Jump to content

Daihatsu Fourtrak Project - Rust don’t live here anymore


Recommended Posts

  • 2 weeks later...

Finished a chunk today, which is a great feeling.

DB5D10DA-74CA-4DF1-AC05-D4E35F5740FD.thumb.jpeg.33106cb729deba79073cc3fc0a7804fd.jpegdrivers rear inner arch, tied it all together and welded all the repairs both sides, snd joined it to the body mount.

F2BB4969-357A-4AB2-B4E3-E3602DE14EB8.thumb.jpeg.ec542a70ae6556e43253b3010a122fdf.jpegslapped some primer on. Where the peach paint is here is basically new metal. And the grey. So basically it’s 80 percent new in here. 
98C449ED-B2E6-47CA-907F-CE3C08DE9786.thumb.jpeg.2e430b03e01c5098a5f8720acd5d7174.jpegmy home made spring panel from an age ago, this was the first work I did here.

118C14A2-E187-4FF0-9178-E160B7B94715.thumb.jpeg.2e4b9f3891020038db6c1d7863dc86af.jpegEarly pic of this inner arch, 

A5E00B9A-A7B0-49BC-8763-80BD629A1FD6.thumb.jpeg.f7cac100d04542fc57497af76fc95032.jpegnow looking better and far more steel these days.

AC8609FC-8773-4129-8DED-EE525ABF4057.thumb.jpeg.a0f5f045557998a51702999ff7053123.jpegthe outer sill. This has had a big bit of box welded in. Couldn’t stand how crap it looks, so a quick poke...

7C86BC8E-3FF0-4EBA-BB3F-E27D3771DAC7.thumb.jpeg.7067dd37ad538c537ddce9d94188576b.jpegthe inner sill where the box section is welded to.


Out it all comes.

inner sills are better than I expected, first time I’ve used the words “better than I expected, bodywork and Fourtrak” in the same sentence.

31CA6564-88E8-422F-A537-422DB32D79B2.thumb.jpeg.e34ba0ad82d6378500f3910e058fb256.jpeginside area was treated to a skim of filler. This will make it smoother before paint goes on, and I can get good access here now to tidy this up. 

Next time round the sills will be repaired, and new outer sills put on. Then I can close the last holes, prime it all, and seal it up. Can’t wait to start priming all areas the same colour, it’s gonna transform how it looks. 

Link to comment
Share on other sites

  • 3 weeks later...

Sills time.

Originally this had an inner sill, middle strengthening panel and an outer sill. Some time later a “repair “ was made, and a lump of box section welded in.

6D376D56-AEF6-4B3B-B3C9-9E7856817C0C.thumb.jpeg.7008245637d16e04d2969d1baaf0f637.jpegNice work. I lifted this up with my two poster on these sills some time ago, more crunching than a crisp eating competition occurred.

So I cut out the box section.17D0610B-23FE-4F34-B282-2AC1005E529B.thumb.jpeg.a849a3b80efc843ba3e9d6052820eb04.jpegHeavy box section removed. Existing Strengthening panel is neither strengthening or a panel, or existing in any way at all.


So, overall this should be roughly 140cms, the length of the sill. The rearmost couple of feet atre very rough.


The floor above the inner sill. Sound deadening patch was not for sound deadening, but the only rigidity of the floor.


The inner sill rear section lopped out. And the ever increasing in size flint stone floor option.


Wow! Took about 20 mins of tweaking to get the sill hanging in the right place. Tech screwed this on, to get an idea of the shape the inner sill should be. 

Cut back out all the rust inside before. About 50 percent of the inner sills out complete. The other 50 percent about the bottom 2 inch is cut out.


Couldn’t resist dropping on the arch cover and bumper. Looks almost complete, and in my eyes the sills shape transforms the side of this. Also reminds me how much of this work won’t be seen in the end!

Spent the rest of today making bits for the inner sill. Gonna tack these on with the new outer in place, then remove outer, seam weld inner repairs, make and fit strengthening panel/ mid sill, paint it all and inside the new outer, before fitting up the new outer and welding it on... then finish off the inner arch..... then weld the now about two foot square hole in the floor up.

Nearly done I reckon.

Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak - Sill-y thing to do on a hot day

You are my future! Quite right though, there is something a bit annoying about going to these lengths only for a bit of plastic trim to cover it all up.

I have questions though, and I apologise if these have been asked:

1) what's the peach coloured stuff you're using?

2) do you filler then primer the new stuff? Or do you primer then filler?

3) on the arches where you've welded, are you going to put some seam sealer on it?

4) what are you going to use for the arches to protect them?

I'm interested in the last two really, as I've got it in my head that the best thing to do is to slather on some bitumous isopon underseal stuff I've got in a tin, given how exposed to the harshness of driving they are.

Link to comment
Share on other sites

On 6/15/2021 at 11:54 AM, St.Jude said:

1) what's the peach coloured stuff you're using?

2) do you filler then primer the new stuff? Or do you primer then filler?

3) on the arches where you've welded, are you going to put some seam sealer on it?

4) what are you going to use for the arches to protect them?

Okay, what works for me-

1. Unknown age hammerite rust paint. Found it in my garage and the tin was easily 20 years old, no longer available as is all good hammerite. It’s almost ran out, so I’ll be moving on to summat else soon.

