Daihatsu Charmant

jdm86gtz
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Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:28 am

I bought this early in 2010 with the intention of building a car to stop me doing something stupid to my '87 Trueno.
Still not quite finished but close now :roll:

Copied from http://www.ae86irl.com/ and yeah my hand usually wobbles just as i take a photo so you'll have to excuse the blurry photos


Finally picked up the Charmant yesterday and fitted my spare set of Advans to it. Good points are that there's AE86 fuel lines and hydraulic clutch fitted already and a complete late spec Levin wiring loom

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She was green so gave it a good power hosing (cheers Kev:p) and then inside also as it was manky

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A fine hole in the sill

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I think there's a few bits missing back here

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Good bits shell seam welded and painted black inside and white under the bonnet

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:29 am

Fitted the front end yesterday but blinked and lost the NCRAs and got RCAs in their place

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If I can get the rear Cusco RCA welded to the axle that will be fitted today.

jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:29 am

D1 spec rear pads

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The mintest spot on the car

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Rear axle with Cusco bushed trailing arms and pillow ball panhard rod and you can see the Cusco rear RCA below the original panhard mount on the axle

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She's not mint, but she's rusty :dft003:

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A previous seamless repair job

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:30 am

She got a bit of grinder and welder attention last night

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And I did a bit of wire brushing this afternoon to small rusty spots

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I've sort of gutted the inside now oops and the front and rear windows will be getting cut out for rust repair. 2 of the doors have been repaired with fiberglass so far also.

jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:31 am

a friend was doing the metal work for me and I came out after work one day to discover all this :o


Back turned out nice :nod:

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Where's my sill gone?

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Ahh new steel

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:32 am

My friend Gerry that had the blue Charmant took it on himself to cut out the sill and pressed these repair sections :huh: I would have been happy with a patch up job :P I think the sill was replaced before as there is red paint under the gold (you can see some under 1 of the rear hinges) and a ball of filler.

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No hammer going through this at NCT ;)

jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:33 am

The poor Charmant body has lost out on the priority game, but I've collected a few engine parts:
I got a stripped small port 4A-G from Burner and got the crank polished and collected the following: TRD 0.8mm gasket, ARP head studs, ARP rod bolts, OEM rings, ACL bearings and Toda 256,264 7.9mm cams

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Next have to get block skimmed and start building the bottom end and then rebuild the head.

jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:33 am

Some pictures of the repair done around the windscreen and wiper panel, I'm surprised the windscreen didn't fall out :|

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Far from it

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:34 am

What it was

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How i expect the inside to look 2 seats and a steering wheel and handbrake

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jdm86gtz
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Posts: 306
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:35 am

Coated the front end on both sides with 3M aerosol schutz tonight. The underneath will get something a bit thicker than this stuff though.

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jdm86gtz
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:35 am

Painted the whole floor the other day with Hammerite smooth black

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Tried on Kev's 9.5" and 8.5" Wats for the Padiflush fit, but the 8.5" on the back fit nicely

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:36 am

Fitted ACL Race main bearings and the crank tonight, I have the oil returns tidied up and ground a bit out of the bottoms of the bores as I found before that AE92 rods with ARP rod bolts touch the bores :thumpsdown:
Ran into a snag fitting the rod bolts to the rods though as there is one odd size rod nut in the pack and I have these about 3 years so I doubt I can make a claim :doh:

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jdm86gtz
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Posts: 306
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:37 am

Had to mod the pistons to clear the oil squirters.

Left is OEM small port pistons and the other 2 are mine, and my template

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:37 am

Fitted front and rear Cusco strut braces tonight.
Nice Hammerite dribbles on the bulkhead :P

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:38 am

Rear is 15 X 8 -12 or 4" backspacing

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Front is 15 X 7 -12 or 3.5" backspacing

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:39 am

They are too shiny for good pictures and they are heavy as hell

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:40 am

ot a load of parts today that I was missing
Wiper arms, bootlid seal, sill trims, door surround rubbers, LH tail light, RH front corner light, mirrors and bonnet stay. I'll have to go for another raid some other day.

