Wow! Gotta give you props for taking on all that welding. I've done a tone of welding on rusty panels on my 1953 Chevy suburban and I know what a tremendous amount of time an patience it takes (and my Suburban is a lot thicker gauge steel). Nice job on saving a wagon that few other people would have been able to keep alive. Looking forward to seeing it in paint.
wow, that looks incredible! Was it difficult getting the windshield out of the donor car? I'm tempted to pull one out of a car in a wrecking yard, but I have a feeling I'd break it.
wow, that looks incredible! Was it difficult getting the windshield out of the donor car? I'm tempted to pull one out of a car in a wrecking yard, but I have a feeling I'd break it.
to do that job i asked people who are working at that business. they know how to do job right (but before start to remove it - they told me, that there's no guaranty that glass will come out nicely.)
- After body painting cleaned all traces of polish;
- Cleaned and placed all the door rubbers;
- Arranged all the side windows from the donor + cleaned rubber window guide rail, as well as interior doors (bottom of the door sprayed corrosion prevention ML wax);
- Collected from one set of two: a window and door molding kit, door handles, horns, all them cleaned to black finish and installed;
- Bring together the wings, bonnet, lights (interior wing soiled with corrosion prevention oil);
- Repainted and fitted with plows;
- Luggage trunk inside the ML sprayed wax, left to complete the collection;
- Two interior selected the best seats, drag clothing, wash, and dress up all back.
- Welding seams applied body sealant;
- Welded exhaust with 50mm pipe + Sedan muffler with two pipes (no one did not work, mounting, position, or output tubes), all was modified;
- repaired all suspension with all-new suspension rubbers;
Few photos:
All suspension rubber looks like that:
Seats covers: washed vs not washed, and dress up seat:
Body sealant:
Working on exhaust, mounted exhaust muffler of 4gen sedan:
Re-welded exhaust pipes, that they will come at right place. for this moment it’s “bosozoku” edition exhaust
^very cool... everyone should do this to protect their wagon from rust..
AGREED! The wagon looks great man! Those control arms were pretty corroded looking, were they pretty hard to get out? Makes me so glad to get a 98% rust free wagon.
Time for update. At local forum there was few updates, so it's a time to translate and post some photos:
- finally finished AT to MT swap!
- assembled all interior;
- assembled bumpers, mud guards, fog lights and etc;
- reassembled generator, new bearings;
- new timing belt, tensioner, water pump, spark plugs;
- mounted exhaust manifold from donor, old one had a crack..;
exhaust pipes no more "bosozoku" edition:
- Reassembled front brakes calipers (new pistons, brake pads, brake fluid DOT4, fresh painted);
- New brake hoses;
- New fuel filter;
- From donor mounted throttle body, because old TPS was bad, and power steering pump;
How calipers was:
Parts after rust removing with hydrochloric acid:
Assembled with AT and Plastilube grease:
Final result:
View with fully assembled front (hood is open):
At 3th of March we get some snow:
Test drive was DONE. There was some very bad noises from gear box ( i guest bad bearings). Our guess was - bad noises from transfer bevel gear. Trying to found where and fix that..
Long time there was a silence at this thread. Shuttle was used as daily/winter drive.
After winter it was used a little bit less.. For small trips and etc..
Nothing special was made for shuttle till now. Some major jobs like:
- one more time fixed aircon (because at the beginning of summer it blowed off, and all refrigerant get out of system);
- there was an electrical issues (Main relay was clicking in a strangest situations). After long trouble shouting and head banging in a wall - was found bad spot - alternator. Inside of it was dead rectifier assy.
- changed bad distributor to good one;
- before the autumn rechecked brake system, changed one bad drum wheel cylinder and bought new brake discs:
Got all 4 RUST FREE Shuttle doors, but in cherry color:mad: Let's get some sanding paper and go to work.
Wet sanding, spray some primer, wet sanding again and finally - paint them:
Comments
Today was made front glass transplantation from donor to project car. Operation was successful!
color is OEM Honda: B-50M
to do that job i asked people who are working at that business. they know how to do job right (but before start to remove it - they told me, that there's no guaranty that glass will come out nicely.)
- After body painting cleaned all traces of polish;
- Cleaned and placed all the door rubbers;
- Arranged all the side windows from the donor + cleaned rubber window guide rail, as well as interior doors (bottom of the door sprayed corrosion prevention ML wax);
- Collected from one set of two: a window and door molding kit, door handles, horns, all them cleaned to black finish and installed;
- Bring together the wings, bonnet, lights (interior wing soiled with corrosion prevention oil);
- Repainted and fitted with plows;
- Luggage trunk inside the ML sprayed wax, left to complete the collection;
- Two interior selected the best seats, drag clothing, wash, and dress up all back.
- Welding seams applied body sealant;
- Welded exhaust with 50mm pipe + Sedan muffler with two pipes (no one did not work, mounting, position, or output tubes), all was modified;
- repaired all suspension with all-new suspension rubbers;
Few photos:
All suspension rubber looks like that:
Seats covers: washed vs not washed, and dress up seat:
Body sealant:
Working on exhaust, mounted exhaust muffler of 4gen sedan:
Re-welded exhaust pipes, that they will come at right place. for this moment it’s “bosozoku” edition exhaust
Total view:
Polished vs not polished(+ bad camera focus):
3 pieces are ready:
Driver side corner made from two, because read part was cracked:
All stuff in place:
Preparation:
The stuff i used:
Result:
AGREED! The wagon looks great man! Those control arms were pretty corroded looking, were they pretty hard to get out? Makes me so glad to get a 98% rust free wagon.
- finally finished AT to MT swap!
- assembled all interior;
- assembled bumpers, mud guards, fog lights and etc;
- reassembled generator, new bearings;
- new timing belt, tensioner, water pump, spark plugs;
- mounted exhaust manifold from donor, old one had a crack..;
exhaust pipes no more "bosozoku" edition:
- Reassembled front brakes calipers (new pistons, brake pads, brake fluid DOT4, fresh painted);
- New brake hoses;
- New fuel filter;
- From donor mounted throttle body, because old TPS was bad, and power steering pump;
How calipers was:
Parts after rust removing with hydrochloric acid:
Assembled with AT and Plastilube grease:
Final result:
View with fully assembled front (hood is open):
At 3th of March we get some snow:
Test drive was DONE. There was some very bad noises from gear box ( i guest bad bearings). Our guess was - bad noises from transfer bevel gear. Trying to found where and fix that..
To be continued soon.
Pedal assembly was bolt on, no welding at that place.
To mount RT4WD gearbox i have to remove old mounting bracket (AT), and weld in from MT gearbox.
Bad sounds from gearbox was found and fixed!
Changed all transfer from donor.
After winter it was used a little bit less.. For small trips and etc..
Nothing special was made for shuttle till now. Some major jobs like:
- one more time fixed aircon (because at the beginning of summer it blowed off, and all refrigerant get out of system);
- there was an electrical issues (Main relay was clicking in a strangest situations). After long trouble shouting and head banging in a wall - was found bad spot - alternator. Inside of it was dead rectifier assy.
- changed bad distributor to good one;
- before the autumn rechecked brake system, changed one bad drum wheel cylinder and bought new brake discs:
Installed clear turning lights in a bumper:
And bonus photo of two 4wd friends:
I think someone don't have enough driving skills...
Fucked up man, hope you can find a good door.
Wet sanding, spray some primer, wet sanding again and finally - paint them: