Project Pesto

[SPG]

19 hours ago, Hammer said:

Great thread, thoroughly enjoyed reading through this, great work. Nice to see another one being saved. I'm in the middle of doing mine so it's nice to have a look at the issues you are facing and comparing those with my own findings, I'll sort out a thread at some point. I like what you've had done with the wheels, they'll look great. Really looking forward to your progress with this. 

Thanks buddy, I’ll keep an eye out for your thread, hopefully you don’t have as much bother with your car as I’ve had with this one .

14 hours ago, Herb said:

The wheel color choice is fantastic! Should have come stock like that!

I agree Herb, really unsure why they also had black centres previously, as it was an unnecessary eyesore. 

1 hour ago, evinX said:

Been a while since a mad project has been posted. Looking foward to more updates

Hopefully we see more threads being posted soon, the new site makes uploading pictures a doddle and I can imagine it might have deterred previous thread starters from posting. Mawbs certainly delivered . 
 

Metal work is up shortly, as well as the underside clean up so stay tuned.

[SPG]

Quick shout out to Paul Pridham @TCB Performance for supplying all the OEM parts for the car. 
 

Paul has very reasonable prices and is very knowledgable, I’ve often called him with an elaborate description of what part I need and he usually manages to work out what that means in plain English . 
 

I ordered all the windscreen seal, rear screen seal, boot rubbers, various clips, bolts, bonnet catches etc etc from TCB and have always been happy with the prices and delivery. 

[SPG]

Okay so moving along to the repairs to the bodywork, and the most challenging section of the refresh. 
 

lots get right in to that problematic roof section, as you’ll recollect the passenger side hinge section looked very dubious. 
 

quick reminder of what we were working with: 

 

 

next up was understanding the standard frame/structure configuration, luckily the EPC is handy for explodes diagrams of the sections. After some digging I located the following to supply to ML. 
 

 

 

Then the stripping back was performed, to reveal the true extent of the damage. Fair warn it’s not pretty 

 

 

Rear hatch removed and rubber split grommet removed also, this is what it looked like. 

We can see from the picture above, there was also light surface rust on the rest of the hinge plinth, so the rest was taken back to the metal to be sure it wasn’t anything other than surface rust. 

 

Now fans of Terminator 2 will remember fondly that the T1000 took a grenade to the torso in the closing scene, this was clearly the Supra’s take on it 

 

Searching for inspiration and finding the light. As you can see, rear screen washer hose is holding it all together.  

 

This was after the top layer was inspected and lifted to reveal the bottom layer or underside of the hinge plinth. 

[Dnk]

Scary stuff but anything is fixable. Seen a few Range Rovers looking way worse

 

Great updates and good luck with it 

[SPG]

6 hours ago, Dnk said:

Scary stuff but anything is fixable. Seen a few Range Rovers looking way worse

 

Great updates and good luck with it 

Thanks Dunk I’ve got loads of updates just finding the time to upload them is proving difficult . 
 

 

[mwilkinson]

Any indication as to why it rotted so badly in that spot?

Was there a good bit of accumulated debris there trapping moisture?

[SPG]

Okay so the hinge was left to team ML to work out, I can’t profess to being involved with anything this skilled. 
 

Once the hinge section was stripped back, Martin marked up the section to be cut, and made a template of the original position. This would obviously have to be very accurate as otherwise the boot would bot align correctly.

With the old metal cut out, the lower section plate was offered up and tacked in place. There are other pictures of the process that I’ve missed out but this give you a good idea of the layers.

Next up the mounting point was positioned to check that the correct position was created. Martin did a fair bit of this in his head and I came up to watch him at work, and the guy was as cool as a cucumber. Me on the other hand, I was ready to call Keron for an uplift  .

 

Next up was the new mounting point, this had to be strong and the metal used was a lot thicker that the section below it. Martin luckily has just taken delivery of a much more industrial scale   guillotine which helped with the thicker material. 

 

New mounting point ready to weld in, 

 

Shapes and welded in place.

Etched primer applied on each section. 

 

Metal cutout from pic one used to make up the third and final piece with is the overlay section/water channel.

New section offered up and shaped before being welded in place. 

Nice little shot of the cardboard template above and the new panel below. 

