TDM 2004 Sable V6

Started by Topdownman, March 18, 2018, 11:32

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Topdownman

#25
So, time to do something with the body at last. Due to an inconsiderate badger (I think, after a forensic examination of the hairs stuck in the wheel), it didnt stop to swop insurance details, I had a cracked front bumper so I was on the lookout for a replacement. I didnt mind if it was pre facelft or facelift and a pfl one came up first. This was fitted with an HZ altezza front lip. I went for the GB kit style side skirts and rear spats from Glass fibre products.



Fitting the side skirts took a fair bit of fettling to go on as they were a bit short for my car, I suppose the way your wings are fitted can mean some are wider than others (wheel arch to wheel arch)?

After trimming them and sanding down the insides of the front and rear edges I got them on, they were then secured with 3 self tappers through the skirt and into the wheel arch, once happy with the fit, I took them off, applied tiger seal to the top and bottom and then screwed them back on and left them to set.



Once set, I applied tiger seal to the top to fill any gaps and then touched that up with a paint brush and touch up paint.



I later added on some homemade mudguards to cover the fittings at the end of the skirts and spats.

At the rear, a JDL? style spoiler from ebay went on.



I then fitted rubber skirts to the front and sides.



These have saved me some damage a few times as I have scraped over kerbs as the front is pretty low. It makes a horrible noise though as you scrape along!

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Quote from: Topdownman on April 14, 2018, 08:11
So, time to do something with the body at last. Due to an inconsiderate badger (I think, after a forensic examination of the hairs stuck in the wheel), it didnt stop to swop insurance details, I had a cracked front bumper so I was on the lookout for a replacement. I didnt mind if it was pre facelft or facelift and a pfl one came up first. This was fitted with an HZ altezza front lip. I went for the GB kit style side skirts and rear spats from Glass fibre products.



Fitting the side skirts took a fair bit of fettling to go on as they were a bit short for my car, I suppose the way your wings are fitted can mean some are wider than others (wheel arch to wheel arch)?

After trimming them and sanding down the insides of the front and rear edges I got them on, they were then secured with 3 self tappers through the skirt and into the wheel arch, once happy with the fit, I took them off, applied tiger seal to the top and bottom and then screwed them back on and left them to set.



Once set, I applied tiger seal to the top to fill any gaps and then touched that up with a paint brush and touch up paint.



I later added on some homemade mudguards to cover the fittings at the end of the skirts and spats.

At the rear, a JDL style spoiled from ebay went on.



I then fitted rubber skirts to the front and sides.



These have saved me some damage a few times as I have scraped over kerbs as the front is pretty low. It makes a horrible noise though as you scrape along!
The GB skirts are an appalling fit aren't they? The I'm having a nightmare with the ones I got, like yours they're just not long enough, one of those jobs where I'm now that far in it's too late to give up.


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wotugonado

Great looking car. Sables look the dogs dooberies fully kitted up imo.
Has anyone let the kit manufacturer know they're a poor fit ?
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Quote from: wotugonado on April 14, 2018, 09:55
Great looking car. Sables look the dogs dooberies fully kitted up imo.
Has anyone let the kit manufacturer know they're a poor fit ?
To be honest I got mine second hand, as new but can't remember who the manufacturer was.


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Topdownman

I got the skirts from Nigel in the affiliates section. I suppose they were moulded from plastic ones and so the wider GF causes a problem? I dont think there would be much he could do about that?

I got a mate to come round to give me a hand as I thought i would need a 2nd pair of hands as you cant easily hold both ends on together yourself as they spring off the car. We held it up and he said thats never going to fit, send it back and left me to it!

I obviously persevered and just kept sanding more and more off the inside until they fit. Its easy to sand, I was just a bit afraid of going too far. As soon as you can get one end attached with a screw it is easier to see how much further you have to go.
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Topdownman

Inspired by Leethesparky, I decided to add some Jaguar XKR vents to the bonnet.

They look great (to me), I thought they would improve airflow over the radiator and reduce front end lift at speed.

This does require leaving out the under bonnet plastic though so the air can flow. I had no worries about that but did wonder how much water would get in there.

I went for the abs plastic vents rather than fibreglass so that they could be glued in place with weights on so they would follow the line of the bonnet and not stick up as one end as I thought the FG ones would do.

It is quite hard to decide on a position for these as there are not many easy points of reference when marking your position. The best one was probably the swage line on the bonnet.

Lots of measuring ensued before the angle grinder came out!



The tight corners were drilled and filed to get the shape. The vents have a bit of overhang so there was some leeway for final positioning.



If cutting the first was bad, the second was worse as it has to match the first one!



The vents are glued in with Tigerseal and the bonnet was treated to a respray by Andy, the paint guy.

The water coming in is not a problem and there is sometimes a bit of water on the froot lid but nothing that worries me. I suppose some water must get in the strengthening piece under the bonnet but I have never noticed any so not sure if it drains away or evaporates?


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StuC

Deffo needs an outdoor shot of the painted vents mate. Justsayin'
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Topdownman

Here you go;



The front has a home made de-impalator made from fibre glass.



This was moulded on the bumper then filled and painted. I would make this a bit thicker if I ever do it again and weight it down while it went off so it followed the curve of the bumper better.

I have also cut out some of the plastic grille and then put aluminium mesh on top of that.
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BahnStormer

Quote from: Topdownman on April  2, 2018, 10:17
3


Sounds so simple.  Wrong!  Still,  it was worth it all in the end and it will be nice when it is finished.

Details please! Which engine? Which gearbox? Cost? What was included in that cost? What else was involved?
Black 2006: AC & heated leather: 4x Megillian braces, Koni/Tein custom suspension, MTEC+YS+braided brakes, Toyosports manifold, TTE exhaust, Conti PremiumContact2(summer)/ Conti TS860S(winter) / YokoAD08RS (track/summer), Pioneer MVH-390BT + TS-E171ci, FBSW, Robbins mohair hood.

