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Toyota Celica GT4 Project - Printable Version

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Toyota Celica GT4 Project - Insanity-74 - 04-04-2017

About 5 years ago my last GT4 failed it MOT with rusty sills, they were fixed and it subsequently passed but it set alarm bells ringing in my head that the poor things days were numbered.

I decided that I would buy a shell and swap everything onto it. so I hunted for a reasonable shell to start work on.

While I was looking, I had to extend my garage. I only had a single car garage so not enough space to work or store stuff.

So I decided to extend my garage backwards a bit

Work started.

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and after a few weeks, finished ;0

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About the same time a shell turned up, well it was sold as a shell, but it was more or less a complete car minus the engine and gearbox.

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It was in good condition with no rust, even the interior was in pretty much spot on condition, not that I need much of it

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I set to work more or less straight away

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First job was to strip everything off the car

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everything went, all the looms, glass, suspension the works

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Next job was to remove the sound deadening material

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it then went outside for a thorough jet wash go get rid of all the years of crap

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As I was moving the battery to the inside I could remove the battery tray

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which I did

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Next up I needed to get to the bottom of the car....this was going to require some ingenuity.
I was going to have to make my own rotisserie.

So back off to the wood yard, a few lengths of 2x4 and I made this

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It was about now I realised two things. One I was going to have to learn to weld and two..my plans for this car were changing quite dramatically......a fancied making a cross between a rally car and a GT car...no idea how I was going to achieve this, but the seeds had been set in my mind and for once they stayed there.

So I rushed out and purchased a MIG welder....learning to weld was pretty easy to be honest, by no means as neat as the pros but not bad for a complete novice.

So I made a rotisserie

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It fitted like a glove and worked perfectly

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A quick look revealed the sills were pretty mangled

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so I had to fix them up as best I could

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At the same time I started blasting and painting with good old POR15 the subframes and suspension parts

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The came out quite nice

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did the prop shaft too, started a bit rough

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came up well

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also cleaned up the steering rack

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and the alloy diff end plate....gave it a good polish

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Next up I started the worst job I have ever attempted
Tackling the stone guard on the bottom of the car.

I cant count the amount of drill & angle grinder wire brush attachments I have gone through.

it makes alot of dust and takes what seems like forever

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slow slow work

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this stage took about a month

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at last, more or less done

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I then painted it with more POR15

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More or less at the time I was ready to slit my wrists due to constant wire brushing the roll cage turned up (I still havnt finished under the car....I am going to get the rest sand blasted....i just cant face it any more

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A brief test fitting and I was starting to get excited.....I was going to have to break out the welder again Smile

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First job was to add some strengthening to the top of the rear suspension tops, so i removed the odd metal bracing off them (i think its used to just hold the rear plastics in place?)

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I then made a template

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and then a metal top (3mm mild steel)

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and one for the other side

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Once I had welded these to the car it was time to start getting the roll cage in

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I filled the aerial hole whilst I was at it

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Anyway, back to the cage, more bits turned up

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this was starting to get serious

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this ties in the rear sub frame to the cage, helps keep things stiff

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nearly there

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as you can see my welding isnt great, but as its more or less the seond thing I have ever welded in my life i was mildly pleased with it

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Done

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i had decided that I didnt want a full cage, at the end of the day it will be just a road car so getting in and out easily is a priority

Next up I decided it was about time to learn how to cast new metal parts, as for what I had in mind the parts do not exist, I was going to have to make them.
I was going to have to make myself a mini blast furnace...and learn how to cast metal

I needed these

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I turned the bin into a furnace with the use of some fire cement

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fill it with charcol, attach a heat gun, ignite and stand back

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I made a vessel from a spare piece of square tube...it gets pretty hot

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hot enough to melt alloy

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I still needed to learn how to make sand moulds so stopped there for the time being, I will pick that up again later.
Taking a long look at my roll cage, I was not happy with the welds. so i decided to dress them, smooth them out, add a little body filler and make them smooth

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started looking much better although I did have to remove the main hoop cross member for access

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dont worry its not going to be that colour, thats just filler primer

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at the same time I cleaned up the floor and primed that ready for paint

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the boot aswell....I also welded the cross member back in

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Next up was the seam sealer, so I masked off the areas I was going to apply it to

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then applied the U-Pol grey stripe seam sealer (nasty stuff)

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well here is a little update. I just about finished the seam sealer today but to show you a comparison, one side of the car is finished and the seam sealer has been primed, the other side it has just been applied.

