BradD Posted August 11, 2012 Report Share Posted August 11, 2012 The time has come to man up and do this thing. I have had this car for a few years now and I honestly cant see parting with it ever, time to make it new. For those that don't know the car from previous threads....When I found it a fairly clean one owner car with less then 90k....http://farm3.staticflickr.com/2543/4110541223_8f71123df0_z.jpghttp://farm3.staticflickr.com/2487/4111306642_911e6324a0_z.jpg Then I spent a whole weekend cleaning it and came up with this.....http://farm4.staticflickr.com/3232/4552760773_4f8c95700c_b.jpghttp://farm4.staticflickr.com/3200/4552765557_4776100070_b.jpghttp://farm5.staticflickr.com/4013/4552772919_a3219556eb_b.jpg Drove it like this for quite some time, was very happy with it and thought I might just preserve the original finish despite the minor (or so I thought!!!) rust. Well that was all well and good until this happened...http://i71.photobucket.com/albums/i136/TSiSS350/2011-02-12_19-12-37_391.jpg?t=1344706885 Was hit by an inattentive driver in a Nissan Altima (why are they the worlds worst drivers!!??!) After tear down it was clear that frame damage was going to be an issue...http://i71.photobucket.com/albums/i136/TSiSS350/2011-05-15_15-48-08_61.jpg?t=1344706946 I think the problem was the bottom of the bumper bar was rotted out and the beam did not do much to slow down the impact. So at this point the car was parked on the hill and the search for parts began. Flatty fenders are tough to come by and it took a lot longer than it should have!! Quote Link to comment Share on other sites More sharing options...
ZacMan Posted August 11, 2012 Report Share Posted August 11, 2012 Flatty love . Looking forward to seeing how you progress with this. Quote Link to comment Share on other sites More sharing options...
Dred_85.5_TSI Posted August 11, 2012 Report Share Posted August 11, 2012 Flatty Love!! My 84 ES is more Mod than Resto. Can't wait to see what you do with it. Quote Link to comment Share on other sites More sharing options...
BradD Posted August 11, 2012 Author Report Share Posted August 11, 2012 (edited) Found my flatty fenders with a little help from this site. Coke really came through for me sourcing them, problem is, he is in Buffalo NY and I am about 8hours away just outside of Boston! After convincing family and friends that I wasn't crazy for planning a trip that far to pick up a fender I had an epiphany, why not make a vaca out of it! So I called my girlfriend and said "Hey, how about a trip to Niagra Falls, neither of us have been and I can pick up my parts while we are there!" Thankfully she is down for an adventure so we packed up a car took her eight year old daughter with us and went north. Met Coke (great guy and an asset to this community for sure!) his dad and his Llamas, got my parts and came home. Bonus niagra falls pics...http://farm8.staticflickr.com/7225/7362882190_91613d7e8f_c.jpg http://farm9.staticflickr.com/8005/7362942950_d9c5db8c47_c.jpg http://farm8.staticflickr.com/7217/7177732171_e4b4d63fd2_c.jpg What an amazing site! Spent the better part of a whole day just staring at it, truly worth the trip if you are even considering! Anyway, back to the car. Step one....start the long dormant Starion. A little Mitsu love at work here, jumping it with the Sapporo...http://farm6.staticflickr.com/5463/7393989846_598c1ae847_b.jpg Step two...clean off 18 months of dirt and out door grime.... http://i71.photobucket.com/albums/i136/TSiSS350/2012-06-17_17-36-25_941.jpg?t=1344707047 Step three inspect damage..... Apparently the years of sitting on grass at the previous owners house kept the car moist for WAY to long and the rockers and qtrs are rusting from the inside out. http://i71.photobucket.com/albums/i136/TSiSS350/2012-06-17_17-38-02_314.jpg?t=1344707185 http://i71.photobucket.com/albums/i136/TSiSS350/2012-06-17_17-37-05_828.jpg?t=1344707112 Discouraged but not one to give up as the floors and framerails are good, I drove it to my work, All Star Collision in Salem Ma. http://i71.photobucket.com/albums/i136/TSiSS350/2012-08-06_14-00-59_745.jpg?t=1344606796 Loaded up on the frame machine, disassembled and being pulled.. http://i71.photobucket.com/albums/i136/TSiSS350/2012-08-07_18-03-05_611.jpg?t=1344606914 Rust in side the front fenders on the apron. All Rot will be cut out, replaced and sealed before paint. http://i71.photobucket.com/albums/i136/TSiSS350/2012-08-07_09-57-55_101.jpg?t=1344607038 http://i71.photobucket.com/albums/i136/TSiSS350/2012-08-07_18-02-43_551.jpg?t=1344606880 This is going to be a big project, I certainly have my work cut out for me, but in the end a full re spray new decals all rot removed and a few surprise parts thrown at it will make it all worth the while. I cant wait to show you the wheels that will be going on it!! Edited August 11, 2012 by BradD Quote Link to comment Share on other sites More sharing options...
