Toyota Freestyle GT

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Toyota Freestyle GT

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Demon
Posting Freak

1,614

01-05-2019, 08:15 AM

#411

Another little update, and it may be one of the last now for a while Sad

Looks like we are exchanging on the house on the 24th of this month so the buggy will pretty much stop after that date as i will be mainly beavering away on the house to try and get it in a state where we can move in, probably about 4-5 months work! will try and get a few things done here and there but the house is the priority at the moment.

Well the HUGE tub of bodyfiller arrived last week and me and Paul (Mainly Paul to be honest) started to add the filler to the nosecone. Now comes some sanding and more filling.............
[Image: DSC02368.jpg]

starting to add it.........
[Image: DSC02373.jpg]

Still need to build the shape up around the front area and ignore the shape at the top of the nosecone near the passenger compartment as that will be trimmed to shape after the fibreglass stage.

Also had a few more little parts arrive, black end caps for the front top arms, clips for the coolant lines and a piece of fuel hose for the fuel pressure valve that mounted on the fuel cell.
[Image: DSC02372.jpg]

Started looking at the wiring also this week while Paul was mainly working away on the nosecone. The injector wiring was my first job as i needed to extend the wiring as they where a bit stretched.

this is how it looked before.........
[Image: DSC02370.jpg]

and after.............
[Image: DSC02376.jpg]

Then continued working around the engine cleaning up parts and lengthening/shortening certain wires so they suit the buggy better.

Then came a package from James at CJPerformance. Thermostat housing as the one on the engine has seen better days. and the ECU connection bloack that i have been after now for nearly a year! Finally i can now finish off the engine loom and hopefully start the wiring for the lights,indicators etc.....

[Image: DSC02380.jpg]

The wires on the connection block where really short so first job was to extend them all so i have something to work with...........
[Image: DSC02383.jpg]

Will try this week to crack on with the wiring but probably won't have the time as i have other jobs that need my attention.

Another job i started to do was to get the driveshafts measured up and get them ready to send off. Cleaned and prepped the mini ones with no problems and then did the starlet ones. Thats where i had a problem. Went to test fit the driveshafts into the gearbox and guess what! Yep they don't fit! Turns out there are 2 different types of starlet driveshafts and when i changed the gearbox over for a LSD version i didn't get the driveshafts and the ones i have are the wrong type. Managed to drain the gearbox oil and remove the driveshaft cups to count the splines. Found out i need a set of 23 spline shafts and after lots of searching and messaging people i have 1 on the way and maybe the second as well.

Already confirmed with the guy who is going to do the work that he can do them and he is currently patiently waiting for them.

Few more little updates soon and then will be on hold for a while as the house takes over my life......LOL

Jason Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

01-05-2019, 08:15 AM #411

Another little update, and it may be one of the last now for a while Sad

Looks like we are exchanging on the house on the 24th of this month so the buggy will pretty much stop after that date as i will be mainly beavering away on the house to try and get it in a state where we can move in, probably about 4-5 months work! will try and get a few things done here and there but the house is the priority at the moment.

Well the HUGE tub of bodyfiller arrived last week and me and Paul (Mainly Paul to be honest) started to add the filler to the nosecone. Now comes some sanding and more filling.............
[Image: DSC02368.jpg]

starting to add it.........
[Image: DSC02373.jpg]

[Image: DSC02377.jpg]
[Image: DSC02379.jpg]

Still need to build the shape up around the front area and ignore the shape at the top of the nosecone near the passenger compartment as that will be trimmed to shape after the fibreglass stage.

Also had a few more little parts arrive, black end caps for the front top arms, clips for the coolant lines and a piece of fuel hose for the fuel pressure valve that mounted on the fuel cell.
[Image: DSC02372.jpg]

Started looking at the wiring also this week while Paul was mainly working away on the nosecone. The injector wiring was my first job as i needed to extend the wiring as they where a bit stretched.

this is how it looked before.........
[Image: DSC02370.jpg]

and after.............
[Image: DSC02376.jpg]

Then continued working around the engine cleaning up parts and lengthening/shortening certain wires so they suit the buggy better.

Then came a package from James at CJPerformance. Thermostat housing as the one on the engine has seen better days. and the ECU connection bloack that i have been after now for nearly a year! Finally i can now finish off the engine loom and hopefully start the wiring for the lights,indicators etc.....