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Left side it has just been applied, right side has had two coats of seam sealer and had primer sprayed over the top. I am pleased that you can hardly see anything despite the fact it will all be covered over with sound mat.....just because you cant see it dosent mean it cant be right.

cheeky shot of the cage

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I stripped down the petrol tank

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gave it a good paint

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the obligatory walbro fuel pump

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all back together with some stainless steel bolts

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rejuvenated the fuel tank straps

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started rebuilding the rear axels

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managed to rescue the rear brake disc backing plates

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they came up well

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Found a product called Deox C which is great at getting rid of rust, bought the rear hub carriers up a treat

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and I got alot of bolts zinc plated

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and the door catches chromed

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things are starting to go back together now, the rear subframe and suspension parts are all half built, just waiting for the paint on the rear hubs to dry and cure and they can go back together, need some snap rings for the rear axels, then they can go back on. Rear diff can be completed tomorrow if I get time.
I have taken the bonnet catch apart which I am going to get chromed, then I have had to have custom stepped rivets made so I can put it all back together again. I have also been working on the interior, a few ideas which have fallen by the wayside and a few new ideas.

I started rebuilding the interior plastics to work around the roll cage, a bit more complex than I bargained for, but its going to challenge my fibreglassing skills.

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Now that I have finally taken the other Faff off the road I can start transferring bits over.

After talking to some rally boffins and TTE experts I have decided on two options for the engine rebuild. Initially I am going to use a 185 block and head as these are stronger than the 205 block, the head isn't as good but is more workable...or some am told. Also there are more bits available for the 185 blocks like moroso sumps etc will re using my Link G3 ECU with a brand new engine loom. Plans are afoot for a TTE charge cooler. Smile
I got hold of an ST202 front bumper, an old knackered GT4 front bumper, both of which I have cut up to make into one. I also managed to get hold of a TOMs front lip which I think suits the car very well.

had to use the parts car to line the bumper up.

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still so much to do and it seems like two steps forward one step backwards all the time. i might have retired by the time I finish this rebuild.
Hmmmm shiny bits

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Still removing paint and underseal......sigh. Just the fiddle bits left to do which is no fun at all.

Beginning to wish I had a compressor and sand blaster.

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As you can see there isn't a great deal more on the GT4 than the normal celica for the rear sub frame. For those wishing to do a proper GT4 conversion you should be able to get the extra bits to weld to a non GT4 to allow for fitment of the rear subframe. Would need looking into it in a bit more detail just to make sure there isn't any hidden parts, but it shouldn't be a difficult task. It would make it as close as possible to a GT4 without buying one.

I can check part numbers for those wishing to investigate.


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As you can see, I don't have much room to work in Sad
Well, not much being done today, spent a large portion of the day driving around the country picking up bits n pieces.

Did pick up these though Smile

the obligatory suspension in a box shot....some nice BC coilovers

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The castings are in the garage currently painted in grey self etching primer.


I picked up yet another GT4 front bumper to finish off the SS4 front bumper.....that will be 3 GT4 front bumpers that have bitten the dust thanks to me Big Grin....oh well.

Tomorrow, hopefully I will complete the cleaning off of the bottom of the car so I can do the final derust and clean ready for applying the paint next weekend.
Well finally got to apply some paint instead of stripping it off.

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still some stripping to do in the engine bay area, but I have to get this painted before the weather gets too cold.....paint dosent like being applied in the cold....paints a wuss lol lol lol

After another coat of epoxy mastic, I will apply some seam sealer in a few areas, then some POR high build tie coat primer as the epoxy mastic has load of brush marks, it will then get a smoothing rub down before I apply some POR15 flex coat for a silky smooth glossy finish :thumbsup:
Well, a bit of work today, decided to refurbish a set of spare brake Calipers I had, they are in mint condition so didnt need much fettling, I took them to bits, removed all the seals etc, the bolts will be sent away to get zinc plated.

