Jump to content

Hi, from Uruguay this is my TE27


Trufauru

Recommended Posts

On 2/27/2022 at 10:49 PM, parrot said:

I have to say this is absolutely inspiring as i need to do exactly the same thing on mine.  Fantastic ideas.

You just need to start from some place, and do a thing at a time. As Simone Giertz says, split the job in smaller jobs that you have the confidence to tackle, and build your skillset to tackle new jobs

On 2/28/2022 at 5:35 PM, ke70dave said:

yeah well done on these repairs, fantastic stuff. One day id like to do something similar. Bringing a car back to life essentially - very cool. 

Indedd, by the time the car will be done, I don't think that there is a part of the car that wasn't touched in some way or another.

 

And lets keep up with this, while I was working on the drivers side floor and rocker panel, sometimes you get frustrated with some part, or it gets boring to test fit the same part 10 times, and you want to change what you are doing in order to not burn everything to the ground. So, while the driver side was being made and I got bored I was also working on these parts…

I got the hang on how to make the end of the rocker panel, so I made the passenger side again, and got to weld everything in place. To this day I don’t like how the end cap looks and fit, but it works
49859464011_a669336ed5_c.jpg 

49866980456_be1d9fe3dd_c.jpg 

If you remember, I had removed the front windshield panel, and under that panel it wasn’t all fine. I had to remove the lower lip that when I removed the panel, I just cutted close to the edge as possible, but now I had to fix that
49870974362_ff332c22d6_c.jpg

The worst offenders were the cowl intake vents, so I drill them out and someday I will fix them.
49855322366_a8b38ee9f7_c.jpg 

It leaves a nice hole, and some places to fix.
49859433041_be1d0fd0e3_c.jpg 

While poking some not so good looking metal, I also found a new hole that was right above the drivers feet... yay more work for me.
49862817018_a2f5231936_c.jpg 

Walking around the car, I kept seeing that the spare tire well was very rusted, so I took the grinder and make a brand new hole on the car
49866445113_2a5948ea98_c.jpg 

But fear not! with the dimensions of the spare tire well, I went to a place that sells sheet metal parts for cars and after a lot of talking with the guy at the counter, I got the last spare tire well for a 94-08 Volkswagen Gol (a very popular car over there), but, lucky me, it was the last replacement panel available in the shop hahaha. 
49855296041_fb5a49802f_c.jpg 

And to finish this post, a sneak peek of the next work ahead...
49855299121_9620c630d8_c.jpg 

As with the last post we are on the end of January 2020
 

Link to comment
Share on other sites

  • 1 month later...
Members dont see this ad

Starting february, and starting with a new part of the car, a little grinder love and I got this new hole on the car, on the rear driver side.
49863644222_9258d439b0_c.jpg 

Old metal laid on the bench, for measurement and finding new metal
49871010117_0fec73c54e_c.jpg 

I had some of cuts from the front floors, so I was reusing them
49855407236_f10acc905d_c.jpg 

With the old piece out, you take some time to find a new one and then you just swap them, and go from this…
49858908283_7d7e065af4_c.jpg 

To this…
49863238753_c4b8cf567e_c.jpg 

And before you can realize, you got a whole new floor on the car
49863371971_94f34bcb8f_c.jpg 

Then, since the passenger rear side was in better shape, I didn’t cut the whole floor, and just made some patches, and filled some holes
49863475176_0f5fa71b86_c.jpg 

And given that I had welding gas, I got to finish the steering rack brackets and welded them in place.
49854772538_49e8d81bce_c.jpg 

By this we are February 9th.
 

Link to comment
Share on other sites

Thanks Sebastian,

                                i've been hanging out for the next episode in your Rolla journey for weeks !  (as I suspect others on here have also)

Keep up the good work !   You're an inspiration to all of us, that would not be game to tackle something this epic.

I guess once the floor is finished completely, you will be giving it a good coat of that black "mastic" tar like sealant, above & below; to prevent any further rust taking hold, in your good work ?