2. I filler onto the steel, if an area where it’s gonna flex a bit I’ll skim seams with fibreglass filler first, this cuts down on the amount of filler used to finish too. Once done I’ll prime it. This for the top side of a car, underside I go weld, paint weld seam with very good paint, seam sealer, paint again, and maybe a top layer such as Raptor, Shultz or stone chip. I’ll probably do the Fourtrak under side with epoxy mastic, probably Jotun brand. The ouside I’ll do with upol 2k high build, but I am set for two pack spraying.

3. Once a chunk is welded, I’ll seam seal it. Gonna probably go like this In the arches. Remove old crap, clean, grind back and finish welds. Rust killer (bolt hamber hydrate 80) where needed, one coat epoxy, seam seal, another epoxy coat. Undecided whether to overcoat, as think painted underside maybe easier to jet wash clean. Considering Raptor to finish, but not decided yet.

4. Rust killer stuff, seam sealer, 2coats epoxy, maybe raptor.

Much of the underside of the Dai-rot-su is surface rusty, so I’m aiming to kill the rust, seal it up and make it east to maintain. 

Welding patches to an old motor, I’d prime and seal welds, paint then a coat of 3m Shultz, I’m probably going further with this rusty knacker than a sane person should. 

Link to comment
Share on other sites

  • 2 weeks later...

Another day, another 7000 miles of MiG wire sacrificed to the gods of rusty Japanese steel.

Inner sills then...


Original is spanked

F0062A6F-ACF6-44B5-BA8C-CEF22F7F11FE.thumb.jpeg.533493096935153af45a6d554effd2cc.jpegFolded some strips to length and blobbed them on

7A29196D-D69F-42DD-9538-2CB1A411A3F0.thumb.jpeg.bd6f6ebd50804d82b9364636a9246e05.jpegWith a coat of zinc primer, the inner sills started to come together

86297FA7-EBB2-451D-91BD-62A1DEA88A48.thumb.jpeg.b3e04245ecdfd3598c04815d4c2c32e4.jpegStrengthening panel at the bottom of the quarter panel. This was not even attached to the box section I chopped off

4736060D-2E16-42F1-BE5D-4E0E9364CD4B.thumb.jpeg.1fb1c275e0b3f5bc0f674d2b8d10061f.jpegNo Now I could attach the outer to some steel, so I cut it to size.

979B447F-A89E-4923-B4B4-C2BEAC54DB8E.thumb.jpeg.fc27d2b147df20df4d4a908009b58cbb.jpegFitting well in the door shut area88B49052-56E7-4E79-9F64-D45BC6215BD8.thumb.jpeg.fd9a19e181db909f355720edc56a53e4.jpeg 

the hole to close up in the under arch, but shows the three sill layers together. Most the metal in this pic has never been in a Daihatsu factory.

CE4FBA22-62EC-45DA-B4F3-30E9999CD3CD.thumb.jpeg.9cec3b2cfb73bc19b6c01bb9365f5c3f.jpegNew sill will fit lovely. Gonna butt weld it, so hopefully should look nice and neat. 
Progress is good, but may slow a little. Partners Civic gearbox is crying enough and the Mk2 Golf is clonking over bumps, and has a months MoT.  Good job it’s holiday time soon! 

Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak - Sill-y season continues
  • 4 weeks later...

Rusty old nail update.

Been a bit busy on a few other of the fleet last few weeks, partners Civic had a gearbox and clutch change, Old Golfs needs an MoT and also there’s a rusty vw camper  in the unit next to the beast, so I’ve renamed a corner of the workshop “the bay of decay”.

Works continuing in the rear arch, but not much photo worthy to add. 250FC653-6CB1-4F96-A47F-8876C89253FB.thumb.jpeg.70564c0a040e62f30f6fb2618bb483d5.jpegAs you can see, it’s still raining rust underneath, and it’s not been outside in moisture for about two years. 

Link to comment
Share on other sites

  • 1 month later...

Whisper it quietly, but I think the drivers side is done!

E968A33E-7EFC-4AA8-8BBA-5F4367A50360.thumb.jpeg.7b85c1d24f063d8175ea79c1d81402b0.jpegFirst order of business is to close up the inner rear arch.

E4742390-C364-4DE7-8285-6D55D4319EBA.thumb.jpeg.2cfd2f258ce65013fe1dd9cd2ee56d4d.jpegMade this up, and welded it all in. Outer arch cover is on here too, fits nice and covers so much of the work done.

D2006156-C477-4228-9443-9D8AEC0A0303.thumb.jpeg.a56276a50ce4d4e737903e33261e7587.jpegInside, the rear bulkhead (which I had to make loads of previously) needed to be joined to the floor.

Had to fabricate and fit a floor crossmember, which is fitted to the inner sills (which I made too).

Ive renamed it a DaiRicksu now, as it’s basically coachbuilt in this area.

D68E72DE-FF49-4B7D-8CA7-1FA07AE40962.thumb.jpeg.e8e557c23d276ae33366d7bc1755f6f8.jpegWelded a big chunk of floor in. Had to repair and fit the rear seat support bracket, under the black panel that takes the seat base. Ground back and zinc primed it.

79900064-5CC1-48D3-B913-63E29FD626E3.thumb.jpeg.12189120f7276a4469a0902f8b0d83f2.jpegTerrible pic of underside. Lots of new steel here, needs a tidy, prime and seal up. This is taken under the door area, looking back at the front of the rear wheel. 
It’s had some bloody welding, this old crate!

I do still need to weld the outer sill on, which means it’s not 100 percent done this side, but all fabrication is done this side I reckon. I’m also fairly sure the other side is better to start with, so tune in next time to share my disappointment when I realise it’s a complete kipper!


Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak - Get on the floor! Anti Flintstones specification
  • 2 weeks later...

Thanks for the positive comments all, this type of works a slog at times and it’s nice folk are interested. The internet is really full of weird folk!

Passenger floor then…

55A94A5D-44BE-445D-A3E6-76ABFF60F3AF.thumb.jpeg.a74e6c9ad7d2b47c97c5dab4a550497d.jpegThis is under the seat. There’s a nice big patch here (white bit) this was welded to ever bracket and strengthened going.

03B928BC-554C-4651-87AD-4483AFD63913.thumb.jpeg.ae0cf3f2f00fb4ae4fcc770f909bd924.jpegInside the arch. All been repaired in the past by covering up the rust. Think the last welder sprayed his steel with salt water before tacking it in.

EBDA79D5-504A-4259-9569-1CACD90CDEEA.thumb.jpeg.292da6b18e1b08b9cdb5f26ef59b0703.jpegChopped a load of crap out, and there was not a lot left.9B880226-2729-47FC-B773-F9FEC76B242C.thumb.jpeg.eadb2eee820da9f6e81ec76444bdac8c.jpegPiles of rubbish that fell out or off. Cut the box section sill off with an air chisel, which vibrated all manner of rust and crap loose.
1FD2D004-5B41-4742-8530-8C0AA7892CF3.thumb.jpeg.f098e0a2a5aa505309d6547757ac646e.jpegconcours repair to the sill from the past. Looked great, and for bonus points all the rust was still there, so it was rusting merrily.

AADBE112-5230-45AB-B443-0B763AB1685B.thumb.jpeg.9ef6c62e242b2ac15602dcd0f0317c42.jpegI improved the look of this by cutting it off and feeding it to the skip.

55AE0E1E-56A9-4966-8CBA-3C2920D2F4FA.thumb.jpeg.370aa2c1a5c28ef518980c3ff2e585e8.jpegmmm, there’s a bit too much fresh air in this pic.

0AB9E97D-55D9-431D-A5CF-80D873438F73.thumb.jpeg.56dbcb0583a476c88f41f80dd9262925.jpegThis is the inner sill and floor pan.

Well it would be if there was any left.

Remember I said this side was better?

I was wrong.

Its a kipper, confirmed.


Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak - Dai-rot-su Floorscrap

Brilliant work and cracking thread. You're probably one of a handful of people who would put in the mountains of effort to save a car like this and keep UK roads interesting.

These were THE culchie Irish farmer's choice back in my day. I spent many hours in the back of these along with a mental dog being driven around obscure country roads in South west Ireland. Noisy as F is what I remember

Link to comment
Share on other sites

Had a good few hours today.

Started to reconstruct the missing nearside bodywork.

0DB3A856-BFB9-4F9F-8ABE-A9C4FCF668A1.thumb.jpeg.947c6009a14a47f811573f1851017df6.jpegThis should be a picture of a Fourtrak sill and floor. 

There is a lack of steel on display.

87090FA2-01BB-4EB7-91FE-21BCD6495FD4.thumb.jpeg.5c67961995866df5205c844c68ba23d1.jpegNot sure it looks better inside.

25EA5418-14AF-44D0-892B-9BB7BFC0F6A0.thumb.jpeg.ee5760f68b24f0c84e3c3e78b9cf26d0.jpegStarted on the inner sill right at the back. Approx 2 foot long this piece.

2F427C68-7B0F-42B5-AE59-9EA0A69271DC.thumb.jpeg.3a11c2351c9b3c0e91925e9367bafc38.jpegWith the very top of the inner sill in, I made the rest of the inner sill. 
My eBay outer sill was trimmed up and screwed on and off several thousand times. 
E857FA35-FE67-4F8D-8DFA-D913FA1C5CEB.thumb.jpeg.b1ee68da1348602ab25630bf3fc8b5af.jpegWith the very rear done, I moved onto the mid section. This was fitted to the outer sill shape. 

The total lack of any original Daihatsu shape on this means most repair sections are free hand.


C5C20EF2-70C5-45CF-A986-614EDA34FB84.thumb.jpeg.121ef203772e5cb10c9d547142fc42c8.jpegMade and fitted a floor cross member on this too - it’s whet the earth clamps attached in the second picture.

0C85BD56-E284-45B0-BD88-12A43822DB07.thumb.jpeg.e48536f6e65c9a6e1b97d9f89b2f6003.jpegOuter sill hanging on. The shape looks excellent in my opinion.

456873CE-9A20-4CE9-97E2-0A1961C89C84.thumb.jpeg.abfacae773ab41254a2fc3c1a6d81eab.jpegThe very rear of the sill.

Most of the bodywork here’s never been to Japan.

Looking much nicer than the crap box section bodge.


BEFORE: crap

2D8C7AE5-919A-47A6-BC02-537FF1AE4765.thumb.jpeg.67be68ea85b520b34c9d5a0ca14375aa.jpegDURING: looking good.

Tune in next time to get none of the questions your probably thinking answered.

Such as: Will he ever stop welding the old shit box? Why is he bothering? Does Daihatsu plastic also rust? Is he ever gonna look further forward than the doors, under the front arches?

Im dealing with the front end by pretending it’s fine.

Link to comment
Share on other sites

  • 2 weeks later...

Made some more progress on this today.

6B9586E0-E2BC-4153-B60B-0F5998A64C8D.thumb.jpeg.f4a947c0971cdf0878e916206b3c5131.jpegpassenger side inner sill finished and zinc primed.

BBF83851-A85E-4E92-8CF2-FF4AC7A8D2A5.thumb.jpeg.fe0a5e1fc178d9ac569d60a29fcf10f3.jpegfloor support piece fully welded to sill.7E5DAC72-9AD5-4C72-AB2E-687000EF0ADB.thumb.jpeg.1d5b678e82bcd19b197576f3c6ec9662.jpegThen I moved onto making bits for the floor. This is to go under rear seat area.

3535E352-E11F-454B-AD92-EE9EB8A6B3B8.thumb.jpeg.0649eea089a11fec8586ae6bd51d1783.jpegFloor section welded in, mig welded, and plug welded down to the top of the inner sill.

65688020-1A00-4836-9606-FE198832B08B.thumb.jpeg.42218b7bd808df9b1ef6048919c500fc.jpegThe floor patch above runs from the rear third of door, to the floor strengthener in the pics before, the under seat section goes on top of it all.

4149BCAE-5041-4249-A9D7-2B8BBC3EEB94.thumb.jpeg.b35c42f7e4cc8c0b800f12ae62e63c16.jpegIt nearly floats!, just the inner arch to make and repair, and weld on both outer sills. (They are fitted, just need welding on)

The light at the end of the tunnels getting closer!


Link to comment
Share on other sites

  • 5 weeks later...

Threads due a proper update, but I’ve wrapped up the floors, refiffed the back seat mounts, and closed up the rear inner arch bits left to do.

Had a few hours on it Saturday and the passenger sill is now on.

28945E1B-0892-4975-A6B7-F5CB3856DCD8.thumb.jpeg.bca7917651105357824988f5ced4b82a.jpegAll the inner arch is complete this side now too, as are the floors. Unless I uncover more, I call the passenger side done! 

quick time line:





With this done, I put all its wheels on and dropped it on the ground, for the first in a while.

C9B283BC-5E5E-4CC5-9FB9-D10D81DF8B93.thumb.jpeg.edbac30ba536b352c7ed697beeb15bfa.jpegMost the rear floors look like this now

91C637C7-5A37-4608-B223-95016B8E1B8F.thumb.jpeg.f27e5c9a0d0b35b4dda77e086fb7dca5.jpegNeeds a good clean up inside and out, and hopefully I’ll get the other sill on Saturday. 

Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak Project - Less rusty than it used to be

Busy now prepping up the other outer sill before welding it on.

B3353264-E1EA-438A-9D37-AF6B8670207F.thumb.jpeg.3abc564f12d279626e1528edc071272d.jpegdrilled across the bottom flange for the plug welds.

A60238B9-A32A-462F-A649-65E0D5505931.thumb.jpeg.67a12325cfa4a4f51d691eeb17c7fcb2.jpegpunched the ones across the top flange. (Sills upside down in the pic)04679270-51EE-48B6-BCBB-48980B3B1D2B.thumb.jpeg.17c9f253d95d4115655bbad50adeef4c.jpegCouple of coats of zinc paint. I’m gonna inject the sills with Bilt Hamber Dynax wax after paint.

D925A7C9-1DFC-4572-8106-C28ECBE45A11.thumb.jpeg.01a29dc06002c4e49a470e2a2b50c203.jpeg The inner sill. I reckon I made a better job of this on the other side. Gonna redo the bottom flange here I reckon. More zinc paint in here.

F7B47448-DA10-4DBE-8520-8F7225A3EA5A.thumb.jpeg.7af3ddeb434d14e5a327dad03ce3a8c2.jpegWhilst the primer dried, I cleaned up around and inside the old beast.

BC4E4DB0-972B-44E6-B762-C6BC6C4228C5.thumb.jpeg.206dedc2d9a9c78dd19bb139c3c6c65a.jpegFour dustpans of crap swept out, and a quick hoover later.

BFC1EEE1-336D-423E-8389-22E7BF94CEB2.thumb.jpeg.d1660c5f4bfda382bdeb11c226c0e75a.jpegwaved a torch around underneath it to look for more holes. Found three, this being most obvious.

List of welding jobs left

1. Offside inner sill bottom flange - make and fit

2. fit offside outer sill

3. three holes in floorpan

4. front crossmember behind radiator

5. Exhaust brackets, hangers and cable mounts underneath. 

Once done and painted, mechanical jobs are gearbox oil leak, new clutch, fit remaining rear bushes, New brake pipes and lines, new fuel pipes, new rear shocks and new exhaust. 
Not much then!




Link to comment
Share on other sites

  • 2 weeks later...

This might be the uks only Fourtrak with two 100 percent steel sills now.

0D596235-91BB-430E-99D8-277CAF40B6FD.thumb.jpeg.88118d52ebb1756af8b1bd3b69a99e7b.jpegThis was how I’d left the inner after repairing it a few months ago.

I wasn’t happy with the bottom flange, so rejigged it with a proper flange.1E3D413C-9A52-49DB-8C7C-441FB7C0FF91.thumb.jpeg.3ad77fe9074e148b1bc6470216611da6.jpegThis fitted the outer sill much more cleaner.

D731A38F-980D-49FF-A62B-AA7C375BF6D8.thumb.jpeg.3eb50acf7146c2efb5d622db43d55c76.jpegThis pic shows some of the many bits stuck together to strengthen the sill and floors. Lots of weld! 
4C599A5D-726C-4A0D-8111-855CA56961BD.thumb.jpeg.6cdf2508ed10be98129adae698d2c39a.jpegThen it was time to butt weld the sill on. This is along the rear quarter.

2321D9B9-1F41-40CF-8492-88048CB8F55C.thumb.jpeg.17092a2b1d7cd2d7ecd06a98c6ef1c6e.jpegInside the door, front edge.

31DD3257-FD30-4636-A19A-42EE9E36D0B5.thumb.jpeg.f03a815fabf48c46eb02b65d2211fb27.jpegUsed a jack to push up the bottom a touch, to enable the plug welds to be done.

27C71EE7-8303-489A-9B47-7C10EB4281D8.thumb.jpeg.40579a330ccf3ec864d87fcdaa5c3c30.jpegPlugged along the bottom.

AA3A8B8E-7087-48E8-9FDA-C39D8ED7A3B5.thumb.jpeg.6ce234ec205e988f8928c6f0ddc81131.jpegground the welds at the front and primed it.

3B228785-961E-484A-BB88-5F3B97A9DAD7.thumb.jpeg.050ec2ddc2058266f99bd22a2b1b9f5a.jpegSame for the rear quarter.

All this messing about means sills of steel!


She’s a beauty. (In my eyes anyway!)

Link to comment
Share on other sites

  • 3 weeks later...

Probably end of year update, although I’ll try to sneak another couple of hours in before new year.

Finished of the inner wheel arch to sill join


Tiny bit of weld is where the floor, inner arch and body mount but join. This is strong now! 

F182A30A-D956-4389-BAE8-460920799345.thumb.jpeg.f2c8dcb3905f0732dd72d840a26502ab.jpegAlso been finishing off the filler work on the arches, both sides.

None of this seen. I don’t like to remind myself often.

Also tidying up, derusting, and rust treating the inner arches as I go. Been using Bilt Hamber rust converter, and it’s great stuff.

As I guess this is the last post this year, I’ve added a montage of Daihatsu crap piles, sort of a greatest shits compilation:

A472A8B8-CED0-4369-A73E-39C09C5984FD.thumb.jpeg.d7d0554826936b72010b7827bc1f931e.jpegwicked awesome piece of floor and inner arch.

8F60EDA8-C451-4FE4-BDFE-43C89A90D330.thumb.jpeg.0f0fb1b734267a060db706f075f8ec0c.jpegpart of the rear wing. Surrounded by mud. Which fell out of the bodywork

9810E788-7F9A-490A-83F6-930CF68D52CA.thumb.jpeg.145e7b97f3f2e0949c41e0b378ab36e8.jpegthe wonderous sill. 
E8EA5668-4437-40BF-A4CA-53F50A40F21A.thumb.jpeg.47e9e0a2256328fb1e4f9fc776dcf685.jpegmore rust and mud. Some poo too. And some Fourtrak structural strength


Been a crispy year in Daihatsu world.

Link to comment
Share on other sites

  • 3 weeks later...

Changed from snorting filler and rust dust today, and started on the solvents.

61017E15-D9DE-42C4-B598-89FAB492F174.thumb.jpeg.4f77c2a6754025480e6e1efd1ca05501.jpegBeen filling for a while on these arches, which are a free hand patchwork of metal pieces.

082D3D7E-C9EE-43B4-92F5-6FA32EF850AF.thumb.jpeg.230a0f5d0addbecc10cb1a01d12eb9c0.jpegOther side. Also made the bodywork that sits under the bumpers.


Filler flatted down…

21C4D6C5-6F6C-47C3-A1C4-398ADAA9DD5E.thumb.jpeg.e1471204c5110355a944fa40a9e7a81f.jpegThe other side..

6DE76252-4784-4DC7-BE2D-7A72D4149F69.thumb.jpeg.5e1a1583d03699ed5b407ecb83254a8c.jpegPassenger rear. Jotun Epoxy mastic paint can be seen on the chassis and inner arch. I painted this on last week, now it’s hard enough to seam seal.

1C93FD31-1155-4BF7-A42D-9BEF67B1502A.thumb.jpeg.557b3c19d1428c4c52141444f04bb9b9.jpegMore plates than a Greek restaurant 

358AACD9-65F7-4E97-8771-9D155CCBA5AF.thumb.jpeg.ab2960f730c80abbf62f2d756f432e92.jpegMasking applied. I’m still crap at masking up.

DDC3CF87-6827-45F9-9B1E-C5B5F8866C5E.thumb.jpeg.a4d090beef3a93fae3c2b64f3e56270f.jpegMasking the other side too. Cos I hate myself

20D16D41-AF0B-4C71-9714-5460747BD4D9.thumb.jpeg.4935e9d67743c98f524af9d6316c74b0.jpegPainted! With an aerosol.