The callipers were painted with Eastwood chassis black extreme, a beautiful paint that goes on very nicely and has a great finish.

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and a hint as to what the finished callipers will look like

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Another box of bits (mostly bolts) arrived back from the electroplaters.

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should be fun trying to remember where all the bolts go...i give myself about an 80% chance of getting it wrong Smile

I also managed a few smaller jobs, put the ignitor assembly back together along with the nice shiny dipstick holed, wiper motor which i finally managed to get the bolts for, and the steering shaft gaiter.

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it should look nice on the bulkhead

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Nearly got the front driveshafts finished, just need to locate a replacement vibration damper for the right side drive shaft.

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The brake stopper polished up well

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front hubs also came back from the electroplaters.

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A box of parts ready to be sent off to the electroplaters

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still nothing of much substance really, just all little jobs that make the big jobs easier.
Well got a bunch of tstuff back from the zinc platers and got a few more things back together.

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The brake and clutch pedals refurbished and ready to be refitted

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I took the power steering pump apart, there's quite a few bits inside that all decide they want to head in many different directions when you open the thing up.

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And the tensioner for the alternator belt

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The next task is building a new dolly to help transport the shell around as it doesn't fit on a car transporter with the current dolly, time to break out the welder again.
It's about time I had a new rotisserie, so I have made this one to be very strong, to be able to rotate the car, obviously, but also to enable it to be transported it's wheel width will match that of a car transporter ramps, it's adjustable in both length and height Big Grin a step up from the wooden supports I was using lol

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Should finish it tomorrow :thumbsup:
After deciding the recently applied undercoat was no good I sent the shell away for Media blasting, and it's done.

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Along with a super tough primer/undercoat....not the final colour, but quite a nice colour, not sure if it would suit a celica or not.....think I will stick with me original colour Big Grin
Well, I have managed to sort myself out with a compressor. Got myself a reasonable compressor to start off with and a few bits n bobs.

First off because I have no space in the garage I built a little shed to house the compressor.

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It is well ventilated and sound proofed so it dosnt annoy the neighbours too much.

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Feeds through to a filter and extendable hose

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I need to add more filters though as the one I have dosnt remove all the moisture out of the airline.

I went back to the good old epoxy mastic 121 from rustbusters, thinned out the full 15% it goes on quit nicely and easily.

I am sure pro painters will take one look at this and shake his head with shame with the conditions I have to work in, but there is an Old Scottish Expression
which goes........"You can only piss with the cock you've got" Smile unfortunately I dont have a nice big garage.....yet, plans are to build one eventually Smile

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As its the first thing I have ever sprayed in my life (with a proper air gun, done plenty with aerosols) I will plastic sheet out the garage when it comes to applying the top coat but as all I am doing is the underside it dosent matter too much, I will leave the top side to the professionals Smile

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This needs to dry now for at least a week Sad I will then do a coat of undercoat, final colour, then some ultra tough high gloss clearcoat.
I had to redo the front bumper as i wasn't happy with my previous attempt.......

Once you have cut the two halves of the bumper and matched them up you need to start by drilling a series of holes about an inch from the join about three or four inches apart.

I then zip tied the two ends together and then started zip tying towards the middle, as I went I put the wire mesh on the back

The front

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The back before the glue is applied

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And with the glue applied and pressed into all the mesh and holes

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There is more to do but I need to let the glue fully cure overnight at least. I will then add a bit more glue into the bits I missed and fill in any holes in the join.

A bit of scratch fabrication today, it's still a bit rough and needs finishing off, but it's a...........well, can you guess what it is :confuse: :confuse: :confuse:

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A bit of minor fabrication, the centre beam for mounting oil coolers, the two (yet to be welded) front supports for the FMIC, I hope they are long enough as I had to guess the size and position.

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Some more goodies turned up today.

