Project from Denmark
09-27-2012, 11:49 PM (This post was last modified: 07-05-2017 10:14 PM by Vaptor.)
Post: #1
Project from Denmark
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. Huh

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. Smile

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 Crying

[Image: AEU86 AE86 - Project from Denmark][/url]

[Image: AEU86 AE86 - Project from Denmark][/url]

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.

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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) Banging head

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

More rust Thumbs up!

[Image: AEU86 AE86 - Project from Denmark]

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. Confused

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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)

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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.

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

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:

[Image: AEU86 AE86 - Project from Denmark]

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)

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

Started to close to rusted area.

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

Restoring my AE86, all the way... Going JDM style Big Grin
http://www.aeu86.org/viewtopic/ae86/p/150463#150463
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09-28-2012, 05:27 AM
Post: #2
Project from Denmark
You love dealing with rust, eh? That toyota don't look to rusty but good work. Cool
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09-28-2012, 06:52 AM
Post: #3
Project from Denmark
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.
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09-28-2012, 08:30 AM
Post: #4
Project from Denmark
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 Smile

Restoring my AE86, all the way... Going JDM style Big Grin
http://www.aeu86.org/viewtopic/ae86/p/150463#150463
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09-28-2012, 08:55 AM
Post: #5
Project from Denmark
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?

FABRICA MI DIEM, PVNC!
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09-28-2012, 09:25 AM
Post: #6
Project from Denmark
The rear panel has some sheet metal work, that has to be made again. Besides that, the rear of the car looks okay Smile
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... Confused
When I am finished it will line up perfectly to the rear fender Smile

Restoring my AE86, all the way... Going JDM style Big Grin
http://www.aeu86.org/viewtopic/ae86/p/150463#150463
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09-28-2012, 02:40 PM (This post was last modified: 07-06-2017 11:03 PM by Vaptor.)
Post: #7
Project from Denmark
Another update of what I have been making on the car this year Smile

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 Cool

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

Oh. More rust Confused

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

A lot of room for working on the Levin Cool

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

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 Smile

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

Been organizing my workshop a little.

[Image: AEU86 AE86 - Project from Denmark]

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...

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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:


[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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. Undecided

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

Continuing with the door frame.

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

Fixed the door frame

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

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

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

[Image: AEU86 AE86 - Project from Denmark]

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

Restoring my AE86, all the way... Going JDM style Big Grin
http://www.aeu86.org/viewtopic/ae86/p/150463#150463
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09-28-2012, 03:59 PM
Post: #8
Project from Denmark
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 Smile

mine i order new from ebay germany full kit cost shipped something like 400max euros mayby some less
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09-29-2012, 09:04 PM
Post: #9
Project from Denmark
Nice work saving you AE Thumbs up!

Sarcasme is just one of the things I offer Wink

Daily driver: '92 Toyota Carina E GTI
Rebuilt project: '86 Levin hatch
[Image: AEU86 AE86 - Project from Denmark]
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09-30-2012, 04:19 AM
Post: #10
Project from Denmark
Yes that 1/4 panel was way to cheap!!!!!!!!!!
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