Banpei's two door panda Trueno from Japan

[decryphe]

(04-15-2025 03:41 PM)banpei Wrote:  As I suspected, they are fused to the shelf.

That's weird, mine were screwed to the shelf.

(04-15-2025 03:41 PM)banpei Wrote:  I'll make a new parcel shelf using mine as a template and then mount everything on the new shelf.

I was trying to find a synthetic material that would be suitable, but couldn't, ended up with birch plywood.

We'll be at Reisbrennen this year, if you want to have a look at the lamps. Otherwise I can also take one apart and document it (which I should anyways, one works very intermittently).

[banpei]

This is what I mentioned earlier, my top covers are fastened by some melted plastic:

I remember having the same attachment in my first AE86.
The only way to remove them is by drilling out the molten parts. After this, you end up with some small stands which you can use screws on to fasten them again.

I also checked the part number (64355-12010) and it's non-existent in the Toyota parts catalogue, so I wasn't crazy after all...

Now this is my progress with the copies:


The first version wasn't a huge success, and I quickly mocked up a second one. This one also has some minor flaws, but it's nearly there!
I already have the final design done, including a curve on the angled side and stands with an M3 thread, but that's still waiting in the queue of the printer. Once it starts printing, it will be a printing marathon of 6 hours. I couldn't print it earlier as I wanted to print it in PTEG, and the filament only arrived this afternoon.

I also picked up the dark-blue interior paint I had made for these parts this afternoon.
Once I have the finished prints and painted them, I'll share photos of what they look like.

[banpei]

The progress for today:
- printed Trueno badge with PTEG filament
- printed left and right parcel shelf covers
- Sanded all of them down, and they are all painted in primer

At the bottom we have the Trueno badge printed in PTEG:

The overall quality of the print is much lower than with PLA filament. You can clearly see printing defects on various edges and ridges are much more present. Apparently,, PTEG doesn't flow that smoothly, and this meant I had to do a lot more sanding than I initially thought.

I then realised I never test-fitted the final design. I needed to fetch paint and primer from the garage anyway, so here's the sanded-down badge fitted on the bumper:

A perfect fit!

For the parcel shelf covers, the final PTEG print is on the left side:

I decided to print them in white as the white filament was still in the printer and I didn't fancy switching it back. It took 6.5 hours per side to print!

On the underside, you can see the feet are in the correct position now:

I found out PTEG is much more brittle than PLA; one of the feet broke off when I removed the supports. If I ever print them another time, I'll create them with a larger diameter.
You can also spot an Easter egg on the underside!

A tiny AEU86 logo!


Next up is to cut out a new parcel shelf from soft board and glue on the fabric. I have some leftover soft board sheets I used for stabilising the floor of my house. The upside is that they already feature sound-deadening to their underside, so that saves me a bit of work. I also need to paint all the parts in their final colours. Hopefully, the paint will have dried by tomorrow, and I can mount the new parcel shelf back into the car!

[Ivan141]

I would make the screw posts a bit fatter and size them for melt-in thread inserts, and maybe try some more upright orientations to try to minimize the layer line issues.
Nice work though, useful to have more AE86 part 3D models floating around..

[banpei]

As I had already invested 13 hours in printing, I didn't fancy printing them another time. The screws that I used split two out of four posts, so what I ended up doing is drilling a small hole in the material to allow longer screws to secure them. For the next version, having melt-in posts would be a much better idea. If I redo them someday, I'll definitely do that.

Last night I cut the new parcel shelf and glued the blue fabric on. I also painted the parcel shelf covers and mounted them on the shelf:

The fabric was glued on the old parcel shelf, but the old softboard was already suffering from delamination. So I managed to peel off the fabric with the top layer of the softboard. This made it much easier to glue it on.

This afternoon I went to the garage, mounted the speakers and fitted the new parcel shelf to the car:

It's a perfect fit!
I only attached it with three of the plastic fasteners as I need to replace those with new ones. I've kept one to compare with what the local parts store has in stock.
While I had all the covers off, I replaced the sound deadening that was removed when the rear arches were welded. Hopefully, this results in less road noise.

