Workshop/Project car thread. Maestro rust repairs.

[High Jetter]

Underneath the Arches https://g.co/kgs/GtCiVD

[JMotor]

12 hours ago, High Jetter said:

Underneath the Arches https://g.co/kgs/GtCiVD

I'll put that on before chopping into them.

Then I'll cry, tank a can of Monster then sit for an hour with this expression (sans ciggie).

 

[JMotor]

Some work was done to Boaby the Dobber Maestro today.

This impressive bit of plumbing greeted me. Yes, that is carpet being used to protect it. That had to go. The rubber hose on the rad side was a replacement hose for a Massy tractor!

The last owner had thankfully threw in the old pipe.

Rotten tae fuck that. Nae guid.

Good enough template though. Pipe bought off eBay. Time to fab something up.

Just like that! I fully welded up and painted it with some buzzweld WAR. Looks the part.

Refitted it and made a rad hose to connect that hard pipe to the rad. This time using hose from an old Vauxhall coolant hose I had lying about and a joiner from the lashed up pipe.

Well happy with that! One very tiny pin hole to sort, but that an easy fix. Just wanted it to look neater and close to factory again.

Tomorrow will be spent getting the heater matrix sorted. Old one had been bypassed. Was given another one, so I'll see if that's fit for use.

[Matty]

4 minutes ago, JMotor said:

Some work was done to Boaby the Dobber Maestro today.

This impressive bit of plumbing greeted me. Yes, that is carpet being used to protect it. That had to go. The rubber hose on the rad side was a replacement hose for a Massy tractor!

The last owner had thankfully threw in the old pipe.

Rotten tae fuck that. Nae guid.

Good enough template though. Pipe bought off eBay. Time to fab something up.

Just like that! I fully welded up and painted it with some buzzweld WAR. Looks the part.

Refitted it and made a rad hose to connect that hard pipe to the rad. This time using hose from an old Vauxhall coolant hose I had lying about and a joiner from the lashed up pipe.

Well happy with that! One very tiny pin hole to sort, but that an easy fix. Just wanted it to look neater and close to factory again.

Tomorrow will be spent getting the heater matrix sorted. Old one had been bypassed. Was given another one, so I'll see if that's fit for use.

Are you using it on the road yet? Be interesting to see if you gel with it, what with it being quite different to your usual stuff.

[JMotor]

Just now, Matty said:

Are you using it on the road yet? Be interesting to see if you gel with it, what with it being quite different to your usual stuff.

Aye, had a few runs out now. Took my Dad out in it, instantly called it a tank! 😆

Won't deny it's definitely different to the Altezza. Despite the Toyota actually being older! That car is light-years ahead on every front. Hell the old Nexia felt more modern to drive!!

Funny thing is, I do like it. The A-Series goes well, sits at 60 no problems. Surprisingly roomy and comfortable too. 

Used to chokes, carbs and dizzys from owning 1.0 Novas, MK2 Polos and the such. I just had to remind myself it needs a little warm up time first. Oh and don't dead steer! 😆

[grogee]

25 minutes ago, JMotor said:

Aye, had a few runs out now. Took my Dad out in it, instantly called it a tank! 😆

Won't deny it's definitely different to the Altezza. Despite the Toyota actually being older! That car is light-years ahead on every front. Hell the old Nexia felt more modern to drive!!

Funny thing is, I do like it. The A-Series goes well, sits at 60 no problems. Surprisingly roomy and comfortable too. 

Used to chokes, carbs and dizzys from owning 1.0 Novas, MK2 Polos and the such. I just had to remind myself it needs a little warm up time first. Oh and don't dead steer! 😆

Welcome to the winner's circle. Excellent pipework. I'm strangely jealous of A-series power. 

[Matty]

7 minutes ago, grogee said:

Welcome to the winner's circle. Excellent pipework. I'm strangely jealous of A-series power. 

It's tappety noisy bliss pal. Won't be without one 😄

[grogee]

On 9/20/2023 at 9:49 PM, JMotor said:

These are not going to be fun to fix. 

Did get a pair of wings thrown in. So I've got metal to play with. 

"I'll just open the boot and see what I've got. Ah! Shit, that's not ideal"

Got plastic bumper ones and they are almost too good to chop up.

Fuck it!

I'll not poke the bear for the moment. I'll look into it next year, inners will definitely need done too. That doesn't worry me. As long it's metal back in there, nae one will ken how I made them once the sealer and gravitex is over it. 

Those shite mudflaps are getting thrown tae fuck in aw! Rust causing bastards!

I think you should christen the car "Wobert" 

[JMotor]

Thank you @grogee.

I do feel like a winner. 

The wee 1300 is a fine unit. But I'm the opposite. I think the EFI 2.0 would make a Maestro a much nicer car to use.

Then as @Matty says, they are happy and tappety things.

[Matty]

6 minutes ago, JMotor said:

Thank you @grogee.

I do feel like a winner. 

