1973 TA22 Toyota Celica - Patchwork quilt

Brief window of time over the weekend meant that I could get an afternoon in the workshop before the rest of the Xmas jobs kicked in. So decided I'd start on repairing the rear quarter.

Usual CAD approach meant that I was soon in position to start shaping up a bit of metal to fill the void


Used the Cleco pins to hold bits in place while I moulded the rest. Why moulded? Well I wanted to ensure a close fit to the existing metal work before it was removed so I could pattern and bolt holes etc. from underneath


Once done I could then test fit the position of jack clamp on top


Job done. I'll leave that as is for now while I move on the the inner and outer arch which I need to position accurately before I can tie it all together as the three panels meet in that bottom corner.


Have a great Christmas one and all, here's to much tinkering over the hols and in the New Year. Chef duties now beckon 😂😂

Rant allowed (missed the previous update) - equally I have a low tolerance for poor service (or goods for that matter although I expect chocolate teapots if that’s all I’m paying for). It seems it some organisations/people that getting what you’ve paid for seems a bit of a high aim..

Like your thinking in the “make new before removing old” - must remember that some day!

Firstly, Happy New Year all, trust you had a enjoyable festive period and the start to 2020 has been good so far.

As for my car antics over the break, well in truth not much on my two projects, however I did at least get some car-related stuff done - more on that shortly...
John, yes the arch repair panel is NOS that was sold back in the 80's and 90's from what I understand. These cars used to rust prolifically in these areas so was quite a sizeable market at the time.

While not a bad panel in terms of fit, as per the example I've removed, their effectiveness was often down to how they were fitted at the time which seemingly was not well, often with tack welds and then smothered in filler to hide the underlying rust that was left on the car... exactly as was done to mine in fact.

The panel I have is technically not quite period correct for this car as it should have rounded arch lips, but as these are all but non-existent needs must etc.

Phil, indeed for tricky shaped panels such as this with curves in all directions, plus lots of tabs that need to be made, it is the best way forward for me, assuming there is enough strength in the car I can also use the existing panel as a bit of a former, it's not always the case however...

There is another project that I've started to sort the mess on where lots was cut out to begin with - best not to ask who, how or why it happened but it did. For those of you who have seen grizz 's C10 thread - slow and steady repairs in piecemeal chunks is definitely the right way forward - otherwise it ends up like this (H&S freaks look away now... )


Yes it's a bit of a complete horror show and a definitely lesson in how not to approach a restoration. Still it's a challenge and I'm (currently) looking forward to rectifying it. Which reminds me, I need to put an order in for a load of new lot of sheet metal as definitely won't have enough to do this and everything else!

The front end however is at least now back together and, dare I say it, almost looking like it should!


Talking of the A35, one of the days over xmas, we made a start on fitting up the rotisserie fixings, generously given to me by v8ian . Front brackets bolted on no problem at all..


The rear fixings, for reasons you will have already seen, need to wait a little while yet  . Part of the reason for this is that when the car was originally blasted, very little of the rear suspension brackets and leaf spring fixings remained. To solve this I ended up buying another very rough A35 shell, however crucially though the rear fixings are still in place for me to make a jig from, however until I do that and weld things in place, I can't get it on the spit to sort the rest - catch 22. The alternative as a temporary measure is to flip it on a mattress... however that might be easier said than done. More thought needed...

So as we couldn't do that, it was on with tidying the work already started in prep for getting our heads round it all once more. Only thing for it was to break out the grinders and flap wheels


SWMBO was happy at least. 

As for the Celica... well it got uncovered while I had a damn good tidy of the workshop in prep for some serious time in the coming weeks (seems it's an annual event at this time of year, last year being in prep for the NEC resto show!)




You'll notice the line of wet flooring in the above, alas it's one of the joys of the place having an asbestos roof and condensation forming when it's cold - you get rained on! Part of the reason for working on the A35 outside that day it's that bad! As has been discussed in other threads - sadly for me, it also means that I can't leave any metal in there exposed for more than a day at this time of year as it rusts almost before your eyes  - bstardchild, @grumpynorthener - yes I am jealous . Still beggars can't be choosers so it is what it is.

