Project Pearl

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Re: Project Pearl

Postby DeeCee » Sun Jul 05, 2015 7:59 am

4 July 2015

Have bothered to dedicate some time to Pearl while my fibrglass guards dry. I have a list of things to do and so time to tick them off and get Pearl back on the road.

Main mission is to fix up the exhaust system due to the issues previously mentioned, and while I was under the car, Nick worked on the front end. I got him to move the sugar cube around due to some clutch change issues. Here is the wear on the cube.
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Nick also started drilling the various holes in the bumper for mounting.
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I finally got the exhaust out.
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As you can see, the previous owner removed the resonator and left a big mess.
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And here is the aborted attempt at cutting through the pipe just after the muffler.
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I was rounding the nuts-bolts which held the muffler sections together. They were well and truly rust solide. I had to take an angle grinder and cut sections out to get the nuts and bolts out.
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Removed the rear brace under the diff yoke. Took a while and a lot of torque due the bolts being corroded. With the muffler out of the way, I managed to get some lube on to the bolt threads from the reverse and worked the bolts in and out to clear the rust debris between the threads. Cleaned up the bolts and the threads in the subframe once the bolts were out.
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Time to fix the wiring over the head. Originally the wiring loom was just wrapped up in electrical tape. I removed the tape and cleaned up the wiring a bit using some wax and grease remover.
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Then I positioned the wiring into the spare loom plastic I pulled from an NA at the scrap yard.
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And now the wiring is neatly routed
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During the day we did some minor checks for the warrent of fitness (WOF).
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Re: Project Pearl

Postby DeeCee » Sun Jul 05, 2015 8:00 am

5 July 2015

Today was spent cleaning up the interior and doing minor stuff.
- Tightened down the spoiler and the boot trim on. Was missing some clips for the plastic nearest the hinges as they had rusted out, so I'll need to find some extra clips.
- Put a rubber washer (again scavanged from the scrapyard) under the rear washer nozzle as that was the cause of a leak into the boot.
- Started reassembling the interior at the rear of the car.
- Vacuumed the seats of the dog hair which was embedded into the fabric. Undecided if I will bother steam cleaning, may do as Nick has a steam cleaner.

Nick kept reassembling the front end, doing minor spray and touch ups. He connected up the horns, they didn't work. Relay was clicking so he made a new loom and beep beep, they work. He painted the welded guard panels for some protection with some 040 white spray paint. Looks a bit naff next to the pearl white, but at least it is protected. He fitted the guard and liner on the passenger side.

Front end is looking a lot better though
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Interior is also coming together.
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Nick noticed a broken wire on the AFM plug. I disassembled the plug so I could do a solder repair, but the copper is too corroded so I'll have to find a new plug *sigh. More and more minor issues.
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Re: Project Pearl

Postby bmt » Sun Jul 05, 2015 9:56 am

Jeez Dave didn't realize you had ANOTHER project Celica! Glutton! For punishment anyway.

Next time you are getting welding supplies get 10 sticks of Silicon bronze either 1.6mm diameter or 2.4mm diameter. It melts at a low melting point and makes tig tacks/welds super easy on thinner mild steel and is of a good enough strength for a filling a few spotwelds. It's more expensive so it's kind of a back up plan kind of thing. It's excellent for galvanised material. Ordinarily I'd mig them but if it isn't an available option and the material is bit too crappy or thin for mild steel wire then give it a go. Oh one more thing you can't weld over it with mild steel wire after it's in!
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Re: Project Pearl

Postby DeeCee » Sun Jul 05, 2015 10:07 am

Haha - yes Bruce, I have had an RC since last year. Thanks for the tips on the silicon bronze. I do have a mig, but I don't have a bottle or reg - on the 'to purchase' list if I bother to keep the mig around. Tig does me fine, but I should have done the repairs using a mig as I wouldn't have introduced so much heat and blown a couple of holes. Oh well, I'm just trying to save an RC, so I'm not super worried about a top end job with the prices of RCs nowadays.
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Re: Project Pearl

Postby Dan McBoost » Sun Jul 05, 2015 2:54 pm

Looking great. Very inspirational work!
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:38 am

It's been nearly a year since I've done an update.

