pbaines

PBaines 1977 Toyota Corolla KE30

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Uhh, well. two project, no worries.

 

I bought this off trademe a few months back, original EVERYTHING which was super cool, even have the original registration card from 1977 from Toyota Otago. Was in a family for years and years and sold the guy I got it from who had it for a few years but didn't do much with it. Came with two new front guards (taiwan made) they fit up ok too which is a bonus.

 

Plans. I will stick to them this time round!

-Convert to OG black interior, not a fan of the tan personally.
-Rebuild current 3K motor that's in it, or fire it up and see how it goes
-Do panel and paint myself. Learn along the way. Shell is super straight, few rusty spots as all these KE30's do but that's ok.
-Fit super cool accessories like Monsoons,  and every piece of chrome available (Which will usually be from a Hi-Deluxe KE30)

 

This picture is my inspiration, I am going to go with a similar deep blue also

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Anyway, here is the old bomb for now

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33329172124_e5c2fba5c4_o.jpg20170220-2017-02-20 17.14.42 by phillipbaines, on Flickr

 

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A few weeks later, I had got some goodies over from Malaysia. Included, Monsoons, rear window quarter shades, door/outer window chrome edging, all the black interior panels, black U Channel moulds, 3-spoke steering wheel. Just need to buy some black carpet and wait for the dash to come over as well as the door cards

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Now it'll go sit back in its hole until I drag it out to take more tan yuckness out

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Discussion:
//oldschool.co.nz/index.php?/topic/56136-pbaines-1977-toyota-corolla-ke30/

 

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So I have the week off and the parents went off to Brisbane for the week, what are the chances...
I've pinched their shed for the week so I can ho into this KE30 and get it all stripped down and see how far on I can get with it.

I went to Mitre10 and bought a wire wheel for the grinder as well as a stripping disc to get me underway. I should probably have just paint stripped it, but I still would have had to use the strip disc to get the remainders off, and this is the original paint so is super thin so will come off in no time.

 

So i bought the car in, chucked it on stands and took the exterior panels off

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Got the wire brush attachment out and cleaned this up in no time at all

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Probably the worse section of rust on the entire car.

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I gave it another once over

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Did the other side

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Got the stripper disc out and made quick work of the roof. surprising how bad the back aches doing this for a long period of time. Looks like I will have to have a skim of filler on the roof to fill in the pits from the rust 

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So. This is the rust I have to contend with on the car, for a KE30. This is nothing!

Front left underside.

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Right roof section

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Rear windscreen

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i was attacking the outside of the rear left when I noticed something I wasn't expecting to be honest. Some boggy.

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 Stripped it, looks like the only damage is along the ridge which is minuscule (just small pits) however the entire exposed section was bogged. strange.

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Another update tomorrow when I complete more!

 

 

Discussion:
//oldschool.co.nz/index.php?/topic/56136-pbaines-1977-toyota-corolla-ke30/

 

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So today I got the spot weld drill bit and attacked the front cowl with it, after a bit of persuading with a coal chisel for the front and the side, and a pry bar to undo any of the spot welds on the inside of the car it all popped off pretty easy! 
I think it took about 2 hours to get this off. Some of the spot welds were hard to see externally so I had to pry up the edging with the coal chisel to see between the steel and figure where the spot would be.

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I will have to get this cleaned up also. Possibly even undo all of the spots for this as well. 

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Will get this sand blasted I think

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As you can see, leaves etc have blocked up the drain holes so water has just sat in there and rusted it all up. I will have to cut this entire patch out, hoping to get a rust cut for this from OCA so will have to see how that goes. In fact I am probably going to be needing many rust cuts, however the problem is that all these KE30's suffer the exact same problems so finding good cuts may prove difficult!!

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Next I ripped the entire dash out, simple job. Next I will get some dry ice and get all of the sound deadening out and start on taking the paint off the doors. I will use paint stripper for this, just to see how I get on with that as strip discs aren't cheap when you are using one a day!!

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Hello daylight!!