Anyway back to the reason for the tidy, well asides the fact that it was well overdue, was that I wanted to put in some new racking to move some parts, and shift some of the lesser-used tools out of the way. I also wanted to set up the previous latest addition (yes I'd still not got round to it!). I say previous as we were also given a new pillar drill over xmas (see above photo).

However before I could do so, this thing needed to go on a diet and so had a date with the grinder and cutting disc.


In reality I didn't have to take a lot off, just modify one of the front tray edges so I could more easily slide the grinder in. I also had to adjust the position of the pull handle as it was in the way of the torch and earth clamp connections... simply a case of drilling the handle and moving the support brackets to a different location.



Just need to set the regulator up now with flow meter and order a gas splitter so I can alternate between them if needed (different size wires).

Looking forward to finally using it in anger this weekend - no really this time!

Sam - Could you not create yourself a simple timber frame and cover it with a sheet of DPC or a tarp to underdraw the roof - I did so many years ago when I had the corner of old very leaky & drafty workshop - effectively built a cocoon tent type structure that had a blow heater at one end - did me for 2 years - even painted several motors to very good effect in it - wasn't perfect but it certainty did the job

I imagine the air flow is one of the more important points in stopping the condensation from dripping through?
Might be able to use a few computer fans or something to push the air around?

Ah! I didn't realise that was the same shed!

Had I only known....
I skipped a gazebo 6x3 meters just before Christmas. All complete with a tear in the roof that was gaffa taped up. Would have been ideal 🙄😊

Back to it then...



The plan was to try and get all of the patch panels made up, and if I had time then back on with the inner arch repair. As it happened some were easier than others to make, others took quite a bit of forming and shaping. I blame my OCD as other 'expert' restorers of these just weld in flat plate and are done with it, content in the knowledge that they're under carpet and so out of sight, out of mind. I for some reason can't live with that so make things slightly harder for myself!

So time to get under the car to see what I was dealing with


Some areas definitely need some tlc, other sections are remarkably fine, just need cleaning up


Front was definitely going to need some time spent


so I started with the rear . Out with the cardboard and once templated it was time to start folding


cut the lip out of the way


and proceeded to start shaping up the repair section


Now annoyingly, but not really surprisingly, Toyota decided it would be a great idea to put a join in the floor halfway through the rear section, overlapping the two parts... which means of course it rusts. it also means I had to make a seperate repair up and needed to step where they overlap. now my compressor-powered joggler hasn't got a deep enough jaw to create a big enough step so I had to get creative with the hammer


which left me


then rinse and repeat for the front section, except this time I needed to match the ridges that are already in the floor (there's that OCD again!). So after marking up, a small piece of pipe was put in the vice to hammer over, and eventually I had something that wasn't far off a good match. (bit hard to see with the light but you get the idea)


onto the front then, and where the edge of the arch meets the floor, outer sill and inner sill



Tried to keep pinning things as I went so I have a reference for when I take it all off for etching and painting. Last section was the inner wing kick panel which was err... ventilated.


Repair made up and then stepped



and after a little more fettling, including stepping the rear edge, it was pinned/clamped in place


Which meant the front was all then complete


Before I starting chopping things out I decided I'd get the new welder set up and dialled in. As SWMBO was doing some bits on the A35 and wanted some holes welded, I thought I may as well have a play on that . Nothing much to say other than why the hell did I not buy the thing sooner?! So nice to use, much more controllable and dare I say it, the welds are much nicer to boot.

Alas time wasn't on my side so no rear arch and no welding of the repair panels, but I am now very much looking forward to getting stuck in to the welding on the celica, just a minor issue of 5 days of the day job. B*gger.

Indeed, for what it's worth as a 'token hobbyist' and given my quick 45 min play I'm more than inclined to agree - each to their own and all that

The difference is night and day for me. Control, sensitivity, penetration, small gas overrun after you've let the trigger off (appreciate that might be machine-based). Just was so easy to use.

I think the best indication for how much nicer it was compared to my her ladyships Snap On machine (don't get me wrong, that is still a good/capable machine), is that all I've thought about today is playing some more with it... yes, all very, very sad but hey it's a new toy!

The downside is that I'm now thinking about all my previous welding and wondering whether I should go back and re-do it! 😂