[Image: DSC02380.jpg]

The wires on the connection block where really short so first job was to extend them all so i have something to work with...........
[Image: DSC02383.jpg]

Will try this week to crack on with the wiring but probably won't have the time as i have other jobs that need my attention.

Another job i started to do was to get the driveshafts measured up and get them ready to send off. Cleaned and prepped the mini ones with no problems and then did the starlet ones. Thats where i had a problem. Went to test fit the driveshafts into the gearbox and guess what! Yep they don't fit! Turns out there are 2 different types of starlet driveshafts and when i changed the gearbox over for a LSD version i didn't get the driveshafts and the ones i have are the wrong type. Managed to drain the gearbox oil and remove the driveshaft cups to count the splines. Found out i need a set of 23 spline shafts and after lots of searching and messaging people i have 1 on the way and maybe the second as well.

Already confirmed with the guy who is going to do the work that he can do them and he is currently patiently waiting for them.

Few more little updates soon and then will be on hold for a while as the house takes over my life......LOL

Jason Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Sparkystav
Administrator

14,683

01-05-2019, 09:36 AM

#412

good updates mate, shame its going to go on hold Sad

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

Sparkystav

01-05-2019, 09:36 AM #412

good updates mate, shame its going to go on hold Sad

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

Demon
Posting Freak

1,614

01-05-2019, 10:01 AM

#413

Thanks Mate Big Grin

Yes shame to put it on hold but the house comes first and need to crack on with that Big Grin

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

01-05-2019, 10:01 AM #413

Thanks Mate Big Grin

Yes shame to put it on hold but the house comes first and need to crack on with that

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon
Posting Freak

1,614

23-06-2019, 05:28 PM

#414

Anyway, back to the update.

Got a length of 28mm copper pipe delivered and some bends/joiners with it. This will be forming the coolant lines that run down the centre of the buggy. They are the perfect size and the joiners can be cut in half and soldered on so that they create a better fit for the silicone hose to join to, as shown here...........

[Image: DSC02396.jpg]

just need to work out routing the pipes and hopefully get to it. Going to be tight with everything running down the centre but will keep it tidy if i can pull it off.

Also managed to pick up a connector for the fan switch, comes straight from a fiat cinqy but plugs striaght into the switch mounted to the side of the rad.
[Image: DSC02401.jpg]

Also been looking at the steering wheel, needs to have a radiused edge but its not very IVA friendly so i have started to make a pad piece that will make it meet the regs. Ignore the blue colour at the moment as its going to get trimmed in black when i get some material.
[Image: DSC02402.jpg]

After IVA i will be switching to a removable go-kart steering wheel so it gives more room, will be terrible at speed but should be ok for corners and most normal speeds.

Also finally got the driveshafts sorted via my contact on 16v mini forum. Guy named Adam who is a complete legend. Sent him both shafts and gave him the desired lengths i needed. He cut, sleeved them and welded them up. He has done shafts for honda engined mini's and starbo engined mini's so these should be all good. Was going to get them cryo treated but at £160 for the 2 i think i might just run the risk. Can get them remade for less than that anyway.

stripping down the starbo shafts.........
[Image: DSC02400.jpg]

and the finished Demon shafts ready to assemble and fit.........
[Image: DSC02410.jpg]

Paul has also managed to add more body filler to the nosecone and its really starting to take shape now, hopefully won't be long and i can move the buggy to my garage and start taking a mould from it.

[Image: DSC02408.jpg]

Sort of a weird update as i have been working on lots of little things but i only get like 20 minutes here or 15 minutes there to do work. Just thought you all should know that i haven't given up on this Big Grin

Jason

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

23-06-2019, 05:28 PM #414

*** Mini Update ***

Well as most of you now know i have a house and most of my time and money is currently being spent on that. I have managed to do a few little things on the buggy though and will continue to get a few little bits done, whenever i get time, so not that often then! The house has needed a lot more work then we ever thought and is going to be a real big project and although the buggy is taking a back burner it won't get left or sold! I can promise that Big Grin

Anyway, back to the update.

Got a length of 28mm copper pipe delivered and some bends/joiners with it. This will be forming the coolant lines that run down the centre of the buggy. They are the perfect size and the joiners can be cut in half and soldered on so that they create a better fit for the silicone hose to join to, as shown here...........

[Image: DSC02396.jpg]

just need to work out routing the pipes and hopefully get to it. Going to be tight with everything running down the centre but will keep it tidy if i can pull it off.

Also managed to pick up a connector for the fan switch, comes straight from a fiat cinqy but plugs striaght into the switch mounted to the side of the rad.
[Image: DSC02401.jpg]

Also been looking at the steering wheel, needs to have a radiused edge but its not very IVA friendly so i have started to make a pad piece that will make it meet the regs. Ignore the blue colour at the moment as its going to get trimmed in black when i get some material.
[Image: DSC02402.jpg]

After IVA i will be switching to a removable go-kart steering wheel so it gives more room, will be terrible at speed but should be ok for corners and most normal speeds.

Also finally got the driveshafts sorted via my contact on 16v mini forum. Guy named Adam who is a complete legend. Sent him both shafts and gave him the desired lengths i needed. He cut, sleeved them and welded them up. He has done shafts for honda engined mini's and starbo engined mini's so these should be all good. Was going to get them cryo treated but at £160 for the 2 i think i might just run the risk. Can get them remade for less than that anyway.

stripping down the starbo shafts.........
[Image: DSC02400.jpg]

and the finished Demon shafts ready to assemble and fit.........
[Image: DSC02410.jpg]

Paul has also managed to add more body filler to the nosecone and its really starting to take shape now, hopefully won't be long and i can move the buggy to my garage and start taking a mould from it.

[Image: DSC02408.jpg]
[Image: DSC02407.jpg]
[Image: DSC02406.jpg]

Sort of a weird update as i have been working on lots of little things but i only get like 20 minutes here or 15 minutes there to do work. Just thought you all should know that i haven't given up on this Big Grin

Jason

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

DaveEdin
Posting Freak

5,657

23-06-2019, 09:03 PM

#415

Good stuff Jase :thumbup:

IS200 Sport - Sold
Mazda 6 MPS - Zoom Zoom!

Modifications
Completed:
Currently 280bhp/295lbft; 3" Meercat custom exhaust; KW Suspension; FMIC; SSP; HPFP; Custom Stainless Steel Dials - for the moment, the only set in the world!! (Till the group buy for MPSOC anyway :lol: )

In Progress:
E-Tuning remap ongoing via Cobb Accessport; Braided brake lines; Stubby aerial; Tinted repeaters and sidelights; 3 Port Boost Control Solenoid; 3" HTP Intake

DaveEdin

23-06-2019, 09:03 PM #415

Good stuff Jase :thumbup:

Demon
Posting Freak

1,614

31-12-2019, 04:09 PM

#416

A few weeks back i managed to find 5 minutes to cover the steering wheel centre in foam and then suede so now hopefully its a bit more IVA friendly.

[Image: 2012-02-11075905.jpg]

First thing to do today was get everything sorted out as i have loads of bits just everywhere in the workshop, under my desk, in box's on the buggy etc.....

[Image: 2012-02-11101137.jpg]

also picked these rather nice zip on coilover covers from Autosport International a few weeks back, will keep the rear coilovers all clean and scum free....

[Image: 2012-02-11083154.jpg]

now im all organised and everything is easy to find when i need it.

Then i started by getting the new rear painted calipers fitted.....

[Image: 2012-02-11075803.jpg]

Then got the lime green gear gaiter glued to the surround and on the car.............

[Image: 2012-02-11134316.jpg]

Started making up the compensator for the handbrake and i think i have now sorted it. Will find out hopefully soon when i find time to fit it and trial it out.....

[Image: 2012-02-11131737.jpg]

Got the front nosecone filled with a bit more filler and then gave it a quick sand with the orbital and just sprayed a quick coat of primer to see the rough finish. Obviously it needs a lot more work but its getting there slowly.....

[Image: 2012-02-11120327.jpg]

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

31-12-2019, 04:09 PM #416

Been a while but here goes......................

Right then..................

Think its that time, finally.

*** Update Time ***

Well with all my time being spent on sorting the house i have had very little free time, and with work being really busy as well i just haven't had the chance to get the buggy out and get any work done on it. The workshop is rammed and there is currently no room to get to the buggy to do any work so its just been sat under the dust sheet for the last 5-6 months.

Well today Sarah was dragged into work for the day and its too cold here (-8) to do any brickwork today so i had the day to myself. Rather than just loaf out for the day i decided to go into work with Sarah and get some work done on the buggy. Really glad i did as i managed to geta few bits done and had a good day of just cracking on with it.