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I did some more stripping of this side. I paint strip the rest

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Next time:
Sound deadening removal
Engine removal
Door stripping
Interior stripping
Enginebay stripping
European babes stripping (my girlfriend said this wasn't allowed :cry:)

Discussion:
//oldschool.co.nz/index.php?/topic/56136-pbaines-1977-toyota-corolla-ke30/

 

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Well, today the engine came out.

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I decided to check, if in fact I did have the original motor in the car. 

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Yuss. Turns out I do! Fantastic. Very happy to be giving this KE a full makeover and put the original heart back into it.

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Just so I remember how all of this went. The rest of the bay is pretty self explanatory 
Also showcasing that, I really  should have checked if the gearbox had oil in it. Turns out it did, and my efforts of adding an ice cream container 80% through the drainage process didn't really achieve much. #It'sTheThoughtThatCounts.

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And behold, the bare nude bay. Considering if I should get this entire shell bead blasted or something, just to get rid of all the rusty holes once and for all

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I will be going in tomorrow to get some stripper and strip they bay, and also some dry ice so I can get rid of the sound deadening.

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Started on my cuts as I have sourced all of the replacement sections that I am needing

 

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Found a patch on the car, shame it's rusted through. the whole thing will come out

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After many hours of using paint stripped which did absolutely next to nothing, i went with a wire wheel on a grinder. Will continue more next weekend after I drop the subframe out etc.

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Discussion

https://oldschool.co.nz/index.php?/topic/56136-pbaines-1977-toyota-corolla-ke30/#comment-1844319

 

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More good progress. Shell is now 100% rust free! what a mission...

 

Anyway. I got the wire brush wheel out on the boot and expected holes for africa, just surface rust for africa so I was pleased
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After attacking it i gave it some epoxy
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Next came the front panel section at the end of the chassis rail. looks the same as the original repair except this time I will actually seam seal the edges on the chassis rail so no water can get in there... no point repairing it if you aren't going to do it properly!
Tack
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Weld:
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I thought I would just spot weld the holes but sort of didn't realise how thin the steel was. None the less, the holes are no more
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Now the hardest section I have been putting off. It wasn't too hard in the end, just took a bit of time. I also should have used a press for all of this, but. I don't have one! 

Step One: Plan
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Step Two: Tack
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Step Three: Plan some more
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Step four: Weld
*imagine pic*

Step Five: Grind off welds 
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Rinse and repeat

Step One: Plan
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Step Two: Plan some more
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Step Three: Fiddle around with cutting your new piece up to fit whilst realising you should have done the whole front piece from scratch but then not give up because who wants to then realise they've wasted 3 hours
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Step Four: Weld
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Step Five: Prettify
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Then I attacked the rear boot lip and welded on a nice new one. doesn't have to be clean as possible, the boot rubber will go over it
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There was a massive hole here.. don't think I have a photo. Will get the Dremel out and fix the half circle there. otherwise it's sweet
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Rear left section that needed doing
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This probably looks quite ugly but when I epoxy it it will look good. Very happy with how this section came out with 3 curves I had to compensate for when folding up the cut
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Before:
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After:
Much better!
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Discussion:
https://oldschool.co.nz/index.php?/topic/56136-pbaines-1977-toyota-corolla-ke30/

 

 

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So I started on the doors, oh man. few days work involved there, just doing small patches and also welding up the skins at the bottom of the door edges. I could have made a new lip but really, just as easy to weld the two skins together
 

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There is always a post which is the perfect roundness!
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Like a glooooooove
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All doors dealt to

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Once I was happy with the doors etc It was time to add some filler. Quite averagely.  but i did get it perfect in the end!
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HIgh filler primer time
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I need two new guards and bonnet. But fist, here is why you never rely on Taiwanese guards.
A) perfect edging.
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B) Close as bro 
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A) good parallel alignment
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B) Mr Taiwan put the RHS L piece on the LHS guard. Good work!
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Discussion:
https://oldschool.co.nz/index.php?/topic/56136-pbaines-1977-toyota-corolla-ke30/

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