D1 restoration project

**rar110** · 7th October 2019, 10:12 PM

Now both A&B pillars are done.

We pulled up the carpet on the passenger side just to be sure and found the underlay and floor was soaked. Naturally there was some rust.

Thankfully most of it was just surface rust. So a sand and painting those areas. But we will need some new sill.

**rar110** · 12th October 2019, 06:19 PM

Spent another day on the D1 driver side. Not much to show for it. But driver side is now done other than painting. I will have a go at that tomorrow hopefully. The most visible addition was making/fitting a piece of angle for the door seal to attach to. The less obvious is lots of additional spot welds everywhere, just to be sure.

We did a test fit with the door and was ok but decided to trim the height of the angle/seal strip about 5mm just to be sure.

**rar110** · 12th October 2019, 08:30 PM

Some filler and primer, and ready to paint. I think.

**rar110** · 13th October 2019, 11:15 AM

Another small rust repair.

**rar110** · 13th October 2019, 03:35 PM

One side done, time to reassemble.

**Tins** · 13th October 2019, 04:26 PM

Did it have that horrible stuff glued down the the 'shallow' ribs in the floor? I could have filled a bucket with the water I got out of that stuff alone. No wonder they rust. Mine leaked in from the doors and footwells filling up.

**rar110** · 13th October 2019, 04:56 PM

The floor on both sides had water. The floor has some sound deadener glued in. It seemed to hold a bit of water as was perforated. On ours the water seems to be coming down the inside of the firewall, I think from a join at the top below the widescreen.

**Tins** · 13th October 2019, 06:09 PM

Originally Posted by rar110

The floor on both sides had water. The floor has some sound deadener glued in. It seemed to hold a bit of water as was perforated. On ours the water seems to be coming down the inside of the firewall, I think from a join at the top below the widescreen.

There too. The plenum gets blocked with leaves and stuff..... or is that the D2? Both of mine leaked, well of course they did

. The D1 still does, as I have retired it, although I'm liking your work and ideas, so maybe it'll live again one day. It has no carpet or deadener in it now to trap water.

**rar110** · 23rd October 2019, 07:46 AM

Does anyone know where to buy the nylon screw clips that sit under the inner sill plate?

Similar to these, but with round head that looks stronger than these.

20 Pcs Nylon Nut #10 Screw Grommet Clip For Toyota 90189-06010 | eBay

**AK83** · 23rd October 2019, 09:34 AM

If you're near an Autobarn .. something like this?

They're made by Champion .. and so sold by many auto parts places, like Repco/Bursons/etc.
Question is, will they hold this stuff in stock.

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