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Super86
Joined: 19 Aug 2009
Posts: 9
Location: New Zealand
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 Posted: Wed Feb 24, 2010 9:13 am Post subject: Simon's New Zealand AE86 Trueno |
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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..
It is a 1985, facelift and was supercharged before it was imported into NZ
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.
Welding (poorly) the sunroof skin to the roof
Bog anyone...
Then some fancy primer that I spent hours and hours polishing...
The mould starting to take shape
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Super86
Joined: 19 Aug 2009
Posts: 9
Location: New Zealand
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| Posted: Wed Feb 24, 2010 10:20 am Post subject: |
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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.
The spotwelds on the roof were then drilled out using a small holesaw like tool that I bought for the job
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.
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oldskull
Bunta
Joined: 02 Nov 2005
Posts: 1871
Location: Blaricum, The Netherlands
1985 Toyota Corolla AE86 (early Levin)
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| Posted: Wed Feb 24, 2010 3:31 pm Post subject: |
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Wow! nice project! That roof look nicely done!
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- 1985 AE86 (ハチロク) Levin 3 doors hatchback - Summer time daily driver
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Lajoosh
Ryousuke
Joined: 21 Mar 2006
Posts: 194
Location: Debrecen - Hungary
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| Posted: Wed Feb 24, 2010 3:44 pm Post subject: |
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cool! the mould looks nice
we did the same yesterday except we had a non-sunroof car to start with.
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JonnyAE86
Bunta
Joined: 13 Apr 2007
Posts: 773
Location: Yokohama - Portugal
1984 Toyota Corolla AE86 (early Levin)
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| Posted: Wed Feb 24, 2010 4:48 pm Post subject: |
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Thats a fine looking gel coat, and nice work on the frp
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Super86
Joined: 19 Aug 2009
Posts: 9
Location: New Zealand
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| Posted: Fri Feb 26, 2010 1:55 am Post subject: |
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| 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
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| Quote: | | Wow! nice project! That roof look nicely done! |
Thanks guys, Lajoosh, you will know how much sanding is involved!!
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Lajoosh
Ryousuke
Joined: 21 Mar 2006
Posts: 194
Location: Debrecen - Hungary
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| Posted: Sat Feb 27, 2010 12:17 am Post subject: |
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| 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
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| 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 
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Kryptize
Itsuki
Joined: 24 Feb 2010
Posts: 18
Location: London, UK
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| Posted: Sat Feb 27, 2010 12:30 am Post subject: |
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Wow, that roof was so nicely filled! I'd love to see what it turns out like when its done  .
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robokill
Bunta
Joined: 07 Sep 2004
Posts: 2604
Location: Amsterdam // The Netherlands
1986 Toyota Corolla AE86 (late EU)
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| Posted: Sun Feb 28, 2010 2:41 am Post subject: |
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To bad they messed it up. Nothing wrong with an OEM sunroof
nice work though
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"08 Honda Civic Hybrid
"86 AE86 Kouki Panda Levin GT-Apex (restore project)
"84 AE86 Zenki Blue Levin (project racer) http://www.cardomain.com/ride/613398
AE86 Drive it, Skid it, Drift it.
KIS it
Keep It Sideways
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NZDMAE86
Joined: 27 Jan 2010
Posts: 8
Location: Whakatane New Zealand
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| Posted: Sun Feb 28, 2010 10:22 pm Post subject: |
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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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Super86
Joined: 19 Aug 2009
Posts: 9
Location: New Zealand
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| Posted: Mon Mar 01, 2010 8:25 am Post subject: |
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Thanks for the words of encouragement - its seems that when you a have a car in thousands of pieces it takes much more motivation to work on things than if the car is mostly complete!
After pulling the rest of the car apart I discovered some minor rust spots, and even though the car was in really good condition as far as AE86's go it needed some panel work, so I set about building a rotisserie for it so I could rotate it upside down.
As the car will have a roll-cage and won't have rear seats, the mounting points for these were removed, this both saved a very small amount of weight and makes it look a lot tidier...
Once it was on the rotisserie, a couple of old repairs were found and the decision was made that all the paint needed to come off so that the shell could be fully inspected. I found a local company in Auckland (New Zealand) that specialised in high pressure water blasting and could remove paint without the damage to panels that soda blasting gives. They also put an inhibitor in the water to prevent surface rusting prior to etch priming.
This is the shell during and after, and yep that's bare steel...
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BOOMEX
Takumi
Joined: 31 Mar 2005
Posts: 313
Location: Paris
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| Posted: Tue Mar 02, 2010 3:25 am Post subject: |
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Great Job 
I wich one day i could do what you've make
Respect
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BURN THE RUBER NOT YOUR SOUL!
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