KP's 1989 AE92 GTi-16

JapCarForum Cars, Cars, Cars! Project Cars KP's 1989 AE92 GTi-16

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KPARRIS-JONES
Member

188

24-05-2018, 07:15 AM

Hi all,

Two things are coming your way, and epic wall of text and a truck load of pictures Wink

First things first, the story and thus - epic W.O.T.

I purchased my GTi way back in 2008 when I was 14, she set my back a lovely £495 and another £5.01 in fuel to get her home, which meant I was already over the £500 budget. Great. :laugh:

The night I got her home I stripped her straight down inside, and then out, only to reveal my "little pre driving project" had become a mountainous and pretty epic list of faults, niggles, glitches and wallet draining tasks.

Here is the extent of the damage:

These pictures were taken at a later date from the original strip down so the car is at different stages -

The Sills were... what sills?

[Image: saturday2010027.jpg]

Rear Suspension Turrets were revealing daylight:

[Image: saturday2010029.jpg]

The Sunroof was ridiculous:

[Image: saturday2010025.jpg]

All four arches had rotten out:

[Image: saturday2010026.jpg]

KPARRIS-JONES

24-05-2018, 07:15 AM #1

Hi all,

Two things are coming your way, and epic wall of text and a truck load of pictures Wink

First things first, the story and thus - epic W.O.T.

I purchased my GTi way back in 2008 when I was 14, she set my back a lovely £495 and another £5.01 in fuel to get her home, which meant I was already over the £500 budget. Great. :laugh:

The night I got her home I stripped her straight down inside, and then out, only to reveal my "little pre driving project" had become a mountainous and pretty epic list of faults, niggles, glitches and wallet draining tasks.

Here is the extent of the damage:

These pictures were taken at a later date from the original strip down so the car is at different stages -

The Sills were... what sills?

[Image: saturday2010027.jpg]
[Image: saturday2010018.jpg]

Rear Suspension Turrets were revealing daylight:

[Image: saturday2010029.jpg]
[Image: saturday2010028.jpg]
[Image: NSTurretRust.jpg]

The Sunroof was ridiculous:

[Image: saturday2010025.jpg]
[Image: saturday2010032.jpg]

All four arches had rotten out:

[Image: saturday2010026.jpg]

KPARRIS-JONES
Member

188

24-05-2018, 07:16 AM

My N/S B-Pillar had gone too:

[Image: saturday2010011.jpg]

Rear Corners had bitten it:

[Image: saturday2010016.jpg]

So at this point I was 14, had no money, no tools and a single garage. I had two choices 1. Tank on with the rolla or 2. Scrap her for £50, buy loads of Monster energy and play COD for the rest of my youth.

I chose 1. and I am yet to decided if that was the right choice....

KPARRIS-JONES

24-05-2018, 07:16 AM #2

My N/S B-Pillar had gone too:

[Image: saturday2010011.jpg]

Rear Corners had bitten it:

[Image: saturday2010016.jpg]
[Image: saturday2010017.jpg]
[Image: NSRearCornerRustBack.jpg]

So at this point I was 14, had no money, no tools and a single garage. I had two choices 1. Tank on with the rolla or 2. Scrap her for £50, buy loads of Monster energy and play COD for the rest of my youth.

I chose 1. and I am yet to decided if that was the right choice....

KPARRIS-JONES
Member

188

24-05-2018, 07:17 AM

Anyway, work began and the first job was to replace the Gasket, Clutch and generally learn the basics of an engine:

[Image: April2009212.jpg]

[Image: enginesuspendedandworkcommences009.jpg]

KPARRIS-JONES

24-05-2018, 07:17 AM #3

Anyway, work began and the first job was to replace the Gasket, Clutch and generally learn the basics of an engine:

[Image: April2009212.jpg]
[Image: FluffyInteriorfinished049.jpg]
[Image: IMG_0383.jpg]
[Image: bumpercomingoff028.jpg]
[Image: hoistsetup018.jpg]
[Image: enginesuspendedandworkcommences009.jpg]

KPARRIS-JONES
Member

188

24-05-2018, 07:17 AM

It looked ok for a 20 year old motor:

[Image: Headcomingoff011.jpg]

Not before too long she was stripped down further to be patched and painted:

[Image: IMG_0957.jpg]

I started to make the engine look pretty:

[Image: IMG_1048.jpg]

And then put it back together:

[Image: Enginerebuild2010008.jpg]

At this point I was going to have the engine bay and car resprayed and reassembled at a garage, so the engine had to rest in there and then be taken back out for the respray.

We got her there and soon enough she was clad with fresh Lexus 040-1 Super White in the Bay:

[Image: saturday2010013.jpg]

Sadly the garage closed down during the respray so we had to find another way of getting her done...

During the search time and saving period for the respray, I decided to get her engine working properly. I had countless issues this being my first build and all but eventually I got her there and she sounded great. However I only truly got her engine operating perfectly and the car driving post respray. There are a lot of cross over periods with this, and even times when I had to take a break. This Project can take so much from me which you will later see :glare:

KPARRIS-JONES

24-05-2018, 07:17 AM #4

It looked ok for a 20 year old motor:

[Image: Headcomingoff011.jpg]
[Image: Headcomingoff013.jpg]

Not before too long she was stripped down further to be patched and painted:

[Image: IMG_0957.jpg]
[Image: IMG_0955.jpg]

I started to make the engine look pretty:

[Image: IMG_1048.jpg]

And then put it back together:

[Image: Enginerebuild2010008.jpg]

At this point I was going to have the engine bay and car resprayed and reassembled at a garage, so the engine had to rest in there and then be taken back out for the respray.

We got her there and soon enough she was clad with fresh Lexus 040-1 Super White in the Bay:

[Image: saturday2010013.jpg]
[Image: saturday2010006.jpg]
[Image: saturday2010002.jpg]

Sadly the garage closed down during the respray so we had to find another way of getting her done...

During the search time and saving period for the respray, I decided to get her engine working properly. I had countless issues this being my first build and all but eventually I got her there and she sounded great. However I only truly got her engine operating perfectly and the car driving post respray. There are a lot of cross over periods with this, and even times when I had to take a break. This Project can take so much from me which you will later see :glare:

KPARRIS-JONES
Member

188

24-05-2018, 07:18 AM

Now for the fun bit, the welding, reassembly and respray Big Grin

KPARRIS-JONES

24-05-2018, 07:18 AM #5

Now for the fun bit, the welding, reassembly and respray Big Grin

[Image: IMG_1778.jpg]
[Image: IMG_1782.jpg]
[Image: IMG_1789.jpg]
[Image: IMG_1790.jpg]
[Image: IMG_1791.jpg]
[Image: IMG_1792.jpg]
[Image: IMG_1794.jpg]
[Image: IMG_1795.jpg]
[Image: IMG_1796.jpg]
[Image: IMG_1802.jpg]
[Image: IMG_1819.jpg]
[Image: IMG_1820.jpg]
[Image: Respray4.jpg]
[Image: c4bb98c5.jpg]
[Image: 444636c8.jpg]
[Image: 905b821f.jpg]

KPARRIS-JONES
Member

188

24-05-2018, 07:18 AM

She then arrived at my new location with all the bodywork patched and sprayed and even a new blue tint screen to freshen it up Big Grin

I had a couple of months to then get her to her first show - Japfest 2011

[Image: 3ec5b432.jpg]

KPARRIS-JONES

24-05-2018, 07:18 AM #6

She then arrived at my new location with all the bodywork patched and sprayed and even a new blue tint screen to freshen it up Big Grin

I had a couple of months to then get her to her first show - Japfest 2011

[Image: 3ec5b432.jpg]
[Image: d4688d79.jpg]
[Image: fd707215.jpg]
[Image: f841b854.jpg]
[Image: d393f514.jpg]
[Image: 1a7bbf3a.jpg]

KPARRIS-JONES
Member

188

24-05-2018, 07:19 AM

The Interior goes back in for the first time in over 2 and 1/2 years:

[Image: b4a5509b.jpg]

She is now close to completion.... but BAM, the water pump packed in, now I won't name names, but it turns out that the bloke who put the pump in did so with 1 out of 5 bolts. His initials are KPJ... but I wont reveal him. :laugh:

Still, I carried on:

[Image: 1d92124d.jpg]

Skirts now fitted up:

[Image: 2007d570.jpg]

I had a Carbon sunroof on order from the US which was 3 months late to arrive, but then turned out not to fit. So a week before the show I had to bodge an old spare for a temporary fix..

[Image: e6b7730e.jpg]

Eventually she was ready for her MOT!

[Image: e8643876.jpg]

But as she arrived at the centre, we found her pouring oil out al over the place... off the road she went again:

[Image: eaaa91a5.jpg]

It then turned out that she needed a new Handbrake, Rear Calliper and rocker gaskets along with a few other bits and pieces. Not cool, as this was another £300!

But after all that she passed! And it was time for the sunroof to be wrapped and the final pre-show prep:

[Image: 243a2951.jpg]

The day before the show me and a group of friends all went balls out and finished her off:

*Painted Callipers
*Painted Splash Guards
*Fit Boot Slam Panel Bungs
*Clean Interior
*Clean Engine Bay
*Fit New Clean Plates
*Polish and wax the whole car

Our efforts paid off and she made it to the show, albeit a little steamed due to a loose water pipe:

[Image: 606a1aff.jpg]

KPARRIS-JONES

24-05-2018, 07:19 AM #7

The Interior goes back in for the first time in over 2 and 1/2 years:

[Image: b4a5509b.jpg]

[Image: b0ee4f41.jpg]
[Image: bcee6c02.jpg]

She is now close to completion.... but BAM, the water pump packed in, now I won't name names, but it turns out that the bloke who put the pump in did so with 1 out of 5 bolts. His initials are KPJ... but I wont reveal him. :laugh:

Still, I carried on:

[Image: 1d92124d.jpg]

[Image: ccd2decc.jpg]

Skirts now fitted up:

[Image: 2007d570.jpg]
[Image: d77ad0c2.jpg]
[Image: 521a569f.jpg]

I had a Carbon sunroof on order from the US which was 3 months late to arrive, but then turned out not to fit. So a week before the show I had to bodge an old spare for a temporary fix..

[Image: e6b7730e.jpg]
[Image: 2b2d0922.jpg]

Eventually she was ready for her MOT!

[Image: e8643876.jpg]

But as she arrived at the centre, we found her pouring oil out al over the place... off the road she went again:

[Image: eaaa91a5.jpg]

It then turned out that she needed a new Handbrake, Rear Calliper and rocker gaskets along with a few other bits and pieces. Not cool, as this was another £300!

But after all that she passed! And it was time for the sunroof to be wrapped and the final pre-show prep:

[Image: 243a2951.jpg]

[Image: e8a0e58b.jpg]
[Image: 685b4ecd.jpg]

The day before the show me and a group of friends all went balls out and finished her off:

*Painted Callipers
*Painted Splash Guards
*Fit Boot Slam Panel Bungs
*Clean Interior
*Clean Engine Bay
*Fit New Clean Plates
*Polish and wax the whole car

Our efforts paid off and she made it to the show, albeit a little steamed due to a loose water pipe:

[Image: 606a1aff.jpg]
[Image: 90ceb7f3.jpg]
[Image: 915059b3.jpg]

KPARRIS-JONES
Member

188

24-05-2018, 07:20 AM

I even treated her to some Badges:

[Image: a96b1768-1.jpg]

I had finally built my dream machine and I couldn't be happier, she had made it to her first show with the Club I had started to keep these rare Jap Hatches alive Smile

BUT as always there was a kick in the face....

