Project from Denmark

[Vaptor]

Making this work-log to share my restoration of a AE86, that have been in my possession since 98... Its a Kouki model from 1986, previous owner has fitted a wrong front to it, never noticed it, before I started to research for my restoration of it.

My plan was to make a complete restoration of the car, and give it a lite JDM style look, I will paint the car in the blue metallic the new GT86 comes in. I think that will be a cool choice, and the engine bay will be white metallic. Under the car plain white, with white rubber skin to protect it. It will only be a summer car, so it will never see snow or salt again.

A lot of rust have accumulated on my AE86, so that is going to take some time get rid of it...

This is how it looked in April of 2011, made rear fenders in 2008, but had to stop due to the financial crisis... Crap

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Made the first rust work in a driveway, not the best site when it rains most of the summer...

The engine room, doesn't look that good, all the parts are rusted and just look bad. The engine has a bad 4th cylinder, so that will have to be renovated to.







The interior is in pretty good shape, only the sun visors have been damaged during the past few years, where it just have stood in a driveway. Oh. and some idiot has put in a sun roof, that now leaks, (FINDING A NEW ROOF ISN'T EASY)





More rust



The panels are rusted all the way trough, and even some of the main support beneath the car. there's a lot of work there.



Starting to make the rust go away
I am cutting sections of 600mm out, and bending a new panel to be welded in.





The floor and main support has rusted a lot, made the main support perfectly, but the floor don't look that good, so I will redo it later this year (2012)







Made a lot of rust, and gave it some primer to protect it, all the area that has got the grey primer, has been build up with new sheet metal.









A bit more rust on the drivers side... Its just so much fun



The passengers side, don't look that much better then the drivers side did, a lot of rust... Again I will redo the floor later this year. :wink:



A pretty big hole, took me a lot of time to close it again. (Have supported the hole car beneath, so that it didn't get out of line)





Started to close to rusted area.





And last some primer to close it up for the winter.

[kennedy8383]

You love dealing with rust, eh? That toyota don't look to rusty but good work.

[corolla4agze]

I did have also leaking old sunroof. here the roof so expensive i did put NEW webasto sunroof what slide to top of hood. So it works and dount leak soon and parts still available.

[Vaptor]

Hate rust, and bad sheet metal work... :wink:
I have opend the car some more, and found more rust. And the previus owner, have made some rust that looks awfull... So will redo his work to.

Its not easy to find a new sunroof in Denmark, they are very exspnsive, at leat 800 Euro's, and would rather have a Genuine sun roof, then a fake one. Have found a a complete sheel to salvege the roof without a sunroof and other parts from

[Ivan141]

That looks even worse than mine, good luck, and pay close attention to
the rear of the car, they rust 2 times as fast from the passenger seat to the back.

Your repairs look very good so far, especially since you are doing them with the car on all fours.

That rear fender doesn't look right to me, there's supposed to be a cleaner flat edge to it. Has it been replaced, or is there just a lot of filler applied?

[Vaptor]

The rear panel has some sheet metal work, that has to be made again. Besides that, the rear of the car looks okay
Have more pictures that will come up later today, showing even more rust work.
It will be mounted in a rack later this year, when I start to clean the bottom of the car, and make the last rust in the underbelly.

The rear bumper don't line up, because its mounted with Zenki brackets, another thing the former owner has made...
When I am finished it will line up perfectly to the rear fender

[Vaptor]

Another update of what I have been making on the car this year

Started in April this year, by removing the interior. Love my Black sports interior, needs some new parts to become almost like new, so I have been placing several bids I japan to get a complete Interior almost like new





Oh. More rust



Finally got a place to work on my car, without having to worrying about the weather



A lot of room for working on the Levin





Got my hands on some body parts, like a brand new Right rear fender for only 470 Euro's (Know a guy that has a Left Rear fender, but he wants at least 1000 Euro's for it



Also got two doors imported from japan, no rust and they look like new inside. Two front fenders, a bonnet, the rear panel, and a rear door, also no rust





Been organizing my workshop a little.



Started to pull out the dashboard, wiring and the sound-material in the car. Used a hammer and chisel to remove the sound-material, took a lot of time...













After removing the sound-material, I only found two holes, both in the left rear inner fender, and some surface rust, not that bad :wink:














Even in the trunk room, there were only some minor rust





Next step is to go over the doorframe, don't look there would be anything to find, but the more removed the paint, the more rust and bad sheet metal work came to sight.







Think that the end result looks pretty good, it also takes a bit more time, to do it the right way. :wink:





Continuing with the door frame.



Decided to sandblast the car in steps, to find all the rust, and bad sheet metal work there were on it.



Fixed the door frame



Found some bad sheet metal work, that needed to be fixed.





Drivers side done, just need some primer so that i wont rust again.



The same done to the passenger side, only one place with rust.







More updates will come in a couple of days, so sty tuned for more.

[corolla4agze]

Vaptor Wrote:Its not easy to find a new sunroof in Denmark, they are very exspnsive, at leat 800 Euro's, and would rather have a Genuine sun roof, then a fake one. Have found a a complete sheel to salvege the roof without a sunroof and other parts from

mine i order new from ebay germany full kit cost shipped something like 400max euros mayby some less

[Jan Pedersen]

Nice work saving you AE

[nægterdu]

Yes that 1/4 panel was way to cheap!!!!!!!!!!