The wee 1300 is a fine unit. But I'm the opposite. I think the EFI 2.0 would make a Maestro a much nicer car to use.

Then as @Matty says, they are happy and tappety things.

Perfect bimbling about motor for when you don't feel like having your hair set on fire by the Altezza 

[JMotor]

More dicking about with the Maestro.

Knew the heater had been bypassed. But not sure why.

Fuck me! That's probably a good reason!

Nah. Not even gonna bother with that. Was given another heater matrix. Yeah, that was fucked too. These are NLA, until I saw one on the Bay o' E. 

Not cheap, but looks good quality. Fits perfectly and comes with the rectangular seal for the matrix hard lines.

The metal pipes are sat in a bath of that rust eating acid, then I'll repair those and reuse.

Access on the one piece dashes isn't bad if you remove the glovebox. However go carefully as shit will break. Like what someone had done in the past. I'll have to get creative with some duct tape!

Want to sort this out too.

The amount of different sized screws that were used by one of the previous owners is laughable!

I'd nearly put money on these fuckers being picked from the Danish cookie tin filled to the tits with random screws!

[JMotor]

Altezza went in for it's second MOT.

Another clean pass. 

Aww yis!!!

[grogee]

You bugger! Is that the heater matrix from overseas? I had my eye on that for my Maestro Parts Hoarding Corner. Even though mine seems fine and has been thoroughly flushed out. 

Funny how you don't miss a heater until its not there. Although October is positively balmy at the moment. 

I've had some success fixing* broken trim bits with a glue gun, in case your duct tape idea doesn't work. 

[JMotor]

2 hours ago, grogee said:

You bugger! Is that the heater matrix from overseas? I had my eye on that for my Maestro Parts Hoarding Corner. Even though mine seems fine and has been thoroughly flushed out. 

Funny how you don't miss a heater until its not there. Although October is positively balmy at the moment. 

I've had some success fixing* broken trim bits with a glue gun, in case your duct tape idea doesn't work. 

Never thought about a glue gun!

Might worth getting one to burn myself repeatedly with 😆.

Oh noooo, that heater matrix was from a supplier in the UK.

https://www.ebay.co.uk/itm/303993815231?hash=item46c77180bf:g:YHkAAOSwamZe64kI&amdata=enc%3AAQAIAAAA8Fhs1VzCaiuocrbdHdy4Cp9d6KBfbMUi3UL7c34AVqeOZyq%2Fa6qGBgR8swwQnBbfZymmhfrdjqcPULF%2FZUdzR%2FT%2BXL4jROLPq778NS9NMJA9%2FZEwxfl2KfK6ZIscsaIwUnvFpjny16n9PyuVMqjGVzXZ%2BoBT3bDhT5%2BMAc7hy5lyy36Z0DJ35TafOq2k5957d0cD45EyvRpXwInYGz9f9jU%2FRGrOOV3GlDYtUvUbVwKYtKSgMd5dHPVRR05Nt%2FTgX6hMTzudP5iev3umN5eAaFZNEmZtf5NB%2F4xNbh0CHpkhgSFZQAYsOF2DtSFd9P85cw%3D%3D|tkp%3ABk9SR_6Kk-XgYg

Admittedly it was expensive. However both of mine were ruined. It can be recored in the future as well. Fits perfectly in the blower box.

I wanted to get some heat back in because as you said, it's actually been very mild weather wise. The thing mists up like nowt else.

[grogee]

Ah this is the one I wanted to hoard. Cheaper but would be a week or two in transit then it's customs lottery. 

I may still buy it for the spares hoard. 

https://www.ebay.co.uk/itm/285199809729?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=EM2Bv-_7QgG&sssrc=4429486&ssuid=2Z40wC2iSsq&var=&widget_ver=artemis&media=COPY

[JMotor]

If it's cheap enough.

I'd just buy it and wait on it. It's interesting/alarming to see what is now NLA for these cars.

[JMotor]

This Maestro is a challenge.

(Borrowed picture of these pipes)

These heater matrix pipes were causing me a headache. As they're pish! Mild steel, they rot from the inside out. 

Couldn't buy new ones because NLA. Someone had a batch made in stainless, however they were sold out.

Mixture of chemy metal and welding saw them fixed. Boaby the dobber bastard now has heat inside the cabin.

So far no leaks. Excellent.

Then I stuck my head under the car. Discovered the exhaust from the downpipe back is new. Nice! Except the bore is too small on the centre section. So it can't be clamped down.

That'll be why it's noisy then! Some more chemy metal and mair welding will fix that! 😆

[grogee]

14 hours ago, JMotor said:

This Maestro is a challenge.

(Borrowed picture of these pipes)

These were causing me a headache. As they're pish! Mild steel, they rot from the inside out. 

Couldn't buy new ones because NLA. Someone had a batch made in stainless, however they were sold out.

Mixture of chemy metal and welding saw them fixed. Boaby the dobber bastard now has heat inside the cabin.

So far no leaks. Excellent.