Cheers Banjo

 

Edited by Banjo
Link to comment
Share on other sites

On 4/26/2022 at 10:05 AM, Banjo said:

Thanks Sebastian,

i've been hanging out for the next episode in your Rolla journey for weeks !  (as I suspect others on here have also)

Keep up the good work !   You're an inspiration to all of us, that would not be game to tackle something this epic.

I guess once the floor is finished completely, you will be giving it a good coat of that black "mastic" tar like sealant, above & below; to prevent any further rust taking hold, in your good work ?

Cheers Banjo

 

I forgot about the reminder and nobody comented on it, but I'm back. Yes, you'll see some of that sealant, but mostly paint, and lots of paint in order to try to get everywhere, and get in crevices and tiny places

 

Off we go, ever since the Jetsons, we’ve all dreamed about the flying car, so I had to make my own flying car
49870686336_576b64de0d_c.jpg 

Well actually I just removed the rear differential in order to work more comfortably on the rear underside of the car
49855347751_3c2eb8b88a_c.jpg

 

Without it you have so much room for activities, and I got the car as high as I could safely do so
49862799938_58e5123ed5_c.jpg

Once on the air, I got to cut the rear part of the rocker panel, and reveal all its nasty secrets
49870967827_9126d8655e_c.jpg

 

Also got around inside the wheel well, to get a better view of all the rust (after this, I decided to remove the rear axle)
49858897338_261e11407e_c.jpg

 

Some cleanup and let start to cut some spot welds and pry stuff apart
49863679787_b84ee16f79_c.jpg

 

A little better looking after a lot of wire wheel
49855407296_7ed6a5942e_c.jpg

 

And I had to fix a little piece on the side of the passenger floor
49855601077_60737e5fe0_c.jpg%C2%A0

 

If you remember from the last post, I took another piece as a template for the side panel to the same place that had made the rocker panels, and again it was a great job 
49866444873_df6cf21ee0_c.jpg

Remember to bag and tag everything you remove from the car
49855076303_e4596eff01_c.jpg

 

And back on working, as with other parts, you take the old rusted part, and with a bit of patience you make a new one in fresh new metal
49855916592_ca71a9a5b0_c.jpg

 

Now I just need to weld all the seams and done
49863475511_4512431276_c.jpg

 

And then you well the piece in its new place (it is the end of the wheel well) I also made a new reinforcement for that area, but not as nice as the original
49863475456_7133732649_c.jpg

 

Then make and weld the new inner piece.
49855322346_e1ffa11954_c.jpg

 

And a bit of paint on the inside and it’s done
49859425606_de5d3a5567_c.jpg

 

With all the inner pieces done, remember to paint the back of every inside panel with weld through paint, and it is time to weld everything in place,
49859723492_0df532d6ae_c.jpg 

49858961438_6199f92328_c.jpg%C2%A0

Also in between tasks time, I did some other things. Like, remove the paint to see that the roof was fitted with lead, they used to blend the joint between the roof panel and the quarter panel

49863788123_31141a0c79_c.jpg%C2%A0

Also took another shot at the trunk and remove this reinforcement
49862787888_7f80fdffc2_c.jpg%C2%A0

Only to find more rust than I was expecting
49870666626_4dfc323031_c.jpg%C2%A0

And some new parts, as you might know this is the original dash of the non sport TE27
49863886002_5194034d8b_c.jpg 

So I contacted the guys at speedhut.com and have made a new tachometer that fits inside the original hole, and with an orange background, the name of the car “rustyrolla” and the logo of a group of friends
49855347706_962fcbdf3e_c.jpg

By now we are finishing march of 2020
49870968132_2ed34bc15c_c.jpg 
 

Link to comment
Share on other sites

Simply Inspirational to all those that tackle long term projects; & for various reasons; never finish them.

That will certainly not happen to this project, as it's now 24 months later, & you are undoubtedly more advanced than these pictures indicate.

Cheers Banjo 

Link to comment
Share on other sites

You may rest assured I am absolutely loving your feed. Please don’t stop. Impatiently waiting on completion of a pool which has meant no access to the garage for months, so I can get on with mine. Today yet another concrete pour and an apparent delay with delivery of the tiles……..  cars looking very forlorn jammed up next to each other

Link to comment
Share on other sites

On 4/28/2022 at 7:40 PM, Banjo said:

Simply Inspirational to all those that tackle long term projects; & for various reasons; never finish them.

