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Project Theseus

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  • Got a lot done today! Massive pic dump, sorry.

    Threw the rear together again to make sure I got the hole location correct for the license plate light:




    Cut out the old side flange and made a new one:








    Lotta cleanup to do back here:




    Same deal on the other side. Didn't bother making the bottom corner curved because there's no way it'll be seen and doesn't affect anything.









    Extended both drip rails:














    With the rear done, it was on to the d/s dogleg. It was missing the flange that goes in the wheelarch, so made one and welded it on. Did itr from the inside so I had enough meat in the weld to make the outside radius correct.






    Lower bend was too wide, so cut and welded it:





    super rough mockup:




    Also dug out the spoiler I got with the car when I purchased it 3 years ago. Dunno if I want to run it or get a BRE one, the one I have is kinda growing on me though. Thoughts? I think it will work better with the lines once the bumper is on.









    Near as I can tell, it's this spoiler: https://www.thezstore.com/page/TZS/P...02a01e/50-1575

    Comment


    • I like the BRE look better.
      But a bird in the hand
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      • Originally posted by Casey_z View Post
        I like the BRE look better.
        But a bird in the hand
        Oh yeah, BRE is great too, but as you say, this is what I have currently haha. Still undecided, I think it looks decent but fitment could be a pain, and would need to either rivet or glue it to the hatch due to the flexible nature - not like a fibreglass spoiler etc where warpage isn't an issue.

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        • Didn't do much today, but started on some beefy rear bumper mounts:

          Comment


          • The 432 style BRE spoiler is what I went with after considering the options for some time. I settled on a black finish spoiler on a red car. But, it doesn't matter what we like. You have the one that came with the car. You can paint it the same colour as the car or paint it black put it on and see how you feel about it and how it appears on the car. Or could paint the rearward side of the spoiler black then paint the forward face of the spoiler the same colour as the car. Depends on the look and style you prefer. You are not at the point that you have to make a definite discussion on the spoiler. Give yourself some more time to think about it.

            Comment


            • Originally posted by Dr.Diesel View Post
              The 432 style BRE spoiler is what I went with after considering the options for some time. I settled on a black finish spoiler on a red car. But, it doesn't matter what we like. You have the one that came with the car. You can paint it the same colour as the car or paint it black put it on and see how you feel about it and how it appears on the car. Or could paint the rearward side of the spoiler black then paint the forward face of the spoiler the same colour as the car. Depends on the look and style you prefer. You are not at the point that you have to make a definite discussion on the spoiler. Give yourself some more time to think about it.
              Good points! Definitely still time to think about it, any work I need to do to the car to fit it is just on the hatch itself so not like it's getting in the way of me priming the car etc. I think regardless of what spoiler I do (If I go for one at all, I suppose) it'll be black.

              ------------------------------------------

              Finished the bumper mounts. Should be suitably overkill.




              And mocked up! I have barely any actual bumper hardware yet, but just enough to get it on the car.



              It'll need a bit of tweaking. I got this bumper for dirt cheap or free (can't recall at this point) and the plan has always been to eventually find a straighter, less rusty one. Will clean this one up a bit in the meantime.



              Not bad, only a little bit of bending required.







              And threw the spoiler back on to see how it looks with the bumper:




              It's still super nice to see it all coming together!

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              • D/s dogleg successfully welded in today.



                You can see here that the gap at the corner is a little funky. Pretty sure that's just because this door has been patched and repaired a ton, but if it's still a problem when I get the new doors on I can always do a bit of slicing and welding.



                Leaving this open for now, as it will be much less of a pain to make once the car is on its side. Same deal with the p/s once I do it.




                Started cutting the unneeded metal off the 'new' engine bay frame rails:




                Passenger side dogleg tomorrow, then on to the engine bay.

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                • Got a good chunk of the passenger side stuff done today.

                  Cut out the bad:




                  Took this:



                  And turned it into this after a couple hours:




                  Tacked in the upper section of the main repair. Will finish it and the main lower section in the next couple days, ran out of time today.

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                  • Finished the dogleg today:



                    threw on the door, all seems well. Don't mind the lack of gap, just holding it on with my elbow for that pic.




                    And my new radiator showed up!

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                    • Finally got an electric impact, best purchase I've made in a while.




                      Decided to get the front suspension off the car today, had to start by removing 1/4" of bathroom caulking from the bolts on this side because of course the previous owner would put that over rust....




                      Went smoothly otherwise though, god I love power tools. The subframe/rack/etc is all in great shape happily, should just be a case of clean/scuff/paint.



                      All up on stands:




                      And had another look at all the rust areas I'll need to deal with:





















                      Next up will be to remove the rear suspension the same way, then brace the front and cut off the rad support.