Been pretty busy with work and while I do work on the cars on occasion, sometimes it's pretty hard to get to writing out updates to my normal level of detail as they can be quite time consuming.

Had some very good progress recently, so I thought I'd better provide some updates.

6 July 2015

So a quick attempt at a solder job left me with less copper than I started with. Rather disappointing really.
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Taking some Project Elephant wiring, I found a plug wire connector which was the same as the AFM plug wire with the same wire colour and trimmed back the AFM wire.
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Then after measuring the wire lengths, I crimped the wires together. The crimp was then covered with heatshrink, wire connector inserted back in to the plug and loom wrapped back up.
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As I posted in Project Elephant, I got the GT4A back from the panel beaters on the 10th July. Understandably, it meant Pearl needed to be stored outside.

19 July 2015

Spent some more time on Pearl testing electrics.
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Last edited by DeeCee on Sun Jun 12, 2016 11:05 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:39 am

August 2015

Sometimes I have to head up to get parts for Pearl. Found this monstrosity. I wasn't able to get many parts this time around.
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Being under the car, I found that the engine was sitting lower than it should be, allowing the gearbox transfer case to sit on the front cross member. Got some new engine mounts to fix that.
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Decided to sort out the exhaust system. I did consider getting an ebay special, but after some research and learning about fitment issues, I decided to fab up my own exhaust system.

A friend of mine had a parts car which I was able to get a free custom 2.5" fabricated exhaust system from. I had bought a RPS muffler for $70 for this project, but with the cut up exhaust system, I had the opportunity to make up something a little more special.

I ended up having to get under this GT Four and cut the exhaust system out as the exhaust shop had welded it in, without flanges. Annoying to say the least, but hey, when it's a free exhaust system, you can't be too fussy in some work to get it.
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23 August 2015

Time to get some new engine mounts in. Stock replacements only, couldn't justify Toyota new or solid urethane bushes.
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As you can see, the old mounts look pretty worn out.
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Pulled the engine subframe and cross member out and gave them a scrub and clean
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Look much better
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Old mounts vs new
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Last edited by DeeCee on Sun Jun 12, 2016 11:07 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:42 am

25/26 August 2015

Exhaust clean up time. As I had to cut that exhaust system out of the parts car, I had to clean up and start planning how to get it in installed in Pearl
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As you can see, it was weathered and they had mig welded everything together
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And I had to make my own little mess of the piping which needed to be cut off
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Interesting that they had crushed the pipe, press fitted, then done a lap weld vs a butt weld.
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More mig welding to clean up / remove
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Taking a stripping disc, I started cleaning up the exhaust system. I was pleasantly surprised to find the pipe still in good condition. Nice thickwall pipe was used.
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Side by side comparison of the mid pipe
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So I'm the Vice President of the New Zealand GT-Four Owners Club. The Club president came down for a weekend and I got him around to Nick's place to visit Pearl and Elephant. He was loving the fibreglass parts! Couldn't believe how light the bonnet was!
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Last edited by DeeCee on Sun Jun 12, 2016 11:08 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:43 am

September 2015

More exhaust stripping and clean up.
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For ease of installation of the exhaust back in to Pearl, I decided to add flanges to the exhaust. I took the time to measure the location of the flanges relative to the original exhaust.
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Tig time..
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Not too bad a job
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Took me quite a while to get the angles of the exhaust correct.
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Had to cut sections and weld the length and angle back in.
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Last edited by DeeCee on Sun Jun 12, 2016 11:10 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:43 am

