Anything too scaley or cracked/peppered/obviously thinned I'm cutting out and get replacing.....for the most part (sometimes it pays to choose your battles)

 

[Myles1970]

Next on the agenda is the nearside chassis leg/apron.... The one that I replaced. As far as I can tell, it's factory, ie. no damages or repairs. So I just have to sand off any surface rust around any scratches, and key it ready for the epoxy primer/sealer.

After that, I have the choice of crushed rear chassis rails and rear inner (and outer) wheel arches... Also two outriggers ready to fit, but will have to disengage from the jig to allow them to fit , anyway, one thing at a time

 

[Cosantoir]

Just in case you need any of this stuff

Facebook Groups

Japanese Car Club Ireland has 8,544 members. Buy and sell group

www.facebook.com

 

[Myles1970]

So here's the flange repaired and epoxy primered.



...next onto the nearside:



Battery tray removed. I'll relocate it to the boot. While I'm at this point I may as well shave the inner wings.... I've also started stitch welding the seams, and adding strengthening gussets....

 

[slim_boy_fat]

..... Gives quite a good fan, even if it's hard on the index finger

Something along these lines might help?

CLICK HERE

 

[Myles1970]

Something along these lines might help?

CLICK HERE

Nice idea

 

[Myles1970]

Circles, circles, circles; everywhere I look, circles...I'm going round in circles

 

[Myles1970]

Added a few gussets!
(Ooo-err missus!! )

 

[Cosantoir]

What's the purpose of circle patches why not square?

 

[Myles1970]

@Cosantoir it's the round hole - square patch situation , the holes in the engine bay are all circular, I'm shaving it, aiming for something like this:

 

[Cosantoir]

AHH any fear of water being held in the bay?
I assume there's little risk.

That pic looks awesome

 

[Myles1970]

They're mostly holes for wiring, brake pipes, expansion tank, fuse box etc, not drain holes

 

[Cosantoir]

AHH...

What's your end goal? Something for the road to drive on nice days or track car?

 

[Myles1970]

I'm going for a track focused road car ... I'm not going for mad power, but will have some nice mods, most of the interior - may have rear seats if they'll fit with the cage. But I'd like to be able to take it to a car show/meet and not be ashamed to lift the bonnet...



I used to own this one, put a supercharged engine in, so it was a bit of a sleeper.... under the bonnet wasn't pretty tho'. This time I'd like to have the engine bay look a bit wow

 

[Cosantoir]

Yea makes sense, are you going to do a wire tuck or what's the plan for the wiring that now has no holes to go through?

 

[Myles1970]

Yep, chassis/lights wiring inside the tops of the inner wings, and engine wiring in through the a/c holes in the firewall is the plan

 

[Myles1970]

....at last, all holes filled on the inner wings. Trying to find out what some of the holes on the firewall are for before closing them. Next up: sealer, filler, primer, colour, clear.....I think

 

[Myles1970]

So I finally fitted the two outriggers. Took a fair bit of time what with wash primer on the insides, and weld-thru on the seams... Also had to remove any pre-existing paint and some of the epoxy primer in places to allow me to weld.

Getting the pieces to fit took time too, as using the old dented/mangled ones as a template is not without it's challenges.

I have the shell upside down obviously, but the jig didn't take these outriggers into account, so I had to remove the subframe bolts and replace them with some m12 threaded bar....this allowed me to increase the clearance for fitting using my new Parkside Ugga-Dugga like this.

....and here's the end result!

Please accept my apology for the quality of my vlog/videos