Front ARB off (amongst a few other things at the front). Despite semi regular anti seize treatments over a period of a few months! EVERY SINGLE bolt holding in the front ARB snapped so will need to drill them all out!

Strange considering everything else has been pretty easy, even all of the wishbone bolts were a breeze and have read a few horror stories on here!

Finally, was going to leave the suspension itself all round but talked myself into buying new KYB shocks and springs all round considering I've got most other things unbolted and shouldn't have to touch it ever again. Anyway rear suspension off yesterday and discovered a pesky little snap in one of the springs!

Feeling good that the decision now completely justified

@Nessy

Build threads certainly a thing. 

https://www.mr2roc.org/index.php?board=88.0

Well I'll be damned. I've been sick with the flu for three weeks, hence the mumbling and excessive pondering.

I had the chance to speak to "my guy" at the organization (non governmental) that preps fellow enthusiasts for their build and registration of the changes.


He said that I can fit any width tyres I want, and the Prius front brake and woodsport subframe in conjunction with some adjustable suspension arms (with dust boots of course) and that SHOULD make the government happy... Should is not a favourite word of mine, especially when I see that I spent 5 hours today just to get the right hand front suspension apart. Funny how the left side loosened in ten minutes.

So anyways, hopefully I can put some more cash into aforementioned chassis upgrades and be content with the Prius brakes.

I'm not sure about the adjustable geometry. I have bought D2 coilovers with pillowballs. If I remember correctly 4.5kg F 7.5kg R
Springs. Should be ok allround for starters.

I've seen battle version, technotoy, Megan, ultra racing, but for me most interesting seems to be uniball.fi , they also go by the name rallydesign and seem to be really knowledgeable. They are in Finland so closer and no orangutang tax.

By the way guys, I'm new here and I don't know if build threads are a thing? I just bought the car when I was hungover, I gave in, then the 2zz gave in 6months later and now I'm just basically jumping head first. Maybe I shouldn't ask so many questions and start separate thread?

I a man of simple things, I simply cut the bottom off a 250ml mineral water bottle, take the cap off and hey presto a simple funnel at nil expense. used this techique for nearly 20 years.

Norman

Looks like the Swedish authorities havent seen this video!


Could you do the prius calipers as mentioned above with braided lines and wider tyres to qualify?

+1 on the bilt hamber.

  a good bit of working going on there and the effort will pay off for you  
keep this up and your be up for A* plus     

Forgot to mention rear calipers (handbrake mechanism seized one side) also off, anti roll bar, and finally had some fun with the angle grinder getting the old links off

Have ordered some Bilt Hamber stuff online that is meant for cavities to try and protect the inside of the subframe from rotting

Last week cleaned up the rear including inside the engine bay.

Inspected the Subframe, not to bad condition at all, surface rust mainly on the side that would have been facing the engine but not at rot stage.

Went over everywhere there was flaky rust around the whole rear end with wire wheel. This was mainly subframe, arms, hubs, brake disc dust shields.

After, treated with a couple of sprayed coats of Jenolite rust converter & left to work it's magic for a day.
This stuff appeared to work great, basically all areas of rust turned black!

Finally the bits that were rusty Finished off with some primer then satin black paint.

A point to note, I was surprised to see areas around the engine bay that received little or no paint obviously from the factory!

Some before and after photos..

Just to add to this, the front caliper 'clips' I spoke about are also known as anti rattle shims. Whilst I have 2 very slightly different style shims on each front caliper carrier,  they appear to do the same job so should be no orientation issues for me to worry about!

Thanks all for your input