E6AAA17D-3F0D-4FE4-A2FC-D8ED80B10561.thumb.jpeg.d54a1848605527b6ed9d204165dde74d.jpeglooking less patchwork

03645B26-EFFF-4585-8E9D-4475FF4467FD.thumb.jpeg.e56c9294c3cae0663350985c39f98af9.jpegMassive motivation boost here

349A0DB1-9B2B-47F8-BD54-66441CA2143A.thumb.jpeg.794e1e894cb15487d0d0535ae8a66100.jpegThe other side.

Been using Hycote brand aerosols, both here and with the zinc primer I’ve used on this car. Really impressed, covers well and easy to use.

Inch by inch it’s getting there! 

Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak Project - Less patchwork than it used to be
  • 4 weeks later...

Fresh from the massive morale boosting primer going on, I decided to chuck the old rust bucket on the lift to wrap up some jobs in comfort.

E0513526-9F43-468C-BDF7-FD811765EA98.thumb.jpeg.cbb47cdcfda190a6d707ae97c47120ff.jpegsolid enough to lift!!

0B3275BE-4109-41AB-9E55-084FC3333F1B.thumb.jpeg.624bc4b3523904c2096a0b7b57fa1fc8.jpegThe Fourtrak can fly!

5BC856F6-1271-4268-A423-2183856EA5AD.thumb.jpeg.b8bf03eae50e587d9a0e522b0e8709b2.jpegOff came the wheels

0EC46D5E-C1C8-4339-9D0D-B2E7A679E0F0.thumb.jpeg.4ee5d0baf70c39734676fdf73c72d8fa.jpegBeen dealing with the front condition of this thing by pretending it’s fine so far…


Link to comment
Share on other sites

Let’s have a look then at the front…

22D05A92-2B7A-41E6-A1C1-DF176884471F.thumb.jpeg.0870030b53988fcbff552b66d4c652e7.jpegcute face

B01D0B2B-D9EA-4993-BFFA-C14F422AE9F1.thumb.jpeg.b9bbedca499e2d45c550da8e45e7753f.jpegbumper and grille off. Around the steering box areas looking a bit rough.

29FAB346-A6B5-4927-8E2D-CE781F316AF6.thumb.jpeg.1f349b2afdc7e8d48fcd93c999dd52e8.jpegTide mark of dirt is telling!

179EBB8F-943C-4EC0-821E-4FBA4B016FA8.thumb.jpeg.9e678f6dcebe7421c066f5698ee3b6fb.jpegoff with the wings to get a better look

B01A1872-665D-4680-8C7F-3BDA92D95E1B.thumb.jpeg.8d9dae17b1e9c7946ec375d0ee293ddc.jpegFront panel un bolts. The steering box and chassis is fine, but the area of the front panel fell to bits.

AE55D659-F0CD-4443-A3F3-5518180AB36F.thumb.jpeg.e10205a7e24d2a11c330070d7e8120f3.jpegFront of chassis is very good.

B5F06896-8F9E-410D-B24B-E57276F243CA.thumb.jpeg.2d714e985a2dd493aca8e02c5cc8f3bf.jpegFront of Fourtrak is looking a bit sparse at present.

My partner has summarised recent events as “scope creeping”. 

Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak Project - Gone full frontal!

Great to see you continuing to exterminate the ginger bugs from the underside of the Fourtrak. 

It's brought back memories from just over a decade ago when my brother was into off-roading and greenlaning. I went out with him in his (now virtually extinct on these shores) J Top Pajero which performed amazingly all day. This poor old Fourtrak was being driven by a slightly overzealous lad who hadn't quite got the hang of things though... Paj to the rescue! 

I'd say yours has outlived the huge majority of it's brethren and then some. Keep up the good work!


Link to comment
Share on other sites

  • 9 months later...

 Thread resuscitation:

Spent ages back end of winter / early spring rebuilding my VW T25 engine, which went through my project funds like an oil rig fire.


so the old Daihatsu took a bit of a back seat for a while, but I did continue the grind of cleaning up the whole underside of the shitbox.

D93480F1-F7E0-41C7-802E-78C109F06529.thumb.jpeg.b83b938906b8f149bd4567a4288a782e.jpegClean machine 

8F148CDD-310C-4B8E-90D2-2C35F84BAB03.thumb.jpeg.92fe82fd905501d809e30d5e2162b1dc.jpegDetailing World territory 

D9D89BA8-DF3A-4C88-A408-4EDC6F520DFA.thumb.jpeg.c61fa6ae1c4612464570e0e6306bfa5c.jpeg“Been in cleaner swamps”

Drove myself insane and deaf with one of these


Then had an issue with my trigger finger, so was on the go slow (looks like carpal tunnel) for a while.

1EA08690-D4F3-4F86-A9C5-358895416D6E.thumb.jpeg.27146e2254ce6f290daa109f61d6185c.jpegDid a bit at a time, 787F613D-4E96-4696-BF9B-31A46021123B.thumb.jpeg.7a8265a2145eaca4db2213b5a9838449.jpegrust killer as we go 


I love you, Bilt Hamber Hydrate 80

After a very not short while, it was ready for some primer


Under the boot floor


Nearside rear arch and rear chassis

7BC2836B-594F-404F-8B83-FC4B55CA7704.thumb.jpeg.bec7ad1709862dc49fa46bbb290aa303.jpeg Gearbox area, looking back


Inner arch and crossmembers, it’s the bit where all the suspension and rear axle go


in the bad old days

66A4A2CA-54F3-48C7-8A44-C454A76544F8.thumb.jpeg.294c790ff26859aade25852c89307a9d.jpeg inner arch was like this a while ago 

So, yeah I’m still going with the old knacker

and yeah, it needed so much welding it gave me carpal tunnel

Gotta love a Fourtrak 

Link to comment
Share on other sites

  • rickvw72 changed the title to Daihatsu Fourtrak Project - Rust don’t live here anymore

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

  • Similar Content

    • By danthecapriman
      Thought I'd start a thread about my old Capri since it's now reached it's turn in the que to receive a bit of attention.
      I've actually had this since 2001, it's an early mk2, on an M reg 1974. Being an early car it's still got mk1 rear axle and single acting type rear brake set up aswell as a few other minor differences from later cars just to use up remaining mk1 parts.
      It started life here in the Portsmouth area and doesn't seem to have ventured far since.
      Originally a stardust silver 1.6 L poverty model, which means virtually sod all regarding luxuries. Basic 2 pod dash with black 'crackle' finish facia, no radio, no sun roof or vinyl roof, not even a centre console!
      When I got to it unfortunately it had suffered severely from serious rust and latterly a vandal attack, having it's door and rear quarter panel booted in.
      Over the next couple of years I got it sorted and a cheap re paint into roman bronze, which was a favourite colour of mine at the time. For the first year or two it seemed fine but since then things have deteriorated.
      The respray wasn't good! It's thin in places and started to micro blister in various places, worst of which is all over the bonnet. The same bodyshop also did a bit of the bodywork I hadn't finished which was also pretty poor in some places.
      It's always been a great driver and never struggles at mot time so I just kept on using it and doing nothing more than collecting parts now and again with a view to sort it one day.
      It's also gained a few non original extras over the years like a higher spec wood effect 2 pod dash facia (which I like more than the original), a short console, brown interior instead of the utterly fucked black original, 'laser' 4 spoke alloys and a few other things.
      Anyway, fast forward to last weekend, when I dusted it off after winter and noticed various areas of new rust coming through or older rust that's gotten worse. So the decision was made to go for a professional resto job now before I end up finding something else to distract me (like big american cars with knackered engines!).
      1974 Ford Capri BBK244M by Dan Clark, on Flickr
      Here it is as it currently stands. Looks ok from a distance but the reality is very rough around the edges and the paint is so bad in places it's becoming embarrassing!
      IMG_0509 by Dan Clark, on Flickr
      And the interior which I'll be re trimming into black leather at some point after the body works done.
      It's been taken to the same place that did my Mercury's engine rebuild, since they did such a good job and they seem a good professional bunch.
      I dropped it off Monday afternoon for a thorough check over to build up a list of work and get a rough quote.
      Today I heard back from them.
      Good news so far, I suppose. It is as solid where it counts as I thought it was. Chassis is fine, original strut tops fine, most of the back end is solid and just needs a few repairs here and there.
      The worst is the bottom of the windscreen surround due to the wrong seal being used and then fitted badly causing leaks. Inner sill to A post bottom corner very scabby, front wings pretty crap, and various paint defects etc.
      The engine is fine, compression all in tolerances. Suspension needs work, and some brake pipes are getting quite rusty. So far so good and no surprises!
      There's still more checking to do over the next few days but it sounds alright so far.
      This work should be made a bit easier by having a lot of panels and parts to fix things already. The big find being a new unused pair of front wings. Very hard to find mk2 items now, though I did have to pay for them!
      The plan here is to make the car solid, reliable and good looking. I'm not making a show car or going too mad as that stuffs not my thing and if it was I'd start with a better more original car.
      Some of the later add ons will be ditched like the mk3 boot spoiler that I hate! And return it to more standard looking mk2 as it should be. No go faster mods or anything like that.
      The main priority is to get the body sorted and painted properly (engine out job and everything) then maybe a bit of mechanical work as needed.
      The original idea was to re paint back into original stardust silver, but having thought about it I'm leaning more towards another favourite Ford colour of the era, Miami blue metallic, which is a lovely colour! Any opinions?
      This will be another expensive project but not one I think I could do at home on the drive and do justice to, so I'd prefer to farm it out and get it right this time. It also means I can carry on working on my Transit and Granada at home without another distraction!
      For anyone whose interested I'll try to update this now and then as things progress. I'll also try to get the old pics of the car from when I got it so you can see how rusty it was! Bear in mind though that I paid £100 for this car in 2001 with MOT and tax! Try doing that now.
      I'm sure this is going to be worth the expense, not that I'm even considering selling it of course but I've had it so long I kind of feel obligated to do right by the car in a weird way!
    • By mat_the_cat
      Thought I should probably start a thread, given that a few people have suggested it. For my sins, my first car was a 1985 Hyundai Stellar. Bought back in 1997, when the sun still shone, I had more hair, and the world was generally a better place.
      This may be the earliest photo I have, I think from 1998:

