G28 - Simple Mans, Simple REDO of an G28 LP640

[Simple Man]

Busy work week as trying to get ready for vacation,  but was able to get the flange made for the windshield area made, now just to trim it up and mount it.

[Simple Man]

Doors really take a super long time.  I always heard people talking about them but I didn't fully understand until I started doing mine.  You are making great progress on those.

Thanks Autopro!!   I hope to be where you on your build some day!!!   

[autopro]

Doors really take a super long time.  I always heard people talking about them but I didn't fully understand until I started doing mine.  You are making great progress on those.

[Simple Man]

I also need to add a flange for the door seal that goes under the windshield.   
The PO pretty much removed it. 

The passenger  flange seems pretty wide   

The driver side flange was cut down to a jagged edge, of about 1/8 - 1/4 inch. The passenger side has fiberglass that covers the metal A pillar.  The driver side is exposed metal, not sure what happened there 

Thinking about making one and screwing it to the metal.....   Will have to mull it over 

[Simple Man]

The driver side roof and A pillar were cut by the PO to get the door to shut.

I widen the A Pillar to get a windshield to fit. The Roof needed to be widen by about 1/2 inch and the flange for the door seal needed to be added.

The Passenger side was unmolested and I made 2 templates, one for the curve of the roof and one for the edge.

Drilled in to the drivers side to see how deep the rage gold" filler was. 1/4 inch or so.

Ground down to a solid surface,  used 1.5oz CSM to build it up and Dyna Glass. Will skim with rage to finish.

The door seal flange is still a bit wide but will adjust later.

[Simple Man]

Not sure what possessed me to make a mold of the inner door skin, but i did.  Not sure if I will use it still haven't decided on grafting a new section where the latch goes, or replace the whole thing.   All I can say is what a ton of work!  My hat goes off to you folks who make these!!

   

[Simple Man]

Keep with it.  I feel your pain...

FC,
Its a slow process for sure !

[Footcutter]

Keep with it.  I feel your pain...

[Simple Man]

So the problem with the driver door was the area by the side view mirror was tilted in on the new widened A pillar.

In between the metal door frame, (wrapped in CSM), that was welded to the hinge, and the fiberglass inner door, was a bunch of fiberglass resin. 

Using a saw, about 1/4 inch of resin was cut out.  You can see the gap that was left between the metal frame and the fiber glass door.  This is highlighted by the blue tape behind it.

A hole was drilled into the frame and a bolt/washer/nut was used to pull the fiberglass inner door in. Now the door doesn't rub on the widened A pillar  and open and closes nicely.

Call me crazy  but this door might be salvageable   

I still have the problem of the roof and door seal flange that was cut off so the door would close.  This needs to be added. 

The passenger side wasn't modified, so maybe this will be my guide to restore the drivers side.

Will have to ponder this and possible salvage, while waiting for parts to REDO the driver side.   

[Simple Man]

The threaded shaft on the wiper nozzles were a little short and was unable to use the bolt to secure the nozzles.    No way to drill a hole from the bottom so a nut could fit up into a counter sunk hole.  Had to drill a larger hole from the top.  Used a bolt with a washer and nut... marked at the right depth.  Then Dyna glassed from the top.  Kinda messy but should work... I hope    Will find out tomorrow

[Simple Man]

Nice!

thanks FC!!

[Footcutter]

Nice!

[Simple Man]

Trying to wrap the wipers up.  Added nozzles to the cowl. 

Thinking about putting the reservoir here. The reservoir will be up a little higher and set just under the trunk opening.

Made a bracket and will weld to the frame. 

Still have to run the wiring for the motor to the switch.

[Simple Man]

Toyota Yaris part numbers

[Simple Man]

Finished mounting the Wiper motor by counter sinking a bolt, for one of the attachment points and for the other a bracket was welded and then the linkage was secured by a bolt.

It is pretty solid

Drilled holes in windshield cowl drip piece.

See a few changes needed for the cowl piece but might have to go take a look at a real one.