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Ali's Ground Up Ke25 Rebuild


aalaws

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What for the rotisserie? It was done by me it and not expensive.

 

yeah - I have NIL welding skills and equipment :)

I thought about learning etc.....but there's only a few bits on my car that will need it and i'd rather have it done professionally - plus I don't really intend on building anymore cars after this one.

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  • 2 weeks later...

Ok, so my mate was supposed to turn up, again, this weekend to help me remove the engine etc but couldn't make it.

On a positive note, I met a guy selling his AE86 rally car and bought some reconditioned AE86 struts with hubs and callipers from him (SCORE!! - very rare here)

AND I had a package arrive from Japan with a few other goodies - to go along with my bonnet stand I got from Trade Me.

I've lost out on quite a few auctions lately so it's nice to win a few :)

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  • 4 weeks later...

Finally some more progress to report....little by little (very little at the mo, so busy with work etc)

 

Got the engine/box and shaft out.

My mate could't fit his crane in his van so we lifted it out by hand - luckily he's a massive Samoan - SHOT TJ!! :thumbsup:

 

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Apparently theres a few options available for the front tension rod?? Is the bent one I have above the one I need for an A series block to be mounted??

 

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Also scored a KE20 crossmember with 4AGE mounts already welded on! SCORE! :thumbsup:

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ALSO!!

 

Currently in transit from Japan (Sorry to any Rollaclub members who may have been bidding on these)

 

SUPER RARE under grill and bonnet trim!! :party: and a Clock for my (still to be located) centre console!!

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Edited by aalaws
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  • 3 weeks later...

Collected my AE86 struts today, unfortunately one hub/rotor/caliper is missing, but can't complain as they were gifted to me!!

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It gets better too.......the guy just sold his AE86 rally car that day,

and also has a spare 4AGE Silvertop & T50 which I can have for free!! :wootjump:

 

Plan is now to rebuild this engine and run it in the car while I save for/build a 7AGE

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  • 1 month later...

So I figured I'd have a go at plastic repairs over the holidays.

My centre console was completely cracked in two so I had nothing to lose with having a go.

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I bevelled the edges, primed it and used a special glue to hold the back together, with the plan to then fill in the surface........but that didn't work, and the bonding failed......so I just used a soldering iron and some spare bits of plastic from other parts and 'welded' it together with that

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Sanded it back and it look's really good.......will just fine fill it and paint it at a later date

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My TE27 centre console had the top tabs missing so I took a few of some other standard consoles I had, tacked them on with loctite, and then welded them up. All ready to go.

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Same with the under dash console light. Cut a new bit to shape, welded it in and it's all sanded back and ready for paint one day,

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Had a steering column that was totally stuffed - lots of cracks, inner bolt housings falling off, and it was missing an entire section around the ignition barrel that I had to 'fabricate' from scratch. Once I finish it off, if it doesn't suit I can always find another but it's looking pretty good so far.

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hey, nice project, just a few tips with your paint and body.

i have found that an orbital sander hooked up with a cheap karcher (branded) garage vac works a treat for paint removal, get some 36g discs to remove most of the paint and then 80g for the rest and then go over the whole lot with some 120g discs, the vac will keep dust down to a minimum, then use a 2part epoxy primer to seal it up, etch is a thing of the past and only creates a bond to the metal, it is still very porus and moisture can seep thru to the metal, epoxy actually seals it up so no moisture can get thru, you then do all your bog work on top (after sanding it a little 1st!!)

check out my ke20 build, i have given a little more indepth description in there.

keep up the great work mate, can't wait for more pics!!

krem

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Hey Krem, I checked out your build - very nice work mate, very nice.

I get what you mean about learning to do it yourself and how satisfying it can be.......my project's going to be a mix of that and getting some GOOD pro's involved.

I work as an auto glazier so i'm in panel shops all the time, picking their brains and researching the best methods.I'll definitely be getting the shell etc primed in epoxy so even if it sits for a while it'll still be good

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I used to be a windscreen installer and tinter for tintacar around 15yrs ago, lol, still doing cashies in my spare time, great money spinner!!

epoxy is the go, make sure you get an easy to sand 1 tho, I used an industrial epoxy and it set hard as nails!!

krem

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yeah it's a good job for extra cash if you can get them. At the mo i'm looking into having the shell totally blasted and epoxied by a local guy who know's his stuff.......once i save up I'll have to check the grade of the epoxy - cheers

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  • 2 months later...

Still saving for the Shell to be blasted.......

in the meantime JDM AE86 front hubs, callipers and backing plates in transit.

Centre console in great condition with original radio plate still in place has arrived...

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And a small side project.....

 

SR badges are super rare - so I decided to try and make my own.

SR fender, grille and boot badge all 3D printed (nylon powder), I will make a few tweaks before the next print, and then they will be smoothed, plastic chromed and coloured...should be awesome. I can make SL spec if needed too.....

 

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Edited by aalaws
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How strong are those badges. Interested in making ke35 sr badges? Id think youd be able to sell a few. Grille badges that is

I'm reinforcing them a bit with the next batch and should be pretty sturdy with the chrome also.

if I got a good look at a ke35 badge in the flesh I'm pretty confident i could replicate it pretty accurately - they look pretty simple

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