this is my first attempt at a rebuild and a thread too. the car is a 1988 d90 RHD running a 3.5 v8 off an RRC. i am not a mechanic and also i am not to technically informed but my goal is to be a involved as possible and learn and do what i can. guess I will see how it goes, any technical advice and other forms of advice will be highly appreciated.
Location - Nairobi, Kenya
------ Follow up post added August 30th, 2015 09:33 AM ------
okay im busy trying to figure out how to get pictures up.
meanwhile heres a little general info:
1. got the car early this year, run it as it was trying to get to know it better.
2. in order to make the drive more pleasent sent it over to the shop to get the clutch replaced, turned out the tansfer box was also swimming in oil, got that bit sorted out too. she was a little more drivable now.
3. the more i drove the more i knew needed to be changed, started picking out quotes from different shops and having a look at their work. wasnt pleased at all with the lack of attention to detail and the tendancy to cover up problems like paint over rust and forcing old bolts etc. decided to try and micromanage the project:
a) remove all carpet and trim find out whats lurking underneath
b) strip body to chassis and have a look at that
c) strip dash for replacement / repair
d) strip old terrible fire hazard harness and start on a new one
f) get rid of the rock hard robbs magic dampers and couils
g) replace all bushes
h) new seals all round
i) bolt and nut rebuild
j) find a good yellow paint
k) eventually make up my mind on what yellow to slap on
l) all the other stuff i forgot about
so took out the carpet and the trim and obviously the body needs some work, rust found on front floor and door bottoms rotten bad, rear door seems salvagable.
dashboard = rotten!
Harness and wiring = amatuer training ground? very very dodgy, hazards occasionaly would choose not to blink and remain lit, lights all cracked and connections all made with tape and no plugs or sockets.
started dash rebuild, lower dash that is. i had expanded polyethylene foam that i used to insulate my warehouse its got a 10mm profile and very dense, and hard to collapse or tear, decided to use this as the underlay in place of the low density foam that comes stock. might be interesting to experience its heat insulating properties as well,
again just an experiment.
Bonded it with some high temperature contact bond, left it in the sun for couple of days and tried to peel off repeatedly but is bonded shut.
the foam has a layer of aluminium in both ends making it smooth and easy to bond.
also had the curiosity and help from my niece! as seen in on of the pics below!
i also did line the edge of the lower dash with 5mm self adhesive rubber strip so elimitate any dust ingress or vibration possibilities when mounting.
i got new doors PUMA doors.
during install discovered the pillar is rusty and warped.
while installing the mechanism on the door used 3M double sided seld adhesive rubber strips on the metal to metal areas. was afraid that the mechanism will protude but fitted quite well.
eventually i would like to have power windows but the new door set i got came with manual winders.
this exercise of installing the doors and having to change the strikers and pillar(A or B post?) slowly led to a full take off of the body.
i had a tin of black touch up paint and sprayed the hinges... no surprise its already chipping off! will have them powder coated or something later!