That will certainly not happen to this project, as it's now 24 months later, & you are undoubtedly more advanced than these pictures indicate.

Cheers Banjo 

Indeed it was a long term proyect, but ever since I rented the garage, the work took of and it got a lot of momentum and its getting closer and closer to the finish. Thanks a lot for the kind words, and as you say I have a lot of updates to post :D

On 4/29/2022 at 7:13 AM, parrot said:

You may rest assured I am absolutely loving your feed. Please don’t stop. Impatiently waiting on completion of a pool which has meant no access to the garage for months, so I can get on with mine. Today yet another concrete pour and an apparent delay with delivery of the tiles……..  cars looking very forlorn jammed up next to each other

Well at least after a while you'll have a pool and a garage to have fun with hahaha, so the wait it's worthy

Now I have some short posts, but I tried to split the photos into diferent sections of the car while I was fixing them

And we start with the rear end of the passenger side. First of all let's cut all the rotten metal, and we end up with something like this
49870660171_9fa3c245d7_c.jpg 

And then we have to make all this metal from scratch
49859427896_f801d378db_c.jpg 

Little by little, with a hammer and patience each of the parts for this puzzle come to life
49870974577_062413ee4f_c.jpg 

The process is simple and the same for every part, take some measurements, find a piece of metal with that size, cut, hammer and bend to shape, and fit and refit and test fit until the shape is right.
49863885967_7bf915d102_c.jpg 

When you are happy with the fitment, and also checked with all the other parts in the vicinity, get the metal glue gun, and zapp all the parts together, then a little weld through primer and on to the next piece
49854809953_f980796ab6_c.jpg 

Test and check and weld
49863644107_bf688cffc5_c.jpg 

And with that we have all the corner looking like new
49859464311_0362661e9a_c.jpg 

Onto the next part

  • Like 2
Link to comment
Share on other sites

Then onwards the driver side, the rocker panel was done, but we needed to continue on the rear
49858877238_62eb5bdfb1_c.jpg 

Like before, first cut all the bad metal that we are going to fix
49862871533_e08bb3309d_c.jpg 

And with a ruler, a grinder, and a hammer you can make anything
49862941238_c09b1a308c_c.jpg 

I did the internal reinforcement, I didn’t go all out with the shape, but it's close enough.
49854784133_7bebc0674e_c.jpg 

Making all the little parts behind the corners that nobody will see.
49859875307_5611e01c96_c.jpg 

Also little pieces like this in the floor, while I was in the area
49870666776_a18e331f80_c.jpg 

And then starting with the welding of the panel that I had bent to shape.
49859443201_aea7b10b73_c.jpg 

And again, weld everything, and paint everything to make this panel done (but I still need to bend and trim the end)
49863772056_59b8c66a58_c.jpg 
And we keep going

Link to comment
Share on other sites

  • 1 month later...

And let's keep up with this, and by this, now is time for the trunk that below the bumper reinforcements, it was very bad. So let’s start the grinder
49855648877_52c5d6e2e3_c.jpg

Also the rear panel was rotten and with a lot of holes
49863788553_d88515a55f_c.jpg 

After a lot of thought the best idea was to remove the rear panel to get better access, so I took a deep breath and started to remove all the spot welds, after a while it was something like this
49855606432_cb31ffb66d_c.jpg 

El Corolla Camino any one? You can almost Imagine the dropped tailgate 
49863715187_245f9de416_c.jpg 

And with more access, it was much easier to cut and remove the rusted metal. While I was nearby also started to cut the outside
49858891663_38210d3464_c.jpg 

On both sides it was horrible
49862941313_09b6759ea3_c.jpg 

And the pile of rusted metal to create from scratch was getting bigger and bigger. Also, in the back you can see the reinforcements that were actually in great shape
49859875772_3fa87d7f5c_c.jpg 
 

Link to comment
Share on other sites

  • 8 months later...
7 hours ago, parrot said:

