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ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
12/16/21 11:36 p.m.

In reply to GasTungstenArc :

Happy to help. From talking to the importer I've been using, it seems that the average JDM car of a certain age at auction is one that someone deemed no longer worthy of repair/upkeep, and as a result will typically have some issues. Mine certainly falls into this category, and to be fair to the importer, he offered me a chance to negotiate a deal to buy it sight-unseen for a very fair price with the explicit understanding I was assuming all risk of issues. For a bit more, he is happy to ensure safe operating condition (not full restoration) if you want a turn-key experience, and his services are still a bargain in my books:

Sodo Moto Seattle

It sounds like there are time-capsule cars out there, but they are rare. He offered to look for one given the right amount of money and patience on my part. The typical scenario with these beauties is that a cost-be-damned enthusiast passes away, and nobody else in the family cares about cars. I gathered that if I doubled my budget and had a year or so to burn, he could find that pristine example...but where's the fun in that? cheeky


GasTungstenArc New Reader
12/17/21 9:13 a.m.
ae86andkp61 (Forum Supporter) said:

I gathered that if I doubled my budget and had a year or so to burn, he could find that pristine example...but where's the fun in that? cheeky

I'll tell you where: being able to use it.  With a baby in the house and more projects than I have sense, I can't spare the time to rehab a car--and I don't have the money to buy one that needs nothing.  So your thread here is a much-needed bucket of ice water.

With that being said, I am happy to watch your progress.  

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
12/18/21 12:08 a.m.

In reply to GasTungstenArc :

Touché on the being able to use it! I realized about a decade ago that my enjoyment comes at least as much from building them as driving them, and possibly slightly more in the building side, but then again, I'm a single guy with some time on my hands, a sports car as a daily driver, and several operational motorcycles, so courses for horses. laugh

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
1/30/22 9:46 p.m.

Long time, no update. I've been busy, just not a lot with the Cappo. Holidays, family visit, winter weather, new job, downsizing and dealing with the possibility I may loose my workspace for vehicle projects, working on non-running motorcycle projects at the workspace, and all that other life stuff!

I got another part in, a stiffer, newer, shinier brace/cover to box in the bottom of the central tunnel. This one is from Sagawa in Japan, is made from Duralumin, and is both thicker and more heavily boxed/bent downward. It increases clearance above for exhaust and should be quite a bit stiffer than stock. Not being pitted, corroded, and ugly is also nice and saves me lots of headaches with blasting/sanding/polishing/clearcoating. Time will tell if the reduced ground clearance will be a concern or not.

So to address the elephant in the room; I may be losing this work space in the nearish future. Landlord has been acting weird and making veiled threats, plus kicked out the guys next door who have also been renting space for similar purposes (car/motorcycle builds, steel fabrication, plus occasional bbqs and shenanigans) for even longer than the 9.5 years I've been there!

We don't need to dwell on my issues, but the reality is that I have a non-rolling car up on jack stands in a month-to-month space, so my to-do list has changed slightly. I'm no longer worrying about the transmission rebuild, or suspension or turbo upgrades for now, and probably will forgo fabricating new fuel lines for now as well, and focus on getting her rolling first, hopefully driving second, and then re-evaluate as my Plan B for buying or renting a new Grosh takes shape.

Here's the updated prioritized to-do list:

Blast front diff mount (currently bare with no bushings)

Blast e-brake cable clips (currently removed and stripped) 

Paint/coat diff mount/clips

Drop temporarily-installed rear subframe 

POR15 rust spots on existing fuel lines?

Install existing fuel/EVAP hardlines under car

Finish installing headlights (currently mocked up)

Re-Install front fender liners 

Install diff onto subframe 

Reinstall subframe/diff

Finish fuel plumbing from subframe to body 

Add gas to tank

Reinstall rear suspension/hubs

Reinstall driveshaft 

Fill transmission with gear oil

Reinstall underbody parts/panels

Reinstall shifter

Reinstall misc. interior panels

Reinstall exhaust 

Finish brake lines install 

Finish rear brake caliper rebuilds

Paint rear calipers

Install brakes

Bleed brakes

Install wheels/tires




ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
2/20/22 3:22 p.m.

I'm not going to jinx anything, but  I haven't heard more specifics regarding the shop space I'm renting, so I'm going to presume that I have a bit more time, and try to finish off the rear suspension, subframe, and under-car hardlines properly.