This is what it looked like before and after I was done:




Then you might have spotted the door cups in the first photo. Up until now, I didn't have the time to mount them. While I was already busy removing all panels in the rear, I also removed the door cards and replaced the door cups:

I really need to find a way to match the door cards with this original colour. I have already cleaned them thoroughly in the past and I'm afraid painting them like I did with some of the plastic panels will not make them look nice.

My car didn't come with a retainer for the spare wheel. I mocked up something in Freecad with a stepped-down holder using the dimensions of the Black Racing wheels and the OEM Toyota wheels.

I can improve it by also adding the Almex Y3B dimensions and changing the hole to a six-sided M8-sized hole. At least the current one is functional, and I no longer have to suffer from clunking noises on every speed bump.

Some time ago, I complained about one of the side markers being hazy and discoloured. I found a really cheap one with a small defect on Yahoo Auctions:


So I tried to fix it by plastic welding it:



And then I filed it down to make it smooth again:

I left the weld on the rear of the side marker, as that's where I thought it would need reinforcement.

This is before the first (guide)coat of paint:

Then I found that there were still some visible marks, filled them up and sanded them down. I had a couple of rinses and repeats to make it smooth. I forgot to take photos of the final result, but it looked decent enough. Under a certain angle, the repair was still visible. So I also fitted this side marker to the car this afternoon. Unfortunately, the weld on the rear was pushing against the front fender too much. This then made the crack visible again, but with the cracked paint all my work was in vain...
I'll now move to plan B: put the side marker in the oven to make the glue melt, and then transplant the orange part to the original side marker.

I also finished the Trueno bumper badge and fitted it to the car. Even though I test-fitted it yesterday, I didn't realise the PTEG version was lacking one important aspect: it didn't clamp well enough on the bumper shrouds!
The badge is clamping itself on both ends of the badge as seen in this picture:

The retaining bolt on the rear isn't holding it in. It's there purely to prevent theft or falling off when it's too loose.
The badges printed in PLA clamped fine, so my guess is that it's caused by me sanding down the printed badge to remove print defects.


I did fit it to the car, and it looks like this:

I'm happy with the way it looks, but unfortunately, I have to print it all over again.

As you may have noticed already, I have swapped the Almex wheels for the Black Racing ones:

The reason is that I want to repaint parts of the centre of the Almex wheels and also give the other bits a quick polish.

[r.ave]

nice job, looks good

[Power_uP]

The new front badge looks perfect. It's nice to see that you're keeping the car now.
Please tell me what type of wheel is being used as a spare, it's not a design I'm familiar with.

[banpei]

Thanks! Yes, it's a keeper now.

The wheels are the ones that have been on the car for the past 6 or 7 years:

They are a set of 14-inch Almex Y3B wheels (6-inch wide, +11 offset) that I found in a local classifieds ad. The person selling it even lived in my hometown, and the wheels were filler for a container he shipped from Japan with Nintendo and Sega retro stuff!
Almex is a subbrand of Advan/Yokohama and was initially meant as the entry brand with single cast wheels, but the Y3B is an exception to this. Kyushashoes even suspect it actually was meant to be an Advan wheel. It's a 3-piece wheel from the early 1980s and, if I remember correctly, mine was produced in 1982.

As you can see in this picture, paint is peeling off, and some of the unpainted surfaces have started to get dull:

They need a bit of TLC, hence I switched them with the Black Racing wheels. I'm still doubting whether I should rebarrel and relip them. It's easier to replace both the lip and barrel as the seams are welded, but that will increase the cost.
To complicate things even more, I'm also receiving a pair of Hoshino Impul Pro Mesh wheels. I love the look of those wheels. They are 6.5-inch +11, which is perfect for the front and then I could also source a pair of 7-inch +4 from Japan. Lower cost and much easier.

[The Doctor]

Nice work on the upgrades/fixes!

If you want to refurb the Almex wheels, i've got this.
I still need to finish a few of my wheels, but i'm sure we can work something out when needed

[banpei]

Thanks! That would certainly help and speed up things.
However, if it's only polishing I'll do I'll probably use the same method as last time: I attached a rotational buffing tool to my cordless drill. It didn't give me a mirror finish, but it worked well enough to revive the shine.
This was the result of my efforts seven years ago:

Unpolished (left) versus polished (right)