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:40 am

Got tyres today

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Gonna hide the balance weights with black paint, it was either a few grams outside or 185g stacked inside so I went this way.

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:41 am

Got my new front windscreen and the original rear screen fitted tonight :dft003: Just a good boot lid and it should be watertight and ready to get painted.

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Also got the new gudgeon pin circlips I ordered so assembled the bottom end.

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With my super trick ARP piston sleeve, I love how easy it makes the job :dft003:

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:42 am

Got some more parts yesterday : rusty straight bootlid, RH taillight, LH door mirror bracket:nod:, and some black dash bits

Original dented bootlid

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Rusty bootlid

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A bit of photoshopping and ended up with this

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:43 am

Filled the wheel well and painted it with a yard brush


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and first coat of brush on stonechip crap

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:43 am

Moved sheds so the Trueno and Charmant are now cosy in a new unit

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Built up a 4.1 with Cusco RS 2 way and solid spacer

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Engine mocked with HKS copy manifold and S14 turbo

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Ordered up an engine and rear axle gasket set and axle seals, had spare gearbox gasket set and 4 baulk rings so might as well refreshen the gearbox

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Sitting nice on the back with a boot full of shite

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jdm86gtz
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Posts: 306
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:45 am

A few pictures

Fiberglass bootlid, needs a bit of heat to get rid of the slight rise in the middle. No rust though ;)

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Smoother engine bay

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AE86 twin core rad, 13 row oil cooler and Evo 4 intercooler

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Intercooler hardly visible from the front

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Engine almost done, waiting on adjustable cam pulleys and have to get a oil return pipe tig welded into the sump

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Hope the coils clear the bulkhead but will bash stuff till they do

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T25G turbo now sits in a better position

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Plenty of blue silicone hose

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Last edited by jdm86gtz on Tue Jan 29, 2013 7:01 am, edited 1 time in total.

jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:45 am

Happy with the turbo position now. Not sure if I'll keep the big awkward washer/overflow bottles or relocate the washer into the car and run an alloy coolant breather tank

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Oh and the relay box is wired

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Engine loom next and I/C brackets and piping

jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:46 am

3 coolers are now mounted and waiting on a few reducers to complete the intercooler piping. Also got a Godspeed T25 to 3" V band turbo outlet and waiting on some 3" mandrel bends.
Toying with the idea of a brake pipe tuck as a joke. :p

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jdm86gtz
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Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:47 am

Jackie and Dayo started at her today.
Jackie spent ages dent pulling the LH 1/4 and got it in filler and straightened out the back panel also. Started flaring the arches also.

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jdm86gtz
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Posts: 306
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Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:48 am

Not a whole lot of news yet, but rebuilt the gearbox with new baulk rings and rebuilt the shifter with a T3 bush kit and a new Toyota boot.

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
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Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:48 am

Anyway collected more stuff for this, got an Odyssey dry cell battery and fake carbon box for it, a 1.2L windscreen washer bottle to fit inside the car, a nice small 0.8L alloy catch can and some gold head reflector foil to protect against the down pipe.
Also last few bits to be primed are ready to go:

Last bit of gold to be covered over

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went back to the steel bootlid

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engine bay ready for primer

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note the flushed A/C evaporator area as the bulkhead has been shrank to be flush with the surrounding bulkhead, which is nice.

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:49 am

Only have new corner lamps the rest are old and crud.
Dayo was instructed that the only body area finish I care about is the engine bay so now it's primed he said he will leave it a while to sink.

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jdm86gtz
Club4AG Expert
Posts: 306
Joined: Fri Jan 11, 2013 10:13 pm
Location: Ireland

Re: Daihatsu Charmant

Postby jdm86gtz » Tue Jan 29, 2013 6:49 am

5 base coats, 3 coats of lacquer with holographic glitter and 3 clear coats results in this:

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