A complete superstrut system which I must say is F'in expensive, I hope never to have to buy all this lot in one go ever again. I hate saying goodbye to £1300 ($2095) at once. Less free cash this month Sad

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Also this which should more than handle my fuelling needs Smile i didn't think the previous updated fuel pump would cope.

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Awaiting more tomorrow, hopefully some steel tube for some more fabrication, a special stone guard paint gun so I can try and apply some of that stuff, oh and some plastic sheet so I can burry the bodies....err err I mean protect the car when spraying it.
Some colour at last Smile

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Only one coat, needs a couple more to get a nice even finish. A bit more work for the engine bay before I spray that.

RE: Toyota Celica GT4 Project - Paul Baldwin - 05-04-2017

Another OCD driven build by the looks of this Smile Anymore pics and info of how you got on with the mini blast furnace? Did you use proper refractory cement? How well did it hold up to the heat?

RE: Toyota Celica GT4 Project - Insanity-74 - 05-04-2017

(05-04-2017, 10:44 AM)Paul Baldwin Wrote: Another OCD driven build by the looks of this Smile Anymore pics and info of how you got on with the mini blast furnace? Did you use proper refractory cement? How well did it hold up to the heat?

Yep, practice for the 306 build i have planned Smile

I used fire cement, it worked okay and the bucket never really got hot. It melted aluminium easily but making a cast prooved problematic and getting an even flow was difficult.....so i gave up on the idea.....probably for the best as molten aluminium isnt the friendliest of stuff Smile
Definitely a great day.

At last I have put colour to car and I must say it looks f'in brilliant, I so love the colour. It goes on very well, is very forgiving and is the perfect colour, love it, very happy bunny today. Well chuffed.......and it's only the engine bay, imagine how happy I cam going to be when I paint the topside Big Grin I will be smiling so much the top of my head will fall off Smile

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Only the first layer, a small amount of flating to do, then more colour.
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Well that's the rear sub frame in....not easy to lift that in on your own.....sore back today.
A small bit of progress today.

Fitting the front coilovers

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Took a bit of fettling but its all sorted now

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rear coilovers fitted

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as you can see, i dont have much space to work in...need to build myself a bigger garage.

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A whole lot of fun today, i still hate fibreglassing things. Whos daft idea was it to install a roll cage???? lol lol the top half of the plastics that frames the window will get flocked, the lower half, after a lot more work will get painted a high gloss black, along with the front door lower sections and the bottom half of the dash, dash inserts will get painted a silver.

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A small bit of progress tonight.

Inspired by someone on here I figured its was a good idea to remove the casting marks from the rear lights.

You can see the casting marks.....the dam things always get gunked up with wax polish.

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after a rub down with 600 grit wet n dry.

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Test fitted to the car along with the rear bumper to check its new duct clears the crash bar

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Got some colour put on the other day, managed to hand paint on some extra tough 2K lacquer. its not perfect but to be honest I am not that bothered, its just for protection as it will be covered by carpet etc......the engine bay is better. Some more of the 2K lacquer will arrive in the next day or so, I will then spray it onto the rest of the engine bay and finish the interior. Then i will be ready to install the brake lines, wiring and interior. Busy weeks ahead Smile

My little garage with my cramped working space Smile

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the interior - front

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and the back

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the boot...slight problems in the wheel well, but again it will be covered by sound deadening etc so as long as the rust protection is there i aint bothered.

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hopefully by the end of the week it will be all shiny Smile

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Another coat of lacquer...i have to resist the temptation to touch it for four days now for it to fully harden (That sounds wrong Big Grin)

I gave it a liberal squirt with cavity wax and fitted the front crash bar.

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My compressor set up, working well so far. no water in the lines Smile

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A few more parts added........

Brake & Clutch Pedals & Dash beam thing (whatever its called)

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From the engine bay

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Fitted the first layer of sound deadening, similar to dynomat but lighter and not so thick, other than the boot floor this is the only area I will be putting this stuff. the second layer will be a light closed cell foam which will go all over the floor, roof, boot etc.

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fitted the refurbished wiper motor and wiper mech...what a horrible job.

