DK AE86 renovation and turbo project - Now driveable

[Veiss]

Now it's time for a little update.

Today I filled the brake and clutch fluid line. I had a bit of trouble with the connection from the rear axle, which I had forgotten to tighten properly But I tightened it and everything was peachy! And the clutch working fine also, man that T3 shortens the travel between gears! Feels nice and tight, I can't wait till I'll be able to drive it!

I also got the rear hatch mounted, but it needs a little adjusting before it's all good. But now my remote controlled opening mechanism is out of order... I think it's a poor power relay. But I'll have to look into it, before I can put in the rear window...

Tomorrow I'm getting a new front windscreen installed. It's going to be sweet!

Here are some pictures of the progress today.

[Veiss]

Yet another update.

I just received a package with some new goodies. A 12" fan, and 2½" and 3" V-Band joints for the exhaust.
I mounted the fan yesterday, and I also got around to mounting the doors, and the opening mechanism. I test-mounted the front fenders, but I'll need to mount the hood, before the final installation of the front fenders can be performed.
Man I hate fibreglass fenders... Although I spend two days making brackets and adapting them, the fit still isn't as good as I want it to be, but I guess that's just the way it is.

And as always, some pictures of the progress and parts:

[Veiss]

Front details update!!

Today I have assembled the front end of the car. There is still some minor adjusting needed, but nothing wild. Man I hate those Fibreglass front fenders... The fitting is a pest, but I thing I've got a pretty decent result. But they really pi.. me off, crooked, but not equally crooked... But it's almost done, so I can look forward to driving the car now, and not standing around staring at the stuff I think could have been better. :wink:

Now the plan, getting the car running before the end of may, doesn't feel that unrealistic! I sure can't wait to get her on the road again!

That's all for today, but tune in tomorrow, and I bet there'll be a little more progress.

[Jan Pedersen]

Looks great, Lars!

[robokill]

looking really nice

[banpei]

Nice!
I think about everyone I know who fitted fibreglass replacements complained about fitting them...

[Veiss]

Today my mate Kris and I, installed the front side windows, and some of the trim around them. We also got the rear window fitted, and with quite some effort it was also straight

I didn't expect that it would take such a long time installing the windows, but damn, they were dirty after 2 years of storage. But we cleaned them up, and in they went. And now there's dirty fingermarks all over them...

We also got around to fitting the door-trim. That was some disappointment, they are not in a very good state, and I'm missing two black window regulator handles. All because the previous owner had electric windows installed. And there's a big hole in each side, to fit a speaker... But my plan is to make two new bottom parts of the door-trim, and get the top covered with some nice new black leather.

Here's some pictures of the days work.

[DJexor]

absolutely great! and i love that color combo!

[Veiss]

Thank you all very much for the kind comments!

Today there isn't going to be much progress, but tomorrow we're making a custom 3" and 2½" (at the rear axle) exhaust in stainless steel. I sure can't wait to hear her roar!

[Veiss]

Time for a REALLY big update!

Let's see, where do we start...

Last Saturday we fabricated and fitted a complete custom exhaust. with a Fensport exhaust header (I believe), 3" piping to a 3" free flow oval silencer, then at the rear axle, converted to 2½" piping, over the diff., and down to yet another free flow hks look-alike silencer with 4" tip. The system is build in stainless steel, except for the exhaust header ( and no I can't TIG weld, but I have a buddy who is a blacksmith - who is really good at it).

It makes a nice roar, a bit loud, but the turbo should do a bit of silencing too.

I've also installed the rear side windows, with trim. And temporarily installed the sunroof ( needs a bit of paint-repairing) Fitted the wind shield wipers. And all the small pieces to get the car drive able.

With all this done, I went out and borrowed a pair of "testing"-license plates, and out on the road I went!
The virgin-ride was kind of unpleasant (because of the fault's I found). But I discovered what needed to be done before she is really ready for the road.
Here is a list:

- A little cooling-fluid leakage ( Fixed - some of the clamps just needed a bit of tightening)
- Light adjusting - people flashed at me (sorted)
- A little fuel leakage (sorted)

This was a list of the small problems, which is pretty expected with a completely rebuilt car.

But I also discovered that the rear-differential made a very loud screaming sound. And driving with low speed, it's kind of a growling sound I bought the rear-axle from a Danish importer a long time ago, without a receipt (of course) it looked very nice and new. But now I see it's old and beat.... So tomorrow I have to take it apart and see what kind of defects it has.

We also got around testing the CO of the car. And it's way too high... So I have to change the injectors, and the ECU before it can go through MOT. That is not that big of a problem, and I kinda knew it could be a problem when I put it all together, but I took the chance. So It's back into the garage with the old girl again.

hmmm - what an update! If you read through all of this, you sure deserve to see some pictures of the lot :wink: