LouKoff Posted May 29, 2016 Author Share Posted May 29, 2016 Just waiting on parts for the engine to be reassembled. Expect some engine pics in about 3 weeks when my pistons are supposed to get here. In the meantime I've been working on the body to try to get it as close to ready for paint as I can before I get the engine ready to go. I've got a lot of body work and metal forming to do to fix all the dents and rust on the body, fenders and doors. I cleaned up floor underneath the cab and go it and the transmission tunnel undercoated. Undercoated by Luke Hoffman, on Flickr Trans tunnel undercoated by Luke Hoffman, on Flickr Body work pics Removed windshield by Luke Hoffman, on Flickr Passenger side body working by Luke Hoffman, on Flickr Drivers side body working by Luke Hoffman, on Flickr 2 Link to comment Share on other sites More sharing options...
LouKoff Posted June 7, 2016 Author Share Posted June 7, 2016 Working on tackling the exterior rust and other random stuff. Getting anxious to get it painted and driving so I've been working on it a lot. Here are some pictures of the progress, I've been drilling out spot welds and cutting out the bad and shaping new pieces to weld in, cleaning up the inside and spot welds with a grinder, flap disk and wire brushes, and doing any little pieces that need to be replace in area inside the panel, then coating the inside with a few coats of cold galvanizing compound. Then I take the piece I cut and make a rough outline/template to cut a new place of flat sheet metal to shape a piece to replace the panel the was cut out using a sandbag sheet metal break hammer and dolly and a small stump. Once I'm satisfied with the shape I trim the piece to size and work on little tweaking with the panels and final planishing with the hammer and dolly then coat the backside of the piece with the cold galvanizing compound. Lots of part have been arriving. I have the bearings new water pump and I think I have all the gaskets I need for the engine and carbs, except two gaskets I have to cut out of gasket material for the carburetors base gaskets because I cant find any single ones online and don't feel like buying two more carb rebuild kits to get two gaskets. Waiting on pistons to start assembling the block. Both carburetors have been thoroughly cleaned, reassembled and ready to go back on the manifold once I figure out the carb base gaskets. I made an egr delete plate for the manifold too. Got some new tires for the peugeot alloys, they're 185/70r14 Nexen CP661s and they look pretty good, especially for $40 a tire. I cleaned up the block, removed the studs, and had the cylinder bores honed. Some of the studs were pretty rusty and pitted or bent so I will be using the best ones from the ea71 and ea81, looking at the studs it looked like both the engines had already gotten some new studs. I've also been working on cleaning up and painting miscellaneous pieces from the engine and engine bay that were rusty or tarnished looking. Passenger Rocker pre cut by Luke Hoffman, on Flickr passenger arc by Luke Hoffman, on Flickr Drivers rocker pre cut by Luke Hoffman, on Flickr Drivers Rear Pre-cut by Luke Hoffman, on Flickr Drivers rear post cut by Luke Hoffman, on Flickr Passenger Rocker by Luke Hoffman, on Flickr Passenger arch coated by Luke Hoffman, on Flickr Passenger Rear by Luke Hoffman, on Flickr Passengerer Rocker formed by Luke Hoffman, on Flickr Driver Rocker by Luke Hoffman, on Flickr Drivers Rear by Luke Hoffman, on Flickr Result of Wet mouse nests by Luke Hoffman, on Flickr passenger rocker by Luke Hoffman, on Flickr Coated by Luke Hoffman, on Flickr D Rear by Luke Hoffman, on Flickr Fresh Rubber by Luke Hoffman, on Flickr Block sitting pretty by Luke Hoffman, on Flickr Manifold almost ready to go back together by Luke Hoffman, on Flickr Missing gasket by Luke Hoffman, on Flickr Carbs looking good by Luke Hoffman, on Flickr 2 Link to comment Share on other sites More sharing options...
LouKoff Posted June 14, 2016 Author Share Posted June 14, 2016 Been doing a lot of random stuff trying to tackle little things so they don't hold me up later. Here are some pictures of some of the patch panels welded in. I will clean up the welds more later when I'm getting the car ready for primer and doing body work. Painted lots of engine parts and the driveshaft. Next up is the radiator and continuing to work on the rust and welding in more "new" panels. passenger arch welded by Luke Hoffman, on Flickr passenger rocker welded on by Luke Hoffman, on Flickr Passenger side almost done by Luke Hoffman, on Flickr 1 Link to comment Share on other sites More sharing options...
biffanyus Posted June 14, 2016 Share Posted June 14, 2016 Looking good.. keep the progress coming... Link to comment Share on other sites More sharing options...
dielinde Posted June 19, 2016 Share Posted June 19, 2016 Nice ride waiting for the next update Link to comment Share on other sites More sharing options...
LouKoff Posted June 27, 2016 Author Share Posted June 27, 2016 Only made it out to the cabin for two days the past two weeks so not much progress, but I did work on trying to finish up my custom moped made with fire extinguisher tanks I found in the garbage. While not working on the brat I painted the frame, sewed up a seat, and started putting the thing back together, ported and rebuilt the moped engine. But I will be going up for a long weekend for the 4th and should be able to get a lot of work done! Here are some pictures of the body work progress. Driver Fender Welded by Luke Hoffman, on Flickr Fender Repair by Luke Hoffman, on Flickr Driver Rocker Welded by Luke Hoffman, on Flickr Drivers Rear Rocker by Luke Hoffman, on Flickr I also got 4 of these in the mail. Piston by Luke Hoffman, on Flickr piston by Luke Hoffman, on Flickr 1 Link to comment Share on other sites More sharing options...
LouKoff Posted July 2, 2016 Author Share Posted July 2, 2016 Little update of the rust repair I got done yesterday. Driver Rear Inner by Luke Hoffman, on Flickr Driver Rear Inner Finished by Luke Hoffman, on Flickr Driver Rear Ready for Welding by Luke Hoffman, on Flickr Driver Rear Welded by Luke Hoffman, on Flickr Driver Rear Finished by Luke Hoffman, on Flickr Passenger Fender Top 1 by Luke Hoffman, on Flickr Passenger Fender Top 2 by Luke Hoffman, on Flickr Passenger Fender Top 3 by Luke Hoffman, on Flickr Link to comment Share on other sites More sharing options...
LouKoff Posted July 3, 2016 Author Share Posted July 3, 2016 Todays Progress Got the Passenger Rear Corner finished. Passenger Rear Arch 1 by Luke Hoffman, on Flickr Passenger Rear Arch 2 by Luke Hoffman, on Flickr Passenger Arch Welded by Luke Hoffman, on Flickr Passenger Rear Corner 1 by Luke Hoffman, on Flickr Passenger Rear Corner 2 by Luke Hoffman, on Flickr Started to work on the Drivers side rear corner as well. Found more rust after cutting so that set me back a bit, but I have all the peices formed just need to trim and weld. Driver Rear Arch Cut by Luke Hoffman, on Flickr Driver Rear Arch Coated by Luke Hoffman, on Flickr 1 Link to comment Share on other sites More sharing options...
LouKoff Posted July 4, 2016 Author Share Posted July 4, 2016 Finished up the rust repair on the drivers side rear corner today. Welded in new for the inner skin of the fender, cut the rocker open, cleaned out the mouse nest and dirt the was inside, coated all the inside paneling with cold galvanizing compound, then welded everything up. This side didn't turn out quite as clean as the other fender but it'll clean up nicely with some filler. Next up for repair is fender and doors, but I got a lead on a brat at a scrapyard so hopefully I can run out there and snag some rust free fenders, and a dent free door. Not going to be at the cabin for a few weeks so I'm going to bring those fenders back home with me to work on in case the scrap yard brat is no good. Also in the mean time I will be working on reassembling the engine, went to the auto store and picked up all the gasket sealant, and assembly lube I need to reassemble the engine and I also picked up some gasket material to make the missing carb base gaskets I need. Here are some pictures of the work I did today on the drivers side rear corner. Driver Rear inner Welded by Luke Hoffman, on Flickr Driver Rear Inner Coated by Luke Hoffman, on Flickr Driver Rear Outer Welded by Luke Hoffman, on Flickr Driver Rear Rocker Cut by Luke Hoffman, on Flickr Driver Rear Arch 1 by Luke Hoffman, on Flickr Driver Rear Arch 2 by Luke Hoffman, on Flickr 1 Link to comment Share on other sites More sharing options...
LouKoff Posted July 6, 2016 Author Share Posted July 6, 2016 Went to the junkyard with the brat today and picked up the fenders and some other little things like the plastic box for the glove compartment a blue door panel and the dash vents. It was a shame to see a brat with such an extravagant paint job so far gone, I bet it was sweet in its day. Because the fenders are much better than mine and need no rust repair so next up is fixing some rust on the door corners and body work then primer and filler. Here are some pic of the brat I got the fenders from with its 80's radness. Junkyard Brat by Luke Hoffman, on Flickr Junkyard Brat 2 by Luke Hoffman, on Flickr Junkyard Brat 3 by Luke Hoffman, on Flickr 1 Link to comment Share on other sites More sharing options...
LouKoff Posted July 10, 2016 Author Share Posted July 10, 2016 Finished up the rust repair today as well as a lot of metal bumping on the fenders I picked up the other day. This means the car is almost ready for primer. Driver Door Corner Rust by Luke Hoffman, on Flickr Driver Door Corner Cut by Luke Hoffman, on Flickr Inner door skin was also rusted so I made a new piece for that as well. Driver Door Inner by Luke Hoffman, on Flickr Driver door repaired by Luke Hoffman, on Flickr Passenger Door Corner Rust by Luke Hoffman, on Flickr Passenger door repaired by Luke Hoffman, on Flickr Driver Fender Pre Work by Luke Hoffman, on Flickr Drivers Fender Roughed Out by Luke Hoffman, on Flickr Passenger Fender Roughed out by Luke Hoffman, on Flickr Front end by Luke Hoffman, on Flickr 3 Link to comment Share on other sites More sharing options...
dielinde Posted July 10, 2016 Share Posted July 10, 2016 B) Looks sweet. What colour will you paint Link to comment Share on other sites More sharing options...
BratRod Posted July 11, 2016 Share Posted July 11, 2016 Your metal work is pretty good. Did you ever compete in Skills USA in High school? Link to comment Share on other sites More sharing options...
iluvdrt Posted July 11, 2016 Share Posted July 11, 2016 Great job on this, I am envious of your body skills. Please keep us updated on how things continue to develop! 1 Link to comment Share on other sites More sharing options...
LouKoff Posted July 12, 2016 Author Share Posted July 12, 2016 Plan is to paint it a lighter metallic maroon. Never heard of skills USA before although it sounds fun, actually the only other metal/body work I've done is a few panels on a 1984 Toyota Supra. Link to comment Share on other sites More sharing options...
Wiclipse95 Posted July 28, 2016 Share Posted July 28, 2016 Impressive work, I really like the way it's turning out! Link to comment Share on other sites More sharing options...
BratWarrior Posted July 29, 2016 Share Posted July 29, 2016 How did you go about cleaning the underbody and undercoating it? Link to comment Share on other sites More sharing options...
LouKoff Posted July 30, 2016 Author Share Posted July 30, 2016 To clean the underbody I used a scrapper and hammer and chisel then wire wheels to get rid of most of the old cracked undercoating, touch up any rust with a grinder or the wire wheel, prepped everything with wax and grease remover or whatever I had laying around, primed and painted then undercoated with 3M undercoating. Lots of time underneath the car and a pretty dirty job but its worth it to keep the underbody from rusting. 1 Link to comment Share on other sites More sharing options...
