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Ali's Ground Up Ke25 Rebuild

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Got to love what filler can hide. I reckon just paint. I've had some really disappointing results with powder coating. From waiting forever, parts temporarily (thank god) going missing, poor finish due to poor prep etc etc

 

I'm going with Dulux Metalshield epoxy enamel in a satin black. That way I know it's done right as I have full control over the whole process.

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Got to love what filler can hide. I reckon just paint. I've had some really disappointing results with powder coating. From waiting forever, parts temporarily (thank god) going missing, poor finish due to poor prep etc etc

 

I'm going with Dulux Metalshield epoxy enamel in a satin black. That way I know it's done right as I have full control over the whole process.

 

I knew there was a possibility of finding some there......considering I completely recreated the front of the fenders on my first car with bog when I was 15 - a touch of karma.

Cheers for the tip regarding paint, I had the impression it was a 50/50 thing just wasn't sure if powder coating had any benefits over paint.

I need to decide which parts I get sandblasted and epoxied along with the shell so needed to decide on the finish.

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one shipment of goodies arrived.....few more parts to get and i'll get the front suspension all assembled and ready for later.

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(just found my camera again so better photo's from now on too)

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Finally put an engine stand to proper use smile.png

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This is my first time ever pulling an engine apart and it's going pretty well so far. Filthy as but looks in pretty good nick for 250plus kms

Turns out I went to college with the guy that owns the local engine rebuild shop so I'll be sending the block etc off to them to get it cleaned up and sorted for the rebuild.

 

 

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Started prepping the ae86 diff for trimming off the mounts. The drain plug is STUCK, oh well we'll sort that later.....I was told I could keep the pan hard bar mounts for on the ke25......

a) be gentle........... cool.png which one are the pan hard mounts? cool.png I assume I'll need to fab a mount on the chassis?

 

Also had a few more goodies turn up in the mail.....

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Te27 booster arrived!

Whats the story abut cleaning/fixing these up? will the guts go flying everywhere if I open up the booster to clean it up?

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The booster internals look moderately complex. I've got a NOS rebuild kit for mine and there are quite a few bits in it.

 

I've also got a 1974 brake manual that shows a rebuild procedure. I can send you that if you like.

 

Panhard mount is the one on the left halfway between the damper mount and the trailing arm bracket.

 

And yes, you mount a tower of sorts on the other side of the car. It comes down from the floor. There is some geometry involved in ensuring you have it in the right place, so you might want to spend a bit of time researching that. I vaguely recall that you could buy panhard chassis mounts for some other modified Toyota. I think it was a longer one for an AE86

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Hi there i think mine is like yours exactly. I had opened mine and its not that complicated. Here are some photos of inside it.

 

 

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The booster internals look moderately complex. I've got a NOS rebuild kit for mine and there are quite a few bits in it.

 

I've also got a 1974 brake manual that shows a rebuild procedure. I can send you that if you like.

 

Panhard mount is the one on the left halfway between the damper mount and the trailing arm bracket.

 

And yes, you mount a tower of sorts on the other side of the car. It comes down from the floor. There is some geometry involved in ensuring you have it in the right place, so you might want to spend a bit of time researching that. I vaguely recall that you could buy panhard chassis mounts for some other modified Toyota. I think it was a longer one for an AE86

 

That's a good NOS score! - what do you reckon about NovaLuke's booster in the pics above? same one?

I'd love a copy of the manual mate! don't suppose it includes re-assembling a te27 pedal box also??

Mines off to get sandblasted and painted so I can reassemble it.

I'll do some more digging about the pan hard, shouldn't be a major by the looks of it then.

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Hi there i think mine is like yours exactly. I had opened mine and its not that complicated. Here are some photos of inside it.

 

Good stuff! Those are some gnarly looking hard working hands :)

 

Looks like a LHD booster with that heat shield? did you need to replace much inside? some rubber seals?

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Lol those are my neighbors hands!! I just opened it so i can remove the rust pitting from the out side and spray it and fit it. Inside as you can see was all good. Yes this was a lhd came out from a te27 in U.S.A and fitted it on the car which came out pretty good. Normally the master cylinder piston washers or the bore will be the normal issue of them.

 

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PROGRESS!!!!!!!

Picked up the shell etc from getting blasted and primed.

Waikato sandblasting did a good job of removing all the rust, paint etc from the underside and engine bay, and everywhere i couldn't........and with no panel warpage.

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No extra rust uncovered! just a few spots where it's true extent was revealed

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Also just a little bit of motivation (courtesy of some dude in the pillipines - SIC)

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ALSO: Engine is all good, just need 0.5 OS pistons and new rod bolts.

Diff is all stripped and ready for leaf spring perches to be welded on.

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Long time no post.......2 business's and 2 small kids and buying the house will do that to your time and $$.....but.......

KABLAM!!!!!!

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I've spent a bit of time working on my other Toyota project....to fund my other Toyota project.....
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I am waiting for space to clear up at the Panel shop to get the body work underway. In the mean time I've managed to track down a few panel cuts and some NOS to boot!
There's been a few false leads of random shells around from as far as Horopito to the Phillipines.......Horopito turned out to be a ke35 and the Phillipines never eventuated.
I am still excitedly waiting to hear on another potential shell. I was picking up some camera's for a video job and the guy had a 1200 coupe in the garage......as I usually do now, I asked him if he had a spare ke25 shell and turns out he does.......it is yet to materialise but I will keep chasing this up!

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Just need a drivers side now! Also have a complete rear panel (Taillight surrounds/lower valance etc) currently in the next ML Racing container form Japan.

NOS indicator lenses - Much shiny goodness!

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11 hours ago, Johnny Mac said:

Love the seats! Did you have those door trims made or are they an off the shelf product?

Cheers, John.

There's a guy over here that makes te27 replica seat skins and door cards.......he does a few other models and celicas too. He does amazing work but is pretty much booked out months in advance......the legend is growing!

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Some stuff has actually been happening.......

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Te27 Pedal box all painted and re assembled

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Got some wheels - 14x6 SSR Mesh. I need it on wheels for the panelbeater so these are good placeholders until they get a refurb or something else could pop up.
The lips are a bit scuffed and one is a bit bent, but they'll be getting widened once the car is done if I use them.

Jig made!
It's a bit rudimentary and the welds are hideous but the Leaf Spring perches in pretty much the exact right space - tape measure measurements agree with the chassis repair manual. Just need to make a little bracket to keep the face at exactly 90 degrees, but after that everything is you see is ready for some professional cutting and welding.

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Also had a big stash of bits arrive ready for all the reassembly.  All genuine Toyota except for the eBay bushes....didnt really want to go down the nolathane/urethane etc path.
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Included with all the bearings and shims etc were 2 little ae86 pedal cushions.....I took a gamble to see if they would fit my te27 pedal box....ah yesssss. OCD satisfied.IMG_3970.JPG.5e5184ec6f559505bb1afe81b10d34e2.JPG

Before....

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After.......perfik 

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