Simon's New Zealand AE86 Trueno
02-24-2010, 09:13 AM
Post: #1
Simon's New Zealand AE86 Trueno
Well, after having bought and sold a couple of AE's before I though it was now time to build one that I would keep...

I started of with a good example, purchased 1500km and a ferry ride away, a good chance to see what it was like before pulling it apart..

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

It is a 1985, facelift and was supercharged before it was imported into NZ

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

As I am intending on building it into a street driven club car (for hillclimbs, trackdays etc) the sunroof had to go to to give me enough head room with the rollcage and a helmet on, so with a lot of help from a friend we started building a mould of the factory roof.

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

Welding (poorly) the sunroof skin to the roof

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

Bog anyone...

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

Then some fancy primer that I spent hours and hours polishing...

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

The mould starting to take shape

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

http://www.super86.co.nz
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02-24-2010, 10:20 AM
Post: #2
Simon's New Zealand AE86 Trueno
Once the mould was complete, we added some boards to the bottom to make it easier to work with once it as off the car...the completed mould now just needs to be trimmed and then polished to ensure a good finish. The film you can see is PVA release agent, this washes off with water.

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

The spotwelds on the roof were then drilled out using a small holesaw like tool that I bought for the job

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

Stripping down the rest of the car and removing the engine - fairly sure I'll be ditching the supercharger in favour of a turbo setup, however the supercharger did perform really well even in 5th gear, they just don't seem to like the revs.

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]

http://www.super86.co.nz
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02-24-2010, 03:31 PM
Post: #3
Simon's New Zealand AE86 Trueno
Wow! nice project! That roof look nicely done!

1985 AE86 (ハチロク) Levin - Summer time daily driver
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02-24-2010, 03:44 PM
Post: #4
Simon's New Zealand AE86 Trueno
cool! the mould looks nice
we did the same yesterday except we had a non-sunroof car to start with.
Thumbs up!
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02-24-2010, 04:48 PM
Post: #5
Simon's New Zealand AE86 Trueno
Thats a fine looking gel coat, and nice work on the frp Thumbs up!

[Image: AEU86 AE86 - Simon's New Zealand AE86 Trueno]
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02-26-2010, 01:55 AM
Post: #6
Simon's New Zealand AE86 Trueno
Quote:Thats a fine looking gel coat, and nice work on the frp Thumbsup
Quote:cool! the mould looks nice
we did the same yesterday except we had a non-sunroof car to start with.
Thumbsup
Quote:Wow! nice project! That roof look nicely done!

Thanks guys, Lajoosh, you will know how much sanding is involved!!

http://www.super86.co.nz
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02-27-2010, 12:17 AM
Post: #7
Simon's New Zealand AE86 Trueno
Super86 Wrote:
Quote:Thats a fine looking gel coat, and nice work on the frp Thumbsup
Quote:cool! the mould looks nice
we did the same yesterday except we had a non-sunroof car to start with.
Thumbsup
Quote:Wow! nice project! That roof look nicely done!

Thanks guys, Lajoosh, you will know how much sanding is involved!!

we didnt have the opportunity to make the original surface as shiney as you did, so we have to polish the mould itself Big Grin
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02-27-2010, 12:30 AM
Post: #8
Simon's New Zealand AE86 Trueno
Wow, that roof was so nicely filled! I'd love to see what it turns out like when its done Smile.
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02-28-2010, 02:41 AM
Post: #9
Simon's New Zealand AE86 Trueno
To bad they messed it up. Nothing wrong with an OEM sunroof Smile

nice work though Thumbs up!

Cars:
"99 Lexus IS200
"86 AE86 Kouki Panda Levin GT-Apex (restore project)
"84 AE86 Zenki Blue Levin (project racer)
Motorcycles:
"02 Yamaha R1
"02 Honda Hornet S
"08 BMW R1200GS
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02-28-2010, 10:22 PM
Post: #10
Simon's New Zealand AE86 Trueno
Cant wait to see what you do with this car, looked at it many times on trademe. Good luck with your build.
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