 

This was the patch that had rusted on the roof section, it was cut out etched, and a new piece of metal was welded in. 

Old hinge used for the last time before being retired. Replaced with a good used spare. 

 

[SPG]

11 hours ago, mwilkinson said:

Any indication as to why it rotted so badly in that spot?

Was there a good bit of accumulated debris there trapping moisture?

Martin reckon it was the split grommet that let in the water, this water he believes collected or was absorbed into the headliner and over the years it’s caused the issue. 
 

I had this particular car parked on my parents drive as I didn’t have space at my house. Their drive is sloped and the car was reversed onto the drive. My theory is that the water has collected in the at water channel due to the passenger side nose being angled down and to the left with the gradient of the drive. That coupled with the split grommet, and that square patch we had cut out, all kinda made for a good recipe for corrosion. 
 

This car lived in Aberdeen with the last owner, and my parents also live not too far from the sea, so that’s air can get to the best of cars. 
 

Thats my 2p’s worth anyway .

[Thorin]

Yikes, that hinge section was nasty. Glad to see it being put right and not just being broken for parts. I also love all these progress pics.

[Pudsey]

Looks like a great job in a difficult fiddly location.

I bet you felt much better about it, once you saw the bad bits cut out.

 

[Herb]

People that can repair that hinge area like that are like artists to me!

Incredible work.

[SPG]

5 hours ago, Thorin said:

Yikes, that hinge section was nasty. Glad to see it being put right and not just being broken for parts. I also love all these progress pics.

Certainly agree, never seen anything like it on any of my Supra’s. I really don’t like breaking a good car if it can be saved. I have broken a TT6 around 6years back, but I was always buying that as a parts car and bought it already crashed. This on the other hand was in need of some love . 
 

funnily enough I’ve kept the stripped shell and will be recommissioning it at some point in the future for racing, so it’s not a total loss. 

2 hours ago, Pudsey said:

Looks like a great job in a difficult fiddly location.

I bet you felt much better about it, once you saw the bad bits cut out.

 

Honestly once I saw what light work Martin made of that section, I knew anything was possible and it really got me fired back up and interested in the push to make it right. 

1 hour ago, Herb said:

People that can repair that hinge area like that are like artists to me!

Incredible work.

I’m also amazed at the way Martin managed to repair this, and how relaxed he was about tackling it. I’m sure he’s seen a few challenging jobs over the years whilst working on E-Types and other various classics. 
 

It was great to see he had the love for the Supra, as when compared to some of the metal he works on, the price and rarity factor of the other cars far outweighs that of the Sup. 

[evinX]

Cant believe the times we have reached with supras and the work they are needing now. Just the other day i was 16/17 years old and getting clean shells for small money. Nice work!

Edited November 27, 2020 by evinX (see edit history)

[Annabella]

Artisan. If that can be rescued then many more can be, bet he's a busy man.

[SPG]

14 hours ago, evinX said:

Cant believe the times we have reached with supras and the work they are needing now. Just the other day i was 16/17 years old and getting clean shells for small money. Nice work!

I’m sure this one is probably a little more crusty than the general supra population, but there will be a few horror stories hiding behind things like OEM skirts in the years ahead etc. 

4 hours ago, Annabella said:

Artisan. If that can be rescued then many more can be, bet he's a busy man.

He is really busy all of the time, understandably so, very talented and down to earth.
 

 

[SPG]

Okay so sticking with the metal work theme, next up were the Sills and a naught surprise hiding behind the OEM side pod that left me thinking “Strewth” can you guess why . 

I’ll update this post with more pics, that’s lunch over...

 

Here’s a closer look at the problem section behind the side pod. Perhaps a rare factory double air duct option . 

 

All the surface rust on the inside was taken back to the metal and treated before the rust proof primer went back on. Martin invited me up to check the box sections and the inner structure to be sure that I was happy with the rescue work he and the team performed. There was also some surface rust on the rear arch vent section, you can see a run from the top right side of the cut, this was also taken back to see if anything was requiring a fix, at this point I was happy to sign off on most repairs as I was confident it was not being over looked. 

 

The rusted outer sill cut out, looks a little Australia , almost as big also .  

 

Where it belongs.

Just after the cut out was performed, offending scrap on the floor. 