Dred_85.5_TSI Posted August 11, 2012 Report Share Posted August 11, 2012 If you are putting new wheels on it I would like to know what size the black mesh wheels that are in the pictures are. Might be interested in buying them if you have no use for them. Quote Link to comment Share on other sites More sharing options...
BradD Posted August 12, 2012 Author Report Share Posted August 12, 2012 The wheels on the car are original Enkie 92's. I wont be selling them, when I bought the car he had all the receipts for everything ever done to the car including the wheels and rear spoiler! Back in the 80's my father owned a wheel and tire shop and the wheels were believe it or not bought through him. Certainly cant sell those! Actually they are going to wind up on the Sapporo and these wheels on the Sapporo will be back ups. Quote Link to comment Share on other sites More sharing options...
Dred_85.5_TSI Posted August 12, 2012 Report Share Posted August 12, 2012 ok, just thought I'd ask. I'd do the same thing in your situation. Quote Link to comment Share on other sites More sharing options...
pc85 Posted August 13, 2012 Report Share Posted August 13, 2012 On that note, I still have some nice 16" Riken rims I just took off my flatty when I upgraded to 17"s. Since there aren't a lot of flatty's around, there doesn't seem to be much interest for 4 lug rims anymore. Anyway good luck with the resto, I'll be looking forward to the progress and if your interested in some nice rims that fit our cars, let me know.Flatty Love. Quote Link to comment Share on other sites More sharing options...
BradD Posted August 14, 2012 Author Report Share Posted August 14, 2012 Since there aren't a lot of flatty's around, there doesn't seem to be much interest for 4 lug rims anymore. The bolt pattern on the 4lug cars is the same as 90% of all old Japanese cars, Datsuns, Toyotas, you name it. Plenty of buyers out there, just not here in the club. Besides, even most of the flatty guys go 5-lug now! Been a little busy in the shop with paying customers cars so I have not had much time to touch the car after the first day, but hopefully by the end of this week there will be some progress! Quote Link to comment Share on other sites More sharing options...
pc85 Posted August 14, 2012 Report Share Posted August 14, 2012 Just trying to keep them in the starquest family. If there's no interest they go on E-bay for that 90%. Quote Link to comment Share on other sites More sharing options...
BradD Posted October 20, 2012 Author Report Share Posted October 20, 2012 So its been a few months but the project is in full swing, since the rust started from the inside out, the first step is to remove the outside for access. Outer skin removed....http://farm9.staticflickr.com/8188/8105929890_26e9438b63_b.jpg Next level down... http://farm9.staticflickr.com/8325/8105917367_e77e572f6e_b.jpg Scary looking but its all for the greater good!http://farm9.staticflickr.com/8326/8105915765_608be1d18f_b.jpg You can see in this next picture were the majority of the rust is, between the pinch weld and the floor. Looking down from the interior here.....http://farm9.staticflickr.com/8323/8105931480_9c9fe30429_b.jpg And up from the undercarrige here....http://farm9.staticflickr.com/8044/8105930810_277713719a_b.jpg Other than that small spot on the frame rail, which of course will also be addressed the floor and underside are in amazing shape for a northeast car. Quote Link to comment Share on other sites More sharing options...
BradD Posted October 20, 2012 Author Report Share Posted October 20, 2012 On the passengers side quarter panel a large area of surface has been peeking through the paint for a while. To save from any future surprises we decided to grind down the paint and see what was there... Uh-oh is that bondo showing up?!http://farm9.staticflickr.com/8336/8105930580_d09709dae5_b.jpg After a lot more grinding it seems the panel is in fairly good shape. Must have been hit at some point but the bondo was only a skim coat, decent repair was done but I HATE seeing holes drilled to pull a dent!!! Those will have to be welded up before we get to the final body work stage!http://farm9.staticflickr.com/8043/8105916603_b9fb3443a3_b.jpg Covered in SEM rust-mort, this stuff is amazing! Literally turns rust back into shiny metal, I will have to do a before and after shot somewhere on the car. Amazing stuff! http://farm9.staticflickr.com/8468/8105916339_3fde6a218c_b.jpg Next up full interior removal so we can get to welding up the panels without burning everything. Quote Link to comment Share on other sites More sharing options...
ZacMan Posted October 20, 2012 Report Share Posted October 20, 2012 Whoa, that ambitious, and fantastic. Really need to go the extra mile to keep the flatties alive. Good s***, keep the updates coming . Quote Link to comment Share on other sites More sharing options...