BratWarrior Posted August 1, 2016 Share Posted August 1, 2016 To clean the underbody I used a scrapper and hammer and chisel then wire wheels to get rid of most of the old cracked undercoating, touch up any rust with a grinder or the wire wheel, prepped everything with wax and grease remover or whatever I had laying around, primed and painted then undercoated with 3M undercoating. Lots of time underneath the car and a pretty dirty job but its worth it to keep the underbody from rusting. Awesome. I'm hoping to do the same thing. Thanks! Link to comment Share on other sites More sharing options...
LouKoff Posted September 5, 2016 Author Share Posted September 5, 2016 Been trying to get everything ready for prime, almost there. I tried for weeks to get the torsion bar out with no luck so I decided to bite the bullet and drop the whole rear end. While the gas tank and diff are still out I'm going to clean up the rust and undercoat from the cab back so the underbody will be completely undercoated. After I got the torsion bars lose I lowered the back to where I want it to sit. Trying to get this thing painted before winter so I'm gonna have to wait on lowering the front. Under bed by Luke Hoffman, on Flickr Under bed 2 by Luke Hoffman, on Flickr hover brat by Luke Hoffman, on Flickr Rear lowered by Luke Hoffman, on Flickr From the back by Luke Hoffman, on Flickr 1 Link to comment Share on other sites More sharing options...
LouKoff Posted October 2, 2016 Author Share Posted October 2, 2016 Well I got most of the car primed over the past two weekends, didn't have time to clean up the bed or tailgate and some other small parts. It was my first time painting anything bigger than a bike and I think it turned out pretty well. The primer I used was Spi red oxide epoxy. Made a little makeshift paint booth out of a harbor frieght car shelter and some tarps, masked off the bed and the doors and windshield. Rear End Masked by Luke Hoffman, on Flickr Masked off the engine bay and windshield. Front End Masked by Luke Hoffman, on Flickr All primed and unmasked, ready to come out of the makeshift paint booth. In the booth by Luke Hoffman, on Flickr Turned out pretty good and I'm gonna put it back together so I can do some body work. Primed by Luke Hoffman, on Flickr Somethings missing here but it's starting to look more ready. Bay primed by Luke Hoffman, on Flickr 4 Link to comment Share on other sites More sharing options...
TheLoyale Posted October 4, 2016 Share Posted October 4, 2016 Turned out great from the photos! What are you doing with the Bed finish wise? Link to comment Share on other sites More sharing options...
LouKoff Posted October 4, 2016 Author Share Posted October 4, 2016 (edited) I plan to prime and paint the bed the same as the rest of the car with removable carpet like how it came from the factory. I would've primed it with the rest of the truck but I want to clean up the rust a little better than I had the chance to and wanted to prime it while the weather was still good. Edited October 4, 2016 by LouKoff Link to comment Share on other sites More sharing options...
LouKoff Posted February 27, 2017 Author Share Posted February 27, 2017 Tore into the heater and found a huge mouse nest on top of the heater core. This is after I took out the nest, forgot to get a picture of the thing this time. Heater by Luke Hoffman, on Flickr Replaced all the foam and painted all of the flaps in the heater, got the heater core flushed and pressure tested and painted it too. New Foam by Luke Hoffman, on Flickr All back together HVAC back by Luke Hoffman, on Flickr HVAC front by Luke Hoffman, on Flickr My cam had some bad pitting so I got a hydro cam and got a cam grind from Delta cams. I also had the crankshaft polished. Crank and Cam by Luke Hoffman, on Flickr Got the block resurfaced as well. Resurfaced block by Luke Hoffman, on Flickr Had an issue with some of the piston rings I got sent having too large of an end gap, waiting on a new set and then the engine will finally be going back together! 1 Link to comment Share on other sites More sharing options...
83subaruGLchick Posted March 3, 2017 Share Posted March 3, 2017 This is amazing! Great work cant wait to see it done! Link to comment Share on other sites More sharing options...
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