On the way to view and R32 GTST Skyline she developed a knocking noise, and I took it upon myself to strip the engine back down and sort any problems myself...

This is why you tighten water junctions...

[Image: 416759bd.jpg]

She's out;

[Image: 4e0c5d3f.jpg]

Home and separated from the 'Box;

[Image: 28b0f193.jpg]

Sump off;

Annoyingly, having checked each Big-End carefully the whole Bottom End appears to be absolutely spot on with no issues!! So next stop is removing the Caps and checking the Bearings themselves. I found two very small metal shavings in there but I couldn't be sure of what they were from.

KPARRIS-JONES

24-05-2018, 07:20 AM #8

[Image: f22ef8db.jpg]
[Image: FluffyJapfest.jpg]

I even treated her to some Badges:

[Image: a96b1768-1.jpg]

I had finally built my dream machine and I couldn't be happier, she had made it to her first show with the Club I had started to keep these rare Jap Hatches alive Smile

BUT as always there was a kick in the face....

On the way to view and R32 GTST Skyline she developed a knocking noise, and I took it upon myself to strip the engine back down and sort any problems myself...

This is why you tighten water junctions...

[Image: 416759bd.jpg]
[Image: 5071313f.jpg]

She's out;

[Image: 4e0c5d3f.jpg]
[Image: 4b79fed6.jpg]
[Image: 8a560a59.jpg]

Home and separated from the 'Box;

[Image: 28b0f193.jpg]
[Image: 5043ecd9.jpg]

Sump off;

[Image: 6a1f6604.jpg]
[Image: c1628285.jpg]

Annoyingly, having checked each Big-End carefully the whole Bottom End appears to be absolutely spot on with no issues!! So next stop is removing the Caps and checking the Bearings themselves. I found two very small metal shavings in there but I couldn't be sure of what they were from.

KPARRIS-JONES
Member

188

24-05-2018, 07:21 AM

Scored Horribly:

[Image: d2fa1398.jpg]

Metallic Paste:

[Image: 198c83c2.jpg]

Bearing 2 was utterly Mullered!:

[Image: 3147dfee.jpg]

Here's the Video:

[youtube]idWchJj6rE0[/youtube]

[Image: 069c086d.jpg]

KPARRIS-JONES

24-05-2018, 07:21 AM #9

Scored Horribly:

[Image: d2fa1398.jpg]
[Image: ad4e33fb.jpg]

Metallic Paste:

[Image: 198c83c2.jpg]

Bearing 2 was utterly Mullered!:

[Image: 3147dfee.jpg]
[Image: 0d5c1f4e.jpg]

Here's the Video:

[youtube]idWchJj6rE0[/youtube]

[Image: 069c086d.jpg]
[Image: 0e1f4e61.jpg]
[Image: 875283cc.jpg]
[Image: 39864e22.jpg]

KPARRIS-JONES
Member

188

24-05-2018, 07:21 AM

#10

So after all this I thought I'd bring the engine and bay up to scratch, I was never happy with it and it needed redoing:

[Image: 74893835.jpg]

They're whiter than they all look!

[Image: 3fd509e6.jpg]

Silver Pump:

[Image: 4997a385.jpg]

The Tensioner Pulley Assembly is in one piece now and looking ace IMO. Here are a few more pictures:

[Image: 50a3927d.jpg]

KPARRIS-JONES

24-05-2018, 07:21 AM #10

So after all this I thought I'd bring the engine and bay up to scratch, I was never happy with it and it needed redoing:

[Image: 74893835.jpg]
[Image: 058356dd.jpg]
[Image: 17140632.jpg]
[Image: 2ff52113.jpg]

They're whiter than they all look!

[Image: 3fd509e6.jpg]
[Image: 87e2b910.jpg]

Silver Pump:

[Image: 4997a385.jpg]

The Tensioner Pulley Assembly is in one piece now and looking ace IMO. Here are a few more pictures:

[Image: 50a3927d.jpg]
[Image: 72500457.jpg]
[Image: 921bbcb8.jpg]

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