JDM Import Rev 2 Turbo - 5SGTE build

[rossonza]

Got bored the weekend and took my sills back a bit to see where the spot welds are, i plan to drill them out and get the outer sill off soon (making interior repairs a bit easier).






Also dropped my oil...........




glad ive got a replacement engine coming.

[rossonza]

my steels turned up for the rear arch repair and for welding practice.



still waiting on my drill bit

[Gullzter]

Bloody hell, that's like a watered down choclotate milkshake!

[Gullzter]

Bloody hell, that's like a watered down choclotate milkshake!

[rossonza]

Bloody hell, that's like a watered down choclotate milkshake!

i know...didnt want to taste it to find out though........

[rossonza]

drill bits come... gonna tackle it sunday if the weather permits.

[rossonza]

started on the sill with my spot weld removal drill bit.



also started spraying another wheel in my spray booth (shed)

[craig]

Kudos buddy

[rossonza]

Kudos buddy

cheers mate... quite a way yet.

[rossonza]

drivers side outer replacement sill panel has been ordered from mr2ben off ebay. hopefully have the one side done soon

[Magic Beans]

I used these on Mule VII: http://www.ebay.co.uk/itm/NEW-SET-Toyot ... Swu4BV0iNs

Great quality parts and fit perfectly.

[rossonza]

I used these on Mule VII: http://www.ebay.co.uk/itm/NEW-SET-Toyot ... Swu4BV0iNs

Great quality parts and fit perfectly.

thanks mate, was tempted to make the internal bits myself. but will bookmark in case.

Wheels done:


And my outer sill arrived today, less than 24 hours after ordering!


going to offer it up to the existing sill tonight and figure out where i need to cut in the doorshut etc.

[rossonza]

Had my friends pop over last night so we had a look at the sill again.

New sill offered up:

I plan to drill the upper and lower holes for the spot welds ill be doing to hold them in place. then weld proof primer the whole thing.


Drilled out and started yanking on the outer sill its started to come away:


Then i drilled along the top spot welds and the sill started peeling back:


You can see the gap here between the inner panel and the outer sill:


Any ideas what this it at the back? looks like an old bulb holder to me (behind the radio), The car has had an alarm fitted previously, so wondered if its to do with that or something:


I also didnt realise the underneath of the outer sill has 1 or 2 spots along the underside of the car, so ill be drilling those out tonight hopefully. It was a great sound drilling thespot welds and hearing the panel pop as i went along [/list]

[thomp1983]

The yellowish plastic thing is a sensor it's part of the cars heater system, I can't remember if it's for aircon only cars or not

[rossonza]

The yellowish plastic thing is a sensor it's part of the cars heater system, I can't remember if it's for aircon only cars or not

thank you mate, i asked the guy i got the car off, supposedly its a temp sensor for the climate control. i cant say ive ever seen anything like it before

[rossonza]

got the cutting disc out today.



lower bit of outer sill dangling now ive drilled all the spot welds and cracked it apart from the lower inner sill


an old repair done badly. so after a clean up ill see what im working with


need to remove the drivers door to cut the remaining upper door shut sill section.

[rossonza]

Got to work on the engine removal last night, ran out of light but got a lot out of the way.

Priority sorted (tea):


Found some interesting wiring on my rear lights and electric aerial. The aerial mechanism is just floating around in the back quarter (couldnt see any obvious mounts on it):


ECU all disconnected and wiring pushed through:


Im about here now, However ive started fusebox removal and the clips on that are causing me pain lol.


also.... i cant believe how difficult it is to remove the intercooler. tempted to upgrade whilst its out. save me having to do it again.

pile of parts ive had to squeeze into my shed, trying to think of where i can put the engine when its out lol.

[rossonza]

My mates popped over to give me a lesson on welding and metal forming during the day yesterday. Im happy with the progress made.

What i started with:


Got to work on my first CAD (cardboard aided design) attempt:


transferred design onto my steel sheet and shaped/drilled holes for spot welding:


First piece welded in place and cleaned up a little bit:


test fitting the next piece of the puzzle:


unfotunately thats where the day ended, my retired neighbour came out and had a long rant about making too much noise etc etc. so we stopped about 6:30pm.

So next time, ive got 2 pieces to weld in place, make 1 more piece of metal, then onto welding the new full outer sill on then thats the drivers side done

[Draven]

If I were you'd i'd tell him where to stuff his noise complaint as it sounds like it was the middle of the day

[rossonza]

If I were you'd i'd tell him where to stuff his noise complaint as it sounds like it was the middle of the day

I like to keep the peace, but she was way over reacting. i think its more the fact she doesnt like an older car on axle stands being next to her shiny new ford kuga.

shes a retired dinner lady and home all day and night, so i cant win whenever i try to work on the car. I guess ill just have to get on with it and ignore her.