Any updates to inspire us Sebastian?

of course 

 

With all the rusted metal out of the way, I had to start building new parts, first the parts that are below and behind everything.
49870153948_ff14ceb441_c.jpg 

Making new parts it becoming a hobby
49870701226_de115d9dcb_c.jpg 

49866980631_d85e8d2b78_c.jpg 

Then welding them in place, and painting for some protection.
49863371791_49e1538fa3_c.jpg 

Also this panel had a little dent, so I had to fixit before we keep adding new metal
49858896823_862a88234e_c.jpg 

And after a lot of cursing, it turned out good enough, not perfect, but a little of body filler will take care of the rest
49870126998_8871b32e76_c.jpg 

Now with this pieces, and some measurements for the missing metal
49859737727_a61763c533_c.jpg 

We got this new piece
49863475586_8dd8ee26ca_c.jpg 

It is looking like a car again
49863773131_ed077c4f5f_c.jpg 
 

  • Upvote 1
Link to comment
Share on other sites

On 2/17/2023 at 8:55 PM, Banjo said:

Incredible work & perserverance Sebastion !  I've been looking forward for an update from You !

 

Keep it up, & keep the pictures coming.   You are inspiring others.

 

Cheers Banjo

Thanks a lot Banjo, more pictures this way

First of all, we are going to settle what was pending, which was to shape the tip of the rear fender.
49858959358_20559ce114_c.jpg 

Now we are going to see if we finish the trunk, to make my work easier, again I ordered a piece to be folded with more or less the profile of the upper edge of the panel.
49858926973_890ca57550_c.jpg 

After a bit of cutting and adjusting to make the curve, I welded it to the main panel and the piece was rigid again.
https://live.staticflickr.com/65535/49855784247_c4142ed473_c.jpg

Now with that firmer panel, I proceeded to work inside the trunk (remember to rotate from work to work so as not to hate any more than the other) and start making a very simple piece.
49870153728_4c2fa1d564_c.jpg 

Always using the holes as a reference for the new piece that had to be made, each piece is more or less complicated.
49855606932_1be20d66c0_c.jpg 

In this case, the floor had a rib, and I wanted to keep it to give it continuity. So to the shaping block, I welded a plate as a mold, and with the hammer and patience I hammered that mold to the piece that I was assembling.
49859498681_cf8550124e_c.jpg 

The piece on the other side also had that strengthening rib, also some curves, it was all a matter of replicating all the turns.
49864631667_a25e43b649_c.jpg 

As always, to replicate the pieces, you always have to remove and put the piece in the car a thousand times, verifying that the entire shape more or less matches.
49859737677_712f3edf63_c.jpg 

And after we have the shape in place, it gets welded and it looks like nothing happened. Luckily I remembered to test the rear panel and check that it is in line with it.
49854765703_3a4382ba9b_c.jpg 

On the other side, while trying to make the piece fit the right place, in one of the tests I realized that when hammering the material went where I didn't wanted and the piece no longer matches the width in some parts, but since the piece was 90% ready, so well... I wil welded and fixed it later.
49862836098_6a2b042091_c.jpg 

Luckily with the mig, metal is easily added, and these types of gaps are easy to fill, it's more work afterwards to grind it, but with patience and paint, it's relatively neat.
49855407201_b247388ea5_c.jpg 

As you can see, I was also working on the bottom of the trunk that I found some holes and on the side panels.
49863352991_e33bcec19c_c.jpg 

Here we have a small repair in the curve of the panel, and it is already marked for the cut of the next piece.
49859565241_fc344e16f2_c.jpg 

As always, it is a matter of cutting the problem into smaller parts and solving them one by one.
49858927198_d6d575813c_c.jpg 

Here on the other side, also repairing small and not so small rust problems.
49855311466_faf82eee3d_c.jpg 

In this case I had to bring the tail lights to validate that they were fitting in place and that the whole piece was correct.
49855649777_c1846a1545_c.jpg 

While we were at it, I took a photo with the whole panel in place. Things are changing, but as you remember, the panel has several holes.
49859444896_ca6b34fedc_c.jpg 