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ID plate re-rivetted in place.

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the wiper arm pivot and those little hook things that catch the back of the bonnet

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still all clean......for now

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tonight i will start recovering the wiring loom.....i hate electrics.
There should be a bit of progress every day now Smile

Todays fun and games....brake lines. it dosent look like i have done much, but alot of time is spent retapping bolt holes and cleaning threads up.

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I am having to rebend the brake lines as they dont quite run parallel to each other, but thats an easy fix.

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I also started to fit the closed cell foam (sound deadening) to the roof, its very light, weighs almost nothing, but its a bit expensive for what it is. the floor, bulkhead, roof door insides, boot floor will all get covered in it Smile

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tackled the recaros today....well one of them. i tried one of the ebay bolster suppliers and the quality is spot on, so i will purchase the other bolster for the other seat later.

You can see the split in the foam.

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Under the foam there is a metal support ring, it is this that cuts through the foam making the split. The bolster has this bit re-inforced but i guess old age has taken its toll.

with the bolster replaced

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its a pretty easy job to do to be honest, i was expecting it to be harder, about ten mins to do a bolster from start to finish.

I think thats it for today...i had planned on doing more but Jo has bought me some beers and the last Hobbit DVD so its feet up time Smile

back on with it tomorrow Smile
Painting the roll cage...this is hopefully the last bit of major painting to do until i decide to tackle the outside. Its a rubberised & textured enamel, goes on with some force, but dries nicely.

The roll cage in all its masked off glory Smile

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tomorrows task is to finish a bit more sound deadening on the firewall then start refitting the loom which i started refurbishing at the weekend.
The odd but of progress, I have been doing some design and preparing stuff for the engine rebuild. Getting more parts zinc plated, redoing wiring, battery relocation and basically waiting for the dashboard to get finished.

More parts in the engine bay, pretty much only missing the engine now, and a few radiators Smile


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I dont like to harp on about Bilt Hambre Deox C.......but by god its good stuff.

Rear Diff Before

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235000 miles of crud and salt etc

and after 2 or so weeks in a bath of Bilt Hambre Deox C (and some minor wire brushing to help it along.

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Dash finally back and freshly alcantara'd

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Rear suspensin fitted and the brakes sorted

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Tank....dont know if i will fit the OEM tank guard or make some kind of defuser?

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Hmmmmmmmmstill shiny and new Smile

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In the words of Hannibal Smith....."I love it when a plan comes together"


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So, back into the garage again, this time to do a bit of bodywork checking. i knocked the passenger side rear quarter so after making it smooth i decided i had better check it for symmetry.

I splashed out on a 30cm profile gauge

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not that expensive and well worth it.

First off i checked the drivers side,so i measured to get an exact location so i could replicate it on the other side.] and offered up the profile gauge

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I then moved over to the same spot on the passenger side.

As you can see there was a bit of a difference, at least 1mm out.

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So after alot of hammering (I found that a large rubber hammer was best) I managed to knock the wing back into shape.

Not perfect, still 0.002inch out but i can live with that, the primer might take some of that out :clap: :thumbsup:

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I checked over a large portion of the car and the rear quarter panel was the only one that showed any difference. :thumbsup: :thumbsup:
Frustrating day #618.

After much sanding and sanding and sanding, i was finally ready to apply some epoxy mastic 421 undercoat, i carefully masked off the car, a task which in itself took a whole day. I launched my new Devilbiss GPi spray gun and merrily sprayed away, looking like a pale darth vader in all the spray gear, respirator etc in managed to scare the local cats away and spray toxic material without dieing..........the finished job looked okay for a beginner/amateur/novice but one of my neigbours decided that it would be a good time to "beat a rug", now thats not a metafor for anything rude, but who the hell beats a rug these days? Havnt they heard of a vacuun cleaner? Needless to say, the laws of "f?ck you Nial" came into play and all of the dust from the rug managed to drift directly into my garage, dont swirl around the neigbourhood at all giving me a chance, it was like someone had stuck a dust magnet in my car, the beautiful primer now looked like it had mange, either that or the shell suddenly reached puberty as i am sure theres a pubic hair or two gracing the roof. Luckily the primer had semi set so alot of it just blew off with the airgun, the rest, well it looks like i am back to sanding again, began wet sanding yesterday, finish it off today and maybe get a new coat of primer down......this time the garage door is staying well and truely shut until the primer is dry.