 

The new metal cut and shaped to follow the original lines, this pics shows it being held in place with magnets. 
 

 

Once happy, Martin tacked the new metal into place.

Fully welded now, and ready to be smoothed in with a grinder

 

Rust proofing on top, and then a light skim over in the last pic. 

 

[Hamilton]

1 hour ago, SPG said:

Okay so sticking with the metal work theme, next up were the Sills and a naught surprise hiding behind the OEM side pod that left me thinking “Strewth” can you guess why . 
 

I’ll update this post with more pics, that’s lunch over...

Wow, that looks worrying. Didn't know know some Supras came with an extra side pod!

Really enjoy these updates- seeing a Supra slowly get resurrected is incredibly satisfying. 

[chaoticentity]

Have the interior of mine out at the minute and I'm treating exactly where those rust spots are but it's just barely surface rust on the inside of mine. I too am very much enjoying all the updates, good to see what people are doing to fix these problems when they've gone too far!

[SPG]

2 hours ago, Hamilton said:

Wow, that looks worrying. Didn't know know some Supras came with an extra side pod!

Really enjoy these updates- seeing a Supra slowly get resurrected is incredibly satisfying. 

I think the shock factor wore off after the hinge was fixed, after that it was a case of “hit me with it” . 
 

glad you’re enjoying it, it’s great being able to share it with the club. 

2 hours ago, chaoticentity said:

Have the interior of mine out at the minute and I'm treating exactly where those rust spots are but it's just barely surface rust on the inside of mine. I too am very much enjoying all the updates, good to see what people are doing to fix these problems when they've gone too far!

I know I keep saying it, but there are loads of updates still to come, so keep an eye out for updates. 
 

I've loved the whole process, it’s been unnerving at times but a lot of fun.  

[SPG]

More metal work on the sills, from the earlier testing of the sills integrity. We also used a scope to look behind the solid sections to make sure we didn’t have anything lurking. 
 

 

Okay so what you see here is the Nearside outer sill, there were 2 sections that needed removing from this section, although they were smaller than what we replaced due to the closeness in proximity of each weakened area. 

 

This picture shows the back and the front section of the sill.

Offending areas were cut out and again the new metal was cut shaped and prepared for entry.

As I mentioned the sections behind, inner sill were not bad at all thankfully but to be safe Martin and the team prepped, rust proofed and prime red over each section. 

 

Working in the curvature to suite the replacement section. 

 

This is the back side of the new metal, same process for preventative barrier.

  

Section buffed back to great the contact area for the welds. 

 

New rear sill metal section held in place again with magnets ready to weld into place.

Front nearside repair section, same process really as the rear section, just a slurpy larger area. 

 

Again the inner sill was in good shape, a little light surface rust was forming so a great time to catch it. Area ground back treated and protected as per the previously mentions process. 

 

Etched primer applied, ready I offer up the new metal. 

 

New shaped metal inserted and welded into place. I don’t have a picture but it was welded in, and ground back and treated before it was smoothed over with a light skim of filler. 

 

Last look at the inner sections before being sealed up. 

 

The Offside sill was next on the agenda, but that had only one section to repair, again checked with the scope and when the corroded section was cut open. Pics to follow shortly. 

 

[bradleyh_15]

Some top repair work there, well done and top effort saving this supra

[SPG]

17 hours ago, bradleyh_15 said:

Some top repair work there, well done and top effort saving this supra

Thanks Brad, a few more repair to come but the fact that another is saved makes me feel better about the outlay . 
 

 

[Dnk]

Nice work

 

Got to make you think how many are nightmares waiting to happen 

[mellonman]

Nice to see you bringing it back. Great work reminds me of the first episodes of project pinky with all the metal plates 

[SPG]

11 hours ago, Dnk said:

Nice work

 

Got to make you think how many are nightmares waiting to happen 

I’d certainly encourage and one with the carpets already up to pop a dope into the box sections, fairly easy thing to do if you have access to the tool.

10 hours ago, mellonman said:

Nice to see you bringing it back. Great work reminds me of the first episodes of project pinky with all the metal plates 

It’s been a massive learning exercise and I’ve been lucky enough to be able to watch at the repairs were being done and more importantly to check the condition of the inner sills and box sections myself before dealing back up. Should give the old girl a longer life hopefully.