So it was a matter of cutting, and then making all the necessary pieces, as we are used to..
51888402795_717c3016bf_c.jpg 

To then place them all in place one by one.
49864082342_4a3b0816de_c.jpg 

And the rear panel is taking shape
51888075184_7d752ebee9_c.jpg 

Very crazy to think that everything that is painted is because it had a repair hahaha
51886781597_5e2335237c_c.jpg 

With the back panel soon, I started with the repair of the edge that also had rust (incredible I know), in addition to the ugliest parts, I took advantage of and some small holes, I enlarged them and filled them to cure the problem
51886781942_94cc95131f_c.jpg 

As always, repairing and checking that the panels that make up the piece, in the order that they make it up.
51887829363_611e5c6e07_c.jpg 

And to take advantage that I removed the rear panel, it was the ideal time to convert the VW Gol spare tire well into the Corolla well, so I roughly cut the piece and began to shape it with love and blows, but luckily the size was very similar. and the piece had extra material to work with.
51888402725_388135f2e1_c.jpg 

A matter of welding and grinding until we are happy, then some paint and it is ready. A minor detail, I rescued the central screw from the original panel, and weld it to this hahaha.
51888075649_b1d4e98177_c.jpg 

Many years later once again it had a spare tire in the spare tire well like the first day.
51888403250_aae446519c_c.jpg 

We're already winding this up, so a new level unlocked of hiding ugly welds with body sealer, almost seems like a half good job
51888075694_bbb933fc24_c.jpg 

Trying the trunk lid before calling it quits, and luckily everything clicks into place.
https://live.staticflickr.com/65535/51887829418_e1ac316525_c.jpg 

So it was a matter of starting to weld, and taking out the cleco pins one by one and welding as we control the heat on the panel.
51887745471_f009ff8865_c.jpg 

This process took April and May 2020
 

Link to comment
Share on other sites

Hi Sebastian,

                      Thanks for all your wonderful progress pictures.  In English, I think we refer to what you are doing as "a labour of love".

 

You've taken something, unloved, battered & bruised; & doomed to the dump, & are slowly bringing her/him/it, back to life.

 

My "hat goes off to you", particularly, as you first had to teach yourself to weld, before commencing this project.

 

Just inspiring !

 

Cheers  Banjo

 

 

               

Link to comment
Share on other sites

  • 2 months later...

Sorry I had forgot about this

Thanks a lot Banjo for the kinds words, as you said it was a labor of love, and of need, because noboy wanted to fix this car hahaha.

 

Lets start tying some loose ends

One of the issues that had been left behind was finishing the steering column
51887744951_788149b911_c.jpg 

So clearly, I started with the easy part of cleaning and painting everything.
51887829193_5f1524ba9c_c.jpg 

I don't have pictures, but what I did was take the upper part of the steering column from the Corolla, the lower part of the steering column from the Starlet, and started cutting to see what I was working with, unbelievably it was much easier than I thought, since the internal axle is the same in both cases, so it was a matter of joining both pipes.
51887828943_a27b66bd67_c.jpg 

To match them, I had to open the lower tube of the Starlet a little bigger, and thus place a bearing between the tube and the steering axle that centers everything in the lower part. Then have a bushing turned that centers the lower pipe on the upper pipe and that's it. Unfortunately there are no photos of all this.

And that was it, I just had to fit the bottom bracket of the Starlet to the firewall, with the original part of the Corolla.
51888403180_62e1c56c3d_c.jpg 

Since I was painting, I got excited and painted several things that were laying around. 52327552348_d22c33f120_c.jpg 

Since I was motivated it was the turn of the rear leaf springs.
51886781862_eb837b8ee2_c.jpg 

I got the habit of cleaning parts by leaving them submerged in anti-rust acid.
51887745031_9743c11b45_c.jpg 

They easily come out like new, there is no need to spend work and after washing them they are ready to paint
51888402965_5397eaa862_c.jpg 

And remember I was painting everything.
51888075479_2940c33ca8_c.jpg 

With all this, we are between May 2020

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...
×
×
  • Create New...