First thing to do was get the workshop cleared and get the buggy out and see what was what......

how it started off the day...............

[Image: 2012-02-11075742.jpg]

[Image: 2012-02-11075749.jpg]

[Image: 2012-02-11075828.jpg]

[Image: 2012-02-11075817.jpg]

[Image: 2012-02-11075844.jpg]

[Image: 2012-02-11075833.jpg]

A few weeks back i managed to find 5 minutes to cover the steering wheel centre in foam and then suede so now hopefully its a bit more IVA friendly.

[Image: 2012-02-11075905.jpg]

First thing to do today was get everything sorted out as i have loads of bits just everywhere in the workshop, under my desk, in box's on the buggy etc.....

[Image: 2012-02-11101137.jpg]

also picked these rather nice zip on coilover covers from Autosport International a few weeks back, will keep the rear coilovers all clean and scum free....

[Image: 2012-02-11083154.jpg]

now im all organised and everything is easy to find when i need it.

Then i started by getting the new rear painted calipers fitted.....

[Image: 2012-02-11075803.jpg]

Then got the lime green gear gaiter glued to the surround and on the car.............

[Image: 2012-02-11134316.jpg]

Started making up the compensator for the handbrake and i think i have now sorted it. Will find out hopefully soon when i find time to fit it and trial it out.....

[Image: 2012-02-11131737.jpg]

Got the front nosecone filled with a bit more filler and then gave it a quick sand with the orbital and just sprayed a quick coat of primer to see the rough finish. Obviously it needs a lot more work but its getting there slowly.....

[Image: 2012-02-11120327.jpg]

[Image: 2012-02-11120333.jpg]

[Image: 2012-02-11120341.jpg]

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon
Posting Freak

1,614

31-12-2019, 04:09 PM

#417

cut up, this is the remains of the old cover......

[Image: 2012-02-11101012.jpg]

and the finished article, looks so good in the flesh.....

[Image: 2012-02-11100857.jpg]

Really happy with the finish and its another part fitted that i had lying about.

Then got the rear plate brackets welded to the rear bar.....

[Image: 2012-02-11130643.jpg]

and while i had the welder out i knocked up a quick bracket for the rear tow eye and got that welded to the rear bar as well. This will be fitted after the dreaded IVA test of course.....

[Image: 2012-02-11133847.jpg]

Well that was today Big Grin

Sort of worked on a bit of everything really but was good to get some work done on the buggy and get a few parts out of their box's and fitted. Doubt i will get any time to do much work on it now till after march when work is back to normal and im not working stupid hours.

Comments welcome as always people Big Grin

Jason

The 'Demon' is on its way :Shooting:

Now driving a Sh!tbox Sad

Smurf SOLD
Outlaw No: 016 Cool

Demon

31-12-2019, 04:09 PM #417

While sorting out the parts under my desk i found the clear cam cover that i bought a while back. Had a little think about this as it doesn't fit on the engine with my non stop tunning adjustable cam. Decided to try and cut the standard cover up to create a spacer piece and it worked a treat. Was a bit fiddly cutting it up and sanding it smooth but im glad i spent the time. It looks spot on and you wouldn't think it was the old cover cut down. It also now means that the new cam cover has retained the rubber gasket around the edge so its sealed properly around it....

before.....

[Image: 2012-02-11082611.jpg]

cut up, this is the remains of the old cover......

[Image: 2012-02-11101012.jpg]

and the finished article, looks so good in the flesh.....

[Image: 2012-02-11100857.jpg]

[Image: 2012-02-11100823.jpg]

Really happy with the finish and its another part fitted that i had lying about.

Then got the rear plate brackets welded to the rear bar.....

[Image: 2012-02-11130643.jpg]

[Image: 2012-02-11130634.jpg]

and while i had the welder out i knocked up a quick bracket for the rear tow eye and got that welded to the rear bar as well. This will be fitted after the dreaded IVA test of course.....

[Image: 2012-02-11133847.jpg]

[Image: 2012-02-11134145.jpg]

[Image: 2012-02-11134200.jpg]

Well that was today Big Grin Sort of worked on a bit of everything really but was good to get some work done on the buggy and get a few parts out of their box's and fitted. Doubt i will get any time to do much work on it now till after march when work is back to normal and im not working stupid hours.

Comments welcome as always people Big Grin

Jason