October 2015

As Pearl is at Nick's, I had to load up the wagon and get my tools over. Lots of crawling underneath the car on cold and rough concrete, moving exhaust pipe and flanges around to get the correct fitment.
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As you can see, getting the rear exhaust big bore in the right position meant a S bend.
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And some manipulation on the axle stands
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Spacing the custom mid pipe was a bit of a pain, especially as it wasn't exactly the same shape as the original.
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Slowly but surely, the exhaust system came together. And yes, all done outside. Spot weld bits in, disassemble, run some beads and reinstall. This happened A LOT!
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Some times I got a fine day, so was able to progress. Sometimes I was working late in to the night, wearing thermals and trying to push through. This was a half decent day. Too many parts..
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More tig work
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And finally finished. A spray of heat temp paint and all ready to go back in after a month of work.
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Exhaust tree.. everyone should get one haha. Back section getting some more welding done. Finish the flange to the centre muffler and weld on the support rods on the back big bore
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Last edited by DeeCee on Sun Jun 12, 2016 11:11 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:44 am

November 2015

Got the neighbour to skip the discs at his workshop for free. Used my old rear discs, but they were the wrong size for the RC. So many little differences
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Needed to get the bonnet, bumper and guards painted, so loaded up parts and took them to the panel beater.
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And why is the RC called Pearl? Because of the pearl paint :)
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Needed to repair the drivers seat. I found a Celica up at Pick A Part with the confetti pattern, but the drivers seat was pretty crap. So I decided to take the passenger seat and swap material and possibly foam over.

Following pictures go through the disassembly and reassembly of the seat step by step. Will add little notes where I think appropriate.

Take headrests off.
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You're left with bracket attached to the main plastic cover
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Disassemble underside of seat
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Seat bolster and material destroyed from years of use
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Last edited by DeeCee on Sun Jun 12, 2016 11:12 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:45 am

Main plastic cover needs to be moved up to unclip from the seat back
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Remove the brackets first
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Note locations of the clips
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Back of seat and actuators to adjust the seat
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Remove hog pins. Note, all hog pins were pried apart for reuse later
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Pull through cable
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Remove hog pins which hold in the rubber hoses which hold the seat material in place.
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Unbolt the seat back
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Remove the ajustment dials on the side
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Use a screwdriver or two to pop the clips.
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Last edited by DeeCee on Sun Jun 12, 2016 11:14 am, edited 1 time in total.
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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:46 am

Remove the tilt handle
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Remove screw under the tilt handle
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Remove side cover
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Remove screws for side cover, belt buckle, undo seatbelt sensor wire
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Remove bolts either side to remove seat base
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Then you are left with the seat frame
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Remove hog pins to release seat base material
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Unlatch the plastic side and rear clips
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More hog pins to remove
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Now the base is free
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Last edited by DeeCee on Sun Jun 12, 2016 11:15 am, edited 1 time in total.
GT Four Adovansu "I want to enjoy the powerful and nimble agility behavior."

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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:46 am

Remove hog pins to side. Note, the rubber tubing holds the material in place. Remove hog pins, do not cut the rubber tubing.
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The seat back material is held in with metal rods using hog pins. Remove carefully and yes, they are a pain in the rear to reach.
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Seat back is 5.4kg with motors, no foam or material. Heavy suckers
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As I was swapping material from Passenger seat to drivers seat, here are photos of the passenger seat disassembly
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Last edited by DeeCee on Sun Jun 12, 2016 11:16 am, edited 1 time in total.
GT Four Adovansu "I want to enjoy the powerful and nimble agility behavior."

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Re: Project Pearl

Postby DeeCee » Sun Jun 12, 2016 10:47 am

Headrests. Remove screws inside rubber grommet. Note the different colours and length
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Pull plastic cover down
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Unclip plastic tabs
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Remove material
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Remove foam
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The seat back foam is the same between driver and passenger sides
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Obviously drivers side has actuators to control side bolsters and lumbar support. Doesn't mean you couldn't put in a drivers side seat back on to the passenger side if you wanted. Would just need another control box and loom.
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Seat back material has a rod at the bottom. Thread back through the vinyl
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Last edited by DeeCee on Sun Jun 12, 2016 11:17 am, edited 1 time in total.
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