G28 - Simple Mans, Simple REDO of an G28 LP640

[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.

[Simple Man]

The doors are challenging!  Good work, love the build. 

Thanks FC!!

[Footcutter]

The doors are challenging!  Good work, love the build. 

[Simple Man]

**CAUTION * the following images may be disturbing to some viewers *** 


 

Next on the REDO are the Doors 

The doors on the REDO worked.  It appears the doors were put on the car before the windshield was fitted.  The PO had cut the Drivers A pillar and roof so the doors would go up and down.

If you put a windshield in place, the drivers door could not close.  So the A pillar width was increased to allow for the proper gap on passenger and drivers side.

Here are the REDO's doors......

[Simple Man]

Started to make the windshield cowl drip piece, but it turn into a mold.   

For me it was easier to sand, dura glass and rage filler the mold and get it to fit just right.  Another plus is when I use a mold, I am way more consistent in resin and CSM usage.  Plus the finished surface is nice  and smooth with the Gel coat.   

Gotta make the holes for the wiper, also have to do the final adjustment to the piece so it matches the black windshield border better

[Simple Man]

Got the machined Rear knuckles in and installed.  The Arruat design flaw is solved and the car is a roller.

New 250 lb 10" Spring also installed in the front.  My custom front sway bar is still in not here.

Only one more issue in the Arruat system, (knock on wood).  Its the holes for the bolts in the bushings that are for the rear links, are too big.  This allowed a little play in the the rear tires.

So Its either a new bushing or a sleeve insert.   
Need 3 for each side.