Honda Shuttle RT4WD rebuild [by ilgas]
ilgas
New Wagonist
At last I found some time to make build thread. (p.s. sorry form my English)
Location: Lithuania, Vilnius (The capital of country), Europe.
After 8-9 month of research of shuttle – finally I found it. The shape at first look – was a good start for project, because old owner started repair rust and etc. For my big disappointment – old owner made a lot of mistakes, which now I’m fixing and rebuilding for second life;)
Old owner take this shuttle with defect of automatic gear box, some rusts at rear arches, door steps. But that was EE4 D16Z2 RT4WD with ~163k km, electrical windows, mirrors. The car was not used about 4 years. After that he made conversion to manual transmission (still need to make some fixes). And the worst thing, that him started body worksL I don’t know why, but he cut too much.. started welding a door steps (used new repair 4 doors sedan doors steps) they don’t mach exactly like shuttle ones, so they tried to adopt them (but that was not a good try). After some time he decided to sell this car, because there’s too much work. So, I was that lucky one, who take that pain of headJ
Some photos how it looked before I take it:
Shuttle is going at new home:
From here I started to do things right. First job was one more time modify welded door steps, use some hammer, cut, weld it again and etc.. here some photo:
Driver side:
Passenger side before my touch:
Before one week ago I found one more Shuttle RT4WD with very bad body.. I took it for ~400$. He will be used like donor;)
i'll try update this thread often - so, to be continued..
Location: Lithuania, Vilnius (The capital of country), Europe.
After 8-9 month of research of shuttle – finally I found it. The shape at first look – was a good start for project, because old owner started repair rust and etc. For my big disappointment – old owner made a lot of mistakes, which now I’m fixing and rebuilding for second life;)
Old owner take this shuttle with defect of automatic gear box, some rusts at rear arches, door steps. But that was EE4 D16Z2 RT4WD with ~163k km, electrical windows, mirrors. The car was not used about 4 years. After that he made conversion to manual transmission (still need to make some fixes). And the worst thing, that him started body worksL I don’t know why, but he cut too much.. started welding a door steps (used new repair 4 doors sedan doors steps) they don’t mach exactly like shuttle ones, so they tried to adopt them (but that was not a good try). After some time he decided to sell this car, because there’s too much work. So, I was that lucky one, who take that pain of headJ
Some photos how it looked before I take it:
Shuttle is going at new home:
From here I started to do things right. First job was one more time modify welded door steps, use some hammer, cut, weld it again and etc.. here some photo:
Driver side:
Passenger side before my touch:
Before one week ago I found one more Shuttle RT4WD with very bad body.. I took it for ~400$. He will be used like donor;)
i'll try update this thread often - so, to be continued..
Comments
bottom was welded by my friend in two days ago:
it's time to weld top of door step, dirlle holes then weld them. From here i started to weld by myself, because my friend have a lot of work, and can't find some time to help me. I think - result is pretty nice for not professional welder:)
that's how this look from inside the car:
I don't have time to work with shuttle at weekend, so next update you can expect on next week.
I can't write answer to your PM and others (maybe moderators can fix that?):
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Anyway, i dont see how that blue civic has a bad body? Ive seen alot worse. HELL!!, im buying one that is a lot worse.
But for 400 bucks......sweet deal!!
Good, job and good luck. Btw arkos = quarter panel
Trust me - blue one isn't a good base for project ( from photos which i posted you can't see all rust, cracked roof, trunk hood with out window and etc).
Welded 3 holes in front (that’s not most beautiful welding example, but I don't care - because it will be hided with plastic side sills). Also made holders for plastic side sills:
Now we will move to the rear quart panels.
First of all, take the rear bumper off and made body inspection to find bad places:
Let’s start to cut rusted places, made new ones from metal which I borrowed from old Ford Fiesta doors, forming right shape and weld it in:
To reform inner arch I used front wing of 89-91 civic, because it have quite close shape. After some modifications those parts fitted quite nice:
Finally found time to clean all welded surface (and other open metal places) and painted them with epoxy primer (two components). That’s really good stuff!
Making drivers side rear quart panel. I’ll used 2 brand new repair kit for 4gen Honda Sedan. How all was done – you can see at photos:
Going to other side to passenger side rear quart panel. Inspecting what is bad and moving to work:
To reform passenger side rear quart panel – was used the donor rear quart panel, just replaced some rusted place by welding fresh metal.
Small fixes with inner arch:
Welding cuted peace in place. All rest was made the same way, like drivers side rear quart panel:
Next – cleaning rusts from doors and everywhere we can found them, putting rust beater, painting with epoxy primer:
that's all for this time..
Good work!
*standing ovation!
Removed gear box to finish automatic to manual transmission swap. Found some nice gift inside :oops:
Clean that shit out:
Drilled out mount of automatic gear box, and welded in bracket from manual RT4WD gear box.
The difference between automatic and manual gear box. (red one are from automatic).
Replaced clutch release bearing, clutch disk because old one was not nice to leave:
Replaced bush at front lower arm:
Adjusted trunk and other doors:
And finally – let’s go for painting
same as before - B-50M
Great work and fair play for saving this Wagon!!!