      Anyway, I drove everywhere in it, and clocked up over 100k miles before I was given an Alfa Romeo 75. So I took the Stellar off the road for some much needed TLC. Made some progress on it - Rebuilt all the suspension, fitted a rebuilt Cortina* rear axle, Princess 4 pot front calipers and Capri vented discs etc - before a couple of house moves and renovations put it on the back burner.
      * before anyone says they are identical underneath, there are some differences. I fitted a replacement axle fairly early on in my ownership, only to fit that not only was the propshaft flange the wrong size, the UJ was totally different so I couldn't even fit a new yoke. Finding a company on the day before New Year's Eve who could cut off the end, weld a new UJ on and balance it wasn't too easy, especially one that was accessible by push bike!
      Anyway, late last year I found some renewed motivation, and have been working on it when time and money permit. Here is what it looked like in October:
      OMG barn find?

      Front suspension OK at first glance...

      ...but it has turned out the calipers had seized (so are away being rebuilt) and all the (brand new) ball joint boots had perished:

      Quite a bit of welding is needed too, but I had a setback just before Christmas when we were burgled and my welder stolen

      Crusty roof rail

      I've cleared some of the crap away from it now (it's not stored at mine - I'd love to own somewhere that big!) so might be able to get more photos. Currently working on the rear brakes, and disappointed to find that the shotblasted rear axle is now starting to rust after two coats of POR15 and 7 years storage under cover...

    • By mat_the_cat
      A mate of mine at work has just restored this, and now it's (just about) finished, is selling it. He wants what seems like a fair price for it, and it might be my only chance to indulge a boyhood dream before values climb too high. And hopefully I shouldn't lose out!
      Is there anyone around who knows the values they actually sell for? Obviously I've looked at adverts and completed eBay listings, but don't know if they reflect reality!

    • By Zelandeth
      Well I've been meaning to sign up here in forever, but kept forgetting. Thanks to someone over on another forum I frequent poking me about it recently the subject was forced back into my very brief attention span for long enough to get me to act on the instruction.

      I figure that my little varied fleet might bring you lot some amusement...

      So...we've got:

      1993 Lada Riva 1.5E Estate (now fuel injected, as I reckon the later cars should have been from the factory...).
      1989 Saab 900i Automatic.
      1987 Skoda 120LX 21st Anniversary Special Edition.
      1985 Sinclair C5.
      2009 Peugeot 107 Verve.

      Now getting the photos together has taken me far longer than I'd expected...so you're gonna get a couple of photos of each car for now, and I'll come back with some more information tomorrow when I've got a bit more time...

      Firstly...The Lada. Before anyone asks - in response to the single question I get asked about this car: No, it is not for sale. Took me 13 years and my father's inheritance to find the thing.

      Yes, it's got the usual rusty wings...Hoping that will be resolved in the next couple of months.


      Next, a proper old Saab. One of the very last 8 valve cars apparently, and all the better for it. I've driven two 16v autos and they were horrible - the auto box works sooooo much better with the torque curve of the 8 valve engine. Just wish it had an overdrive for motorway cruising...

      Next up a *real* Skoda...back when they put the engine where it belongs, right out the back. In the best possible colour of course...eye-searingly bright orange.

      Seat covers have been added since that photo was taken as it suffers from the usual rotting seat cloth problem that affects virtually all Estelles.

      Then we have possibly the world's scruffiest Sinclair C5...

      Realised when looking for this that I really need to get some more photos of the thing...I use it often enough after all! We have a dog who's half husky, so this is a really good way of getting him some exercise.

      Finally - again, I really need to take more photos of - we have the little Pug 107.

      Included for the sake of variety even if it's a bit mainstream! First (and probably to be the only) new car I've bought, and has been a cracking little motor and has asked for very little in return for putting up with nearly three years of Oxford-Milton Keynes commuter traffic, before finally escaping that fate when my housemate moved to a new job. Now it doesn't do many miles and is my default car for "when I've managed to break everything else."

      I'll fill in some more details tomorrow - I warn you though that I do tend to ramble...
    • By danthecapriman
      As many of you might have read on the grin thread and my thread about yank headlights on Volvo 740's, I should have acquired myself this one. I've just got a few pics of said Volvo pre rescue as it sits.
      For those who don't know, it's an 88 740 estate in 2.3 auto GLE spec (my favourite!) which was owned by my sisters boyfriends grandad. He passed away this year and the cars just been sat unused since mid 2015.
      The family are clearing the property and I was told the Volvo and others were going to most likely go for scrap. I said I'd take the Volvo and asked for a price only to be told I could have it!
      The Wolseley 1300 apparently is already spoken for so hopefully that will be saved or at least donate some parts. The Volvo should become mine at some point but the caravan and Omega will probably get weighed in.
      So here are the few pics I have to go on.
      IMG_0331 by Dan Clark, on Flickr
      IMG_0332 by Dan Clark, on Flickr
      IMG_0329 by Dan Clark, on Flickr
      IMG_0333 by Dan Clark, on Flickr
      The Volvo looks ok from the little I can see and having run an MOT history check it seems a good one. It's a low miler at 90k and seems to of only done a couple of thousand miles between tests. Most of the fails seem to be for stupid stuff.
      So the plan at the moment will be to try to get it running and moving then try to get it back home. At the moment it's a 100 miles or so away.
      To be continued...
  • Create New...