Topdownman

OK, so in no particular order and to the best of my knowledge, the V6 conversion involves the following;

A 1MZ engine from a Camry, 2998cc, there is also a 1MZ VVTI engine from a Lexus (RX300?) which can be used but costs much more for the donor car.

An inspection hatch is created in the rear firewall to allow access to the front bank of cylinders.





The rear subframe is "notched" to clear the gearbox and exhaust.



The car runs 2 ECUs.



There is an additional engine mount on the drivers side of the engine bay.

The top of the rear cross member is cut out between the rear suspension turrets and reworked for the larger engine.

A 5 speed gearbox from a Mk2 MR2 is used (ST202?) with a longer 5th gear installed as the ratios give a lower top speed than a 1ZZ.

A Mk2 MR2 turbo/NA hybrid clutch is used (and is nice and light).

I had my LSD transferred across to the new set up.

The battery needs to be relocated, mine is in the Froot but they can also go on the top of the rear cross member.



A larger capacity Mishimoto radiator is fitted.

A custom exhaust and sport cat is needed.

A cone filter is needed due to the space issues.



The place that did my conversion are no longer doing them. As far as I know, the only people who may still do this conversion would either Patrick Chambers (Headcase on the forum) or Rogue Motorsoport. At the time I had mine done, the cost was only slightly higher than Whifbitz would have charged to do a complete turbo installation.
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Topdownman

So, thought I had better do an update as its been a while. I have been very busy this year and not had much time to play with the car. That hasnt stopped me buying stuff so have a number of bits to go on at some stage next year.

I did get lost on my way to the grout shop this morning and ended up in Wales somehow.



One thing I discovered I need to sort out before the next winter top-down run is the heater control knob. I have a set of the mazda style ones but as you need a fair bit of force for the left hand knob for the heater direction, it has rounded off. This means that I cannot change the direction off demist only so cant get any heat on me! Brrrr.

Very nice out there this morning though.



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delhusband

That second pic is stunning Simon
Hate pointy animals

jonbill

That's not how I remember Wales in winter!

Joesson

Quote from: jonbill on December 30, 2018, 20:23
That's not how I remember Wales in winter!

Nor most of the year!

Topdownman

OK, well spotted, the first picture was in Wales and the second back in England!
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Topdownman

With the Highland Drive rapidly approaching it was time to try to get the car running today as I have been having starting issues and it hasnt been running for a week or two.

The battery has been running down as it hasnt been used much for months but it is only 2 years old so I was hoping that wasnt the problem. After charging it last weekend, it was OK when I ran a load test. I decided to have a look at the starter motor connection today. I was very relieved to find that while not actually loose, I could tighten it up quite a bit so was hopeful that when the battery was charged up again it would start.

To get to the starter, I took off the air intake pipe and discovered that the last time I had cleaned the MAF, the rubber gasket had sagged at the bottom (the bit you cant see) when I put it back together meaning air would have been getting in there. Cleaned the MAF and seated the gasket properly this time.

I could see my catch can had about 2-3" of erm, contents, so decided to empty it and fit the silicone hoses to replace the manky ones.

Not quite enough to make a pot noodle but not far off.



The engine bay looks a little better now.



I think thats everything, oh yes, the car started 1st time....
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Quote from: Topdownman on March 31, 2019, 15:06
With the Highland Drive rapidly approaching it was time to try to get the car running today as I have been having starting issues and it hasnt been running for a week or two.

The battery has been running down as it hasnt been used much for months but it is only 2 years old so I was hoping that wasnt the problem. After charging it last weekend, it was OK when I ran a load test. I decided to have a look at the starter motor connection today. I was very relieved to find that while not actually loose, I could tighten it up quite a bit so was hopeful that when the battery was charged up again it would start.

To get to the starter, I took off the air intake pipe and discovered that the last time I had cleaned the MAF, the rubber gasket had sagged at the bottom (the bit you cant see) when I put it back together meaning air would have been getting in there. Cleaned the MAF and seated the gasket properly this time.

I could see my catch can had about 2-3" of erm, contents, so decided to empty it and fit the silicone hoses to replace the manky ones.

Not quite enough to make a pot noodle but not far off.



The engine bay looks a little better now.



I think thats everything, oh yes, the car started 1st time....
Beautiful. I look forward to following you around on our holidays, although I think you need a splash of blue in there for some balance...


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Topdownman

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Call the midlife!

Quote from: Topdownman on March 31, 2019, 16:15
John, no, just no!
Words fail me...


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Topdownman

So, work is continuing trying to get the car ready for the Highland Drive.

Oil and filter change and new discs and yellowstuff pads fitted.



Got the cheap voltmeter fitted and wired up to help me keep an eye on the condition of the battery too.



Still a fair number of things on the list of stuff I would like to do though.
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Topdownman

Hopefully now sorted out the issues that were throwing up error codes.

The offset spanner worked a treat on the coolant temperature sensor.



The offset O2 sensor socket wasnt so useful but I got it swopped over using a good old fashioned adjustable in the end.



The error codes stopped me taking the car to Scotland though but luckily the back up vehicle performed well!







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At first glance I thought that was a BGW on the Lotus.


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Topdownman

Quote from: Call the midlife! on May 11, 2019, 18:48
At first glance I thought that was a BGW on the Lotus.


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Pretty sure it is.
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Quote from: Topdownman on May 11, 2019, 23:12
Quote from: Call the midlife! on May 11, 2019, 18:48
At first glance I thought that was a BGW on the Lotus.


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Pretty sure it is.
The bench in front of it I mean, your red looks well though.


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