                      Anyone have tips for order of operations for removing the rear? Looks like a lot of bolts blocked by other things that are blocked by other things lol.
                      Last edited by Noll; 06-17-2020, 09:52 PM.

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                      • Worked on getting the rear subframe out today.

                        Super high-tech jacking points:



                        Got it all out. This would not have been fun without the impact, with it it was a breeze.




                        Got the diff separated. I'll have to deal with the pain that is the spindle pins soon, and the outer axle bolts are also proving a pain. Thinking I might just grind the heads off, although they aren't exactly the world's cheapest bolts to buy replacements for.




                        Got the fuel lines out too. I wire-wheeled them a bit, and other than where they rotted out above the rear diff they're super solid .Probably will clean them up and re-use to save the effort of re-bending new ones as they are so good.



                        Next up, back to the regularly scheduled welding. Need to rip out the old rad support and frame rails so I can get started with the repairs.

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                        • I'm surprised that your lines were so good. There wasn't a piece longer than two feet after I pressure washed under my car.
                          Eric Zondervan
                          72 240Z
                          54 Chevy 3100 pickup
                          91 Nissan Figaro
                          11 Sierra 4X4
                          17 Nissan Juke Nismo
                          18 Audi SQ5
                          18 Polaris Switchback XCR 800
                          17 Yamaha FZ-10
                          65 Honda Moped

                          Comment


                          • Originally posted by zedfoot View Post
                            I'm surprised that your lines were so good. There wasn't a piece longer than two feet after I pressure washed under my car.
                            Me too! Given the condition of the shell I didn't have high hopes, but they're pretty much perfect all the way back to the dark patches you can see at left side of pic. Even still have the zinc coating visible in spots. Plan is going to cut back to good metal, put a flare near the ends, and a short bit of fuel hose between the rear section that I'll have to make. Clean/paint them for future protection and away we go.

                            The suspension is surprisingly good too. surface rust abounds as you'd expect, but everything has come apart OK and is totally re-usable other than the darn outer half-shaft bolts. I'm thinking I may grind one face of the nuts till the threads of the bolts are visible and then try to un-do or snap them while they're red hot and weak. Just want to try to save the bolts themselves at it looks like 8 will end up being 100$+ if I need new ones due to the special shanked bit.

                            Comment


                            • Originally posted by Noll View Post

                              Me too! Given the condition of the shell I didn't have high hopes, but they're pretty much perfect all the way back to the dark patches you can see at left side of pic. Even still have the zinc coating visible in spots. Plan is going to cut back to good metal, put a flare near the ends, and a short bit of fuel hose between the rear section that I'll have to make. Clean/paint them for future protection and away we go.

                              The suspension is surprisingly good too. surface rust abounds as you'd expect, but everything has come apart OK and is totally re-usable other than the darn outer half-shaft bolts. I'm thinking I may grind one face of the nuts till the threads of the bolts are visible and then try to un-do or snap them while they're red hot and weak. Just want to try to save the bolts themselves at it looks like 8 will end up being 100$+ if I need new ones due to the special shanked bit.
                              They are a very high grade nuts as well and thinner than standard. i WOULDN'T grind. I've always been successful with heat. Dull cherry red then quench with WD40. Before you start make sure you have a good 6pt. box end wrench that completely engages. I have one that is specially ground down on the outer circumference to clear the axle yoke. With them out of the car it may not be as critical if the shafts bend away further. Shock the wrench with a hammer to loosen. Steady pressure doesn't work.
                              Work the nut back and forth once it starts, and keep dowsing the thread by the lock nut with WD

                              good luck!
                              Last edited by Ont240; 06-22-2020, 12:12 AM.

                              Comment


                              • Originally posted by Ont240 View Post

                                They are a very high grade nuts as well and thinner than standard. i WOULDN'T grind. I've always been successful with heat. Dull cherry red then quench with WD40. Before you start make sure you have a good 6pt. box end wrench that completely engages. I have one that is specially ground down on the outer circumference to clear the axle yoke. With them out of the car it may not be as critical if the shafts bend away further. Shock the wrench with a hammer to loosen. Steady pressure doesn't work.
                                Work the nut back and forth once it starts, and keep dowsing the thread by the lock nut with WD

                                good luck!
                                Thanks for the advice! I'll definitely give that a go first, will need to pick up a 6pt 14mm wrench or two. At worst if I need to grind the nuts off I've found them for sale for about a dollar each at a couple places (actual OEM ones, correct part number etc,), so as long as I don't damage the actual bolts with the grinding, I can put everything back together with the correct hardware for pretty cheap.
                                Last edited by Noll; 06-22-2020, 12:32 AM.

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