For the rear I have new adjustable upper control arms, plus lower lateral link and toe control link, so the only stock arm/link I'll be reinstalling is the trailing arm/fore-aft lower link thingie. I ordered some Monster Sport hard rubber bushings because they work best for a dual-duty car in my experience.

I pressed out the somewhat-worn stock rubber bushings and have the arms ready to media blast.

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
2/26/22 12:07 a.m.

Not much progress to report, sadly. Pretty bummed and frustrated right now. I want to finish refurbishing the rear hubs, and ordered the Suzuki special service parts to do so properly after making no headway with my available sockets, pressing tools, and bits of metal. I got the two parts from different sources, since nobody had both. One was ordered on the 19th of January (from Japan) and the order is still "in work" with no updates as of today. The other order (also from Japan) has a tracking number generated on February 1st, and an update that the "outward office prepared a dispatch" on February 5th...then crickets. 

I'm also tearing my hair out trying to build new fuel hard lines under the car. I bought rolls of stainless tubing from Summit, but they just keep slipping out of all of the flaring tools available to me (including a fancy hydraulic Mastercool) with at most a modest but insufficient change to the shape of the end of the line I'm trying to flare, and at worst a modest change but bent/misshapen end. I'm taking great care to cut perfectly square and completely de-burr, plus also cleaning all the grooves on the clamping portion of the tool and make sure it as square as possible. What am I doing wrong?

Is there someplace closer to the Pacific Northwest than Classic Tube or Inline Tube that can duplicate my old lines if I take the lines to them? I'm not sure I want to try and box and ship 6-7 feet with multiple bends all the way to upstate New York, to wait multiple weeks, and then pay return shipping on another gargantuan box.

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
2/27/22 12:07 a.m.

I gave up on the stainless, pried open my wallet once again and bought rolls of bulk NiCopp, which allowed me to make some good progress. I got my eye in for flaring and bending on the short bits (which aren't rusty and probably don't need replacement) so I will have completely new parts from the tank all the way to the fuel rail. I'll tackle making replacements for the rusty, long, complex, twisty underfloor-and-up-the-firewall runs tomorrow.

In other good news, part of the special service tools has made it to US Customs in California and should be in my hands this week.

I didn't get photos, but also made some progress on blasting some of the remaining rear suspension parts that are slated for powdercoating before getting new bushings and bearings.

obsolete GRM+ Memberand HalfDork
2/27/22 9:34 a.m.

I, too, am waiting for someone to tell me the secrets to getting good results with stainless tubing. Glad you went with the NiCopp, I really like that stuff. Only thing to watch out for is if you bend the same spot too many times, it will work harden a bit.

How'd you form the beads on the ends? The nearest one looks really nice.

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
2/27/22 3:44 p.m.

In reply to obsolete :

Thanks! For the bead on the ends I am just starting the beginning of a standard brake flare with a Mastercool/Eastwood hydraulic flaring tool like the one below:

Thanks for the caution on work hardening as well. I'm thinking on the long runs with lots of bends that I'll start in the middle between the two tightest bends closest to each other, and work outward in both directions.

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
4/24/22 1:16 a.m.

Made a little progress today on the rear hub bearing replacements. Now that I have all my special service tools, I dove into the bearing replacement. I got the inner races off of both rear hubs.


I tried blasting some of my next batch of parts for powdercoat, but was struggling to get the blaster to work well. I'm not sure if the issue was lack of media, or clumping media due to moisture, or perhaps I'm clueless on how to optimize the adjustable parameters of the cabinet, but in any case it wasn't working well. It just wouldn't pick up media reliably...Harbor Freight cabinet converted the gravity-feed with an upgraded gun, foot pedal, and inline pressure regulator and air drier, so not sure which direction to go from here.

MiniDave New Reader
4/24/22 7:58 p.m.

That's a slick tool. If you ever need to get one off without the tool, just take your angle grinder with a cut off wheel and score a groove in the race, then hit the groove with a cold chisel, it will pop right in two.

I like that flaring too also....nicop is the best stuff to use for lines anyway, that or the grey/green alloy they sell  in the parts stores, but it's a lot tougher to bend.


timster New Reader
4/25/22 5:42 a.m.

Great thread. I just moved to Okinawa a couple weeks ago (I'm a civilian government employee) and had been searching for Kei trucks/van build threads. Of course this isn't a van or truck, but still good reading about your