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A Potential Rebuild Project


Jack Taylor
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I've used this method to make a carb gasket for an old Nikki carb I had fitted to a Suzuki SJ. No damage to the carb at all. It's a matter of being gentle and not beating the c**p out of anything. The gasket paper doesn't need much persuasion.

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Wow, that's a pretty cool technique... I feel it's tricks like that we're starting to loose!

I bet it takes a fair bit of practice and experience to do; I'd probably hit too hard and break the thing I was trying to template! :laugh: 

My mum has a very nifty cutting machine she uses for art and crafts that you can feed it vector files of shapes that it will cut out, but you can also scan a shape into it, which it will then cut out on a different piece of paper/thin card. Could be useful for things like this!

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2 minutes ago, Cyker said:

I bet it takes a fair bit of practice and experience to do;

No, not really. I would suggest practicing with an old part if you don't feel confident. Try it with a piece of normal paper and an old car part that would use a gasket. It's easier than you think. 

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I’ve made many a gasket from an old Cornflakes box.  If you don’t have a ball pein hammer, a spanner will do the job just as well.

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6 hours ago, Stivino said:

I’ve made many a gasket from an old Cornflakes box.  If you don’t have a ball pein hammer, a spanner will do the job just as well.

I remember watching a documentary where Australian truckers would use cardboard boxes to make gaskets to keep their trucks running.

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15 hours ago, Big_D said:

I remember watching a documentary where Australian truckers would use cardboard boxes to make gaskets to keep their trucks running.

If it seals it seals! 🤣 Specially in the outback when you need to get back to safety.

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Tonight was a quick night of work. Just decided to start it up to let it warm, and then also measure the vacuum hose connection pipes using a set of digital calipers that I borrowed from a friend at work.

 

I have found the following sizes for the required internal diameters of the hoses. (For anyone that needs that info).

Small cam cover breather (plumbs into filter housing) - 6.30mm

Vacuum pipe (To valve on rear of filter housing) - 6.30mm

Large cam cover breather (Plums into intake manifold) - 9.50mm

All small control pipework for carburetor vacuum conections & actuators - 4.00mm

 

I have now ordered a 1m length of each of the sizes, along with some nice little spring clips, and a couple of larger jubilee clips for the 9.50mm hose.

20220119_161838.thumb.jpg.8b4517390502a79b37da4a0088959a9f.jpg

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Today I replaced any vacuum pipe that I have disturbed. Some were really broken on the ends which I think would have been causing air leaks.

The large breather (9.5mm) is really quite stiff pipe and as such needs a different type buying. It fits, but it's tight up against the bottom of the air filter housing which is annoying. I have now ordered some thinner walled 9mm ID silicone hose for that and will try that instead.

The small 4mm pipes fit nice and snug, but the little "clamps" that came with the pipe have pretty much zero strength to them which is annoying. Oh well! I suppose with the hose being pretty tight on the metal pipes it should be okay anyway I would think.

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I also used one of these to test the head gasket. It seemed to bubble through from the radiator, but didn't change colour, so hopefully that's a good sign!

2109412482_Headgaskettester.thumb.jpg.c9d157efc7d3348f6c005feaf97159ae.jpg

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Today was a quick day on the car.

I ticked off a couple of little things. The first one being the poor fitting pipe that I bought for the breather. I replaced it with softer, thinner walled silicon hose which has fit perfectly.

The second issue solved was the sticking choke that was causing poor starts from cold. The flap for some reason would never quite close fully. I have since found out that the last time I had the carb apart (a few years back) I had refit the linkage from the choke incorrectly!

Annoyingly, I have since had the carb apart 2/3 times, and every time I have reassembled it how it was when I incorrectly put it back together the first time!

It is now, MUCH easier to start, and idles when cold correclty! 😄

I had the linkage going through the large hole in the top of the first picture! As you can see in the second picture, there is a smaller linkage hole behind this one on a different lever! That is the one the linkage was supposed to be in!

20220129_110204.thumb.jpg.881bdda85d21cd90a3881061a19842ed.jpg    1982189202_IncorrectCorrectLinkage.thumb.jpg.8178b19edaceab32d01aa9ca043102b0.jpg

On a not so good note, we had a guy from the local bodywork specialist come and look at the rust and welding required. He reckons it'd be at least a weeks work (Which at who knows how much per hour) is probably going to cost a serious amount of money!

Either we need to bite the bullet and accept the initial outlay to get this project off the ground, or we need to get good at welding... fast...

 

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Well! It's good news. We've had a quote for the welding, we have hummed and pondered over it for a while and then decided that "There are much worse things to spend money on than a good project" so it has been given the go-ahead. We are getting it booked in for a lot of the metal work soon, so prior to that I'll be stripping the car down as much as possible and refurbishing the parts I can in the garage as I take them off and box them up for storage. 😄

More updates to follow. 😄

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On 1/16/2022 at 2:04 PM, Stivino said:

I’ve made many a gasket from an old Cornflakes box.  If you don’t have a ball pein hammer, a spanner will do the job just as well.

Yes I’ve used a spanner quite a few times, last time I used one was making a carburetor gasket for my 1948 American built McCormick International Farmall Cub, tricky but it’s been there for years and works great.

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Right! We have a date for the welding work. It's going to a local garage on the 28th February!

So, before then I have loads of bits to strip off, clean up, box and refurbish. Plenty to get busy on now!

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When you strip everything, take photos. You'll be glad you did when you start to re-assemble everything.

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  • 1 month later...

Just to update this a little. The project hasn't stopped. The car has been sent off for a serious amount of welding to be carried out! I am not sure how long it'll take, but hopefully not too long! 😄 Fingers crossed all goes to plan.

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  • 3 weeks later...

Well it's back from the welders. They had to rebuild the entire right hand sill, most of the left sill, both rear arches, the two rear door bottom corners and the front right arch. They did a load of work, and now it's time to just get a bit of paint on it (Amazingly we have found a full can of colour matched paint). This is basically just going to be sprayed on to stop it rusting through the primer until we fully strip, filler, and paint it.

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On another note, the carb seems to be clearing up the more we run the car and move it around. Before it would stumble when revved hard (blips of the throttle), but now it appears that his has cleared up and it revs very smoothly.

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1 hour ago, Roy124 said:

Starting to look good. 

Cheers! 😄 We'll get there with it in time! The biggest discussion at the moment is what colour we want to go for it! 🤣 

I like the idea of a dark metallic red or blue.

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Will it be kept in a standard Carina colour OR will you pick another Toyota or other colour?

Maybe some work with photoshop will help make a decision. 

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On 4/10/2022 at 6:05 PM, Big_D said:

What about Metallic Blue with Red accents?

The metallic blue sounds nice. Not sure about the red accents.

It is tempting to go two tone so bottom half one colour, roof another colour, or something like this.

File:Volvo480 TwoTone.JPG - Wikimedia Commons

16 hours ago, forkingabout said:

Will it be kept in a standard Carina colour OR will you pick another Toyota or other colour?

Maybe some work with photoshop will help make a decision. 

We're really not sure at the moment. Just whatever we think looks nicest I think. 😄

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As @forkingabout recommended, have a play around with photoshop or similar. You'll be able to get a basic idea of colours and see how they fit with one another

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