Dred_85.5_TSI Posted October 21, 2012 Report Share Posted October 21, 2012 That rust looks like my 85.5.... Yay road salt!. looks good so far! Quote Link to comment Share on other sites More sharing options...
BradD Posted October 22, 2012 Author Report Share Posted October 22, 2012 Interior out, floors are in pretty good shape all things considered.... http://farm9.staticflickr.com/8466/8113710736_fe4a3deedd_b.jpg Carpets will get a good shampooing, or replacement if they don't clean up 100% http://farm9.staticflickr.com/8328/8113711026_643485c03a_b.jpg Next step metal replacement on the drivers side floor/pinch weld. Quote Link to comment Share on other sites More sharing options...
kev Posted October 23, 2012 Report Share Posted October 23, 2012 That is my fav car ever made right there. Love the beige leather seats. My old 84 es had beige cloth. Keep us posted. kev Quote Link to comment Share on other sites More sharing options...
BradD Posted November 6, 2012 Author Report Share Posted November 6, 2012 Some more work done this weekend....... Brought in this antique to help with the sheet metal. A very old break that has been around for years... http://farm8.staticflickr.com/7254/8161045524_249501b06c_b.jpg All the rusted metal cut out. Rest of the sheet metal exposed to see any other damage. Little bit of rust under where the heel would rest. http://farm8.staticflickr.com/7253/8161045284_7823d5edbf_b.jpg Rubens firing up the torch to heat the metal. Need to make it pliable to bend the floor to match the factory design. http://farm8.staticflickr.com/7249/8161011529_79bf794c0c_b.jpg http://farm8.staticflickr.com/7259/8161044682_41fbfdacc2_b.jpg Without him none of this would be possible, big thanks goes his way! He has been doing this for 30 plus years and is so knowledgeable in metal work! Decided it would be easier to make the shapes after it was tacked in place. http://farm9.staticflickr.com/8070/8161010863_ea00e43e1b_b.jpg http://farm9.staticflickr.com/8064/8161043964_b585f6951b_b.jpg Pinch weld taking shape again.... http://farm8.staticflickr.com/7246/8161010389_bc28c93109_b.jpg Good amount of work done but still a lot to go! Getting excited. Looking to replace the decals on the sides if any one has any info on reproductions. Quote Link to comment Share on other sites More sharing options...
importwarrior Posted November 7, 2012 Report Share Posted November 7, 2012 great start so far. cant wait to see it finished. Quote Link to comment Share on other sites More sharing options...
BradD Posted January 4, 2013 Author Report Share Posted January 4, 2013 A little slow work going on, nothing of note. I have the rest of the interior out, small exterior trim, mirrors, rear liftgate moldings, wipers, cowl etc... is coming off this week and going to be refinished in semi-gloss black. What I am really trying to find right now is the decals for the sides. I had found a link to some vector files a year or so ago and I was wondering if anyone has info or links to anything? I have not priced out having them copied and printed, but I cant imagine that would be affordable! Quote Link to comment Share on other sites More sharing options...
BradD Posted February 8, 2013 Author Report Share Posted February 8, 2013 Sorry everyone, been a little backed up with the bill paying jobs in the shop. Have a good update for you all now. Rockers rebuilt and closed off....http://farm9.staticflickr.com/8230/8455825307_4607a1e15d_c.jpg Quarters closed up, still needs a little finishing obviously...http://farm9.staticflickr.com/8249/8455825403_e08fb04159_c.jpg Factory style joint between the rocker and the quarters...http://farm9.staticflickr.com/8245/8455825805_42a8315a6a_c.jpg The part that made me the most nervous, the door jamb. Reused a lot of the factory metal here after treating it with rust-mort to keep the factory look.http://farm9.staticflickr.com/8386/8455825751_a81f2b20e2_c.jpg Floor mostly finished, just needs grinding, finishing and a few small areas need filling.http://farm9.staticflickr.com/8246/8456923254_850c7830ac_c.jpg Floor section in the rear foot well area.http://farm9.staticflickr.com/8518/8456923160_30085c0c1b_c.jpg Coming right along now! Light at the end of the tunnel for the heavy body work. Quote Link to comment Share on other sites More sharing options...
pc85 Posted February 9, 2013 Report Share Posted February 9, 2013 Good amount of work done but still a lot to go! Getting excited. Looking to replace the decals on the sides if any one has any info on reproductions. Great progress, keep it up! I think Burton has all the decals you might need, if not he can make the necessary reproductions. Quote Link to comment Share on other sites More sharing options...
BradD Posted February 11, 2013 Author Report Share Posted February 11, 2013 Great progress, keep it up! I think Burton has all the decals you might need, if not he can make the necessary reproductions. Natallica is taking care of me on that. Getting very excited now with the progress. Hopefully within the next two months the car will be ready for paint. Quote Link to comment Share on other sites More sharing options...
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