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I also managed to get hold of some projector headlights which after repairing two broken tabs look fabulous. Once i have managed to get this primer down, i will put all the panels on to make sure everything lines up okay before i apply any more paint....fingers crossed its not rug beating day again. Grrrrrrrrrrr
TRD strut brace finished and fitted with stainless domed nuts or acorn nuts.

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I thought that the regular nuts didn't look very smart, these finish off the suspension tops a lot better.

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The project has been on hold for a few weeks whilst I rewire the garage, and add some lights Smile

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Back to spraying again tomorrow.
Starting to get some colour down Smile its only the underside of the bonnet, but a successful step for a diy novis paint sprayer

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And the Toms front lip done

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And getting thebrear crash bar refurbished

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Managed to get the front bumper sprayed, not perfect but it will be soon, a couple of runs and some dust but easily sorted with a bit of wet n dry.
Starting to put things back together now. the bodywork needs a bit of flat polishing to get it perfect like a mirror, i have done the roof and it has come up amazing, well pleased.

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These will cool the engine oil and the gearbox oil. all stainless fittings and correctly rubber mounted.

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In front of those is the FMIC also with stainless fittings and rubber mounted.

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RE: Toyota Celica GT4 Project - allye - 05-04-2017

Amazing, really incredible amount of man hours in this! Huge respect!

RE: Toyota Celica GT4 Project - Midnightclub - 05-04-2017

Fair play dude, epic build

RE: Toyota Celica GT4 Project - Danny Wideboy - 05-04-2017

Like.

A lot.

RE: Toyota Celica GT4 Project - Insanity-74 - 05-04-2017

Thanks all, its been a challenge thats for sure......but fun Smile.....getting the engine built as we speak, imported a 2.2 celica block from the USA, its been all machined, getting balanced soon once i get all the rotating mass together........should be good for well in excess of 600bhp but i would be happy with 400....ish, depends which turbo i go for.
I keep losing interest, and having a 306 in my mind as well isnt helping, looking forward to having a poky non turbo engine to play with.

RE: Toyota Celica GT4 Project - WiNgNuTz - 05-04-2017

That is an awesome looking project! Seriously impressive stuff. Gonna keep an eye on this, look forward to seeing the finished product! ThumbsUp

RE: Toyota Celica GT4 Project - zx_volcane - 06-04-2017

What a great project, really gone to town on it.

RE: Toyota Celica GT4 Project - Insanity-74 - 07-04-2017

Re welded the FMIC supports to a better location, added some gussets for strength as i noticed some flex in the cross member, just painted it with 121 epoxy mastic, next i will go over it with some stone guard, colour then some tough clear lacquer.

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RE: Toyota Celica GT4 Project - Insanity-74 - 08-04-2017

No more work on the Celica today, but i did manage to pick up a 306gti6 engine, gearbox ecu etc today ready for the next project, although the ecu has been played with apparently to allow for no Cat but i wont be using it.......i need to learn about peugeots again now, havnt worked on a Pug since the 90s when i had a 1.9....time to order the good old haynes manual.....time for the unrealistic goal of 10000rpm and 300 normally aspirated horses......see how far off i end up once its done, 240 would be nice.

RE: Toyota Celica GT4 Project - twangy - 09-04-2017

Just seen this , your going to town on this , keep it up mate , looks well

RE: Toyota Celica GT4 Project - Insanity-74 - 09-04-2017

(09-04-2017, 01:12 PM)twangy Wrote: Just seen this , your going to town on this , keep it up mate , looks well

Thanks Smile  It has its moments when it tries to mentally destroy me, but hopefully get it finished this year so i can move onto the next project.....getting a little tired of this one.

RE: Toyota Celica GT4 Project - yes306 - 15-05-2017

awesome work you've done there