Then I stuck my head under the car. Discovered the exhaust from the downpipe back is new. Nice! Except the bore is too small on the centre section. So it can't be clamped down.

That'll be why it's noisy then! Some more chemy metal and mair welding will fix that! 😆

Is that part to/from the heater matrix? 

[JMotor]

 

1 hour ago, grogee said:

Is that part to/from the heater matrix? 

Sure is.

[JMotor]

Ran Maestro about. Still hauds watter. Fixed exhaust leak. Mapp gas and some four poond hammer action to the slip joint on the downpipe resulted in nae leaks after.

Grand!

So Boaby! Ya Dobber! Yous oot on daily duties noo! Earn ya keep!

Tomorrow will involve doing something a little different. I'll be using a computer too! No mucking about with welding stuff.

[AnnoyingPentium]

5 minutes ago, JMotor said:

Tomorrow will involve doing something a little different. I'll be using a computer too! No mucking about with welding stuff.

[JMotor]

Had a special guest today.

Mr @AnnoyingPentium paid the shed a visit.

Got a common EcoTec issue sorted. The camshaft sensor had gone bad. 

Had a new style sensor in stock, so got to swapping them out. This involves getting the cambelt cover off and there was some hiccups along the way. Mostly down to me dropping tools or trying to hold wires in a way I could crimp them. 

The new sensor has a completely different plug. So I used the provided crimps, heat shrink and tesa tape to make the job neat.

Laptop with Opcom was used to clear the stored codes. A short test drive by Ryan confirmed that the car was back to full health after some FU GUTTY could be used without issue. Tidy job👌.

I'll leave the rest to Mr Pentium to fill in the rest of the days activities. With this as the last picture for my post.

[big_al_granvia]

You in Scotland jmotor?? Could star radiators in govan not overhaul/rebuild that matrix

[JMotor]

12 hours ago, big_al_granvia said:

You in Scotland jmotor?? Could star radiators in govan not overhaul/rebuild that matrix

Aye, I am.

It worked out easier to get that new matrix from eBay. Would be about half a day in travel to take an old one there and I think they'll not wanted to fix it as both old units were ruined with bodgery.

However, handy to know of someone fairly near to get rad work done if I need it in the future.

[JMotor]

That's how the Maestro is now sat. 

Found a split CV boot. No big deal, got a stretchy boi. Except I left it at work. Bugger!

Drove to Dumfries and a stop at TMS bagged me two more. The guys behind the counter really liked the car. 

Had a blast driving it there and back. Buzzs along with no complaints. Not a bad place to be in. Does car perfectly fine. Brakes could be better, it does stop. Just doesn't have great feel in the pedal. 

When I got back to the shed. Got the driveshaft dropped out. Felt it'd be easier having it on the bench to replace the boot.

But when I tried the outer CV joint, I found quite a bit of play and it felt weird. It's been out of grease for some time. So it's shot. Not ideal, but at £30 for a new one, meh! I'll not cry about it. Drivers side track rod end is fucked as well, again not fussed as it's a wearing part. 

Had a laugh* at the inner CV bolts while taking it off. Like a VAG product they are held with six bolts in three pairs.  

I found at least three different types of bolt used. All drilled and lock wired, which was a good thing as all of them were about bloody finger tight!!

So I'll add bolts to the list too. The poor thing will be stuck on stands until I get the parts in 😔.

GAH! Starting to feel bad for a bloody Maestro! Think I need to give me 'ead a wobble! 😆

[JMotor]

Got a little update, nowt fantastic really. 

Done both the CV joint and track rod end on the Maestro. Dead simple to do. Just need to get it MOT'd next. 

Which will wait for a little while. I moved back on to the Corsa. Mostly to keep some progress going with it.

I decided to do the last major bit of rot on the car.

Hard experience has taught me, that those holes are only letting me know something worse is hiding behind that.

Oh okay. Is that it!? That's bugger all really. Crispy bits were chopped out. Rust killer acid deployed, repairs done and a heavy dose of red oxide to finish.

Hacked up an already cut up replacement sill for the outer piece. Plug and drain holes drilled, I slapped some more red oxide the new section. Then started tacking the new piece on.

Gave up at that point. Was happy with the progress. Another session will see it done. It's not the last welding job to do, just the last biggest area to do. 

[JMotor]

Another session on the sill.

I'm very pleased with that. Probably my best work to date. Will need a skim of pudding to make it straight, but to be honest I can live with that!

That completes the last major section of rust in this pile of Corsa. 

[Matty]

2 minutes ago, JMotor said:

Another session on the sill.

I'm very pleased with that. Probably my best work to date. Will need a skim of pudding to make it straight, but to be honest I can live with that!

That completes the last major section of rust in this pile of Corsa. 

I'd be pleased with that too. Seamless.

[JMotor]

17 minutes ago, Matty said:

I'd be pleased with that too. Seamless.

Thanks 🙂.

I've either gotten better with the welder or my skills with the grinding disc have improved 😆.

[JMotor]

That'll be the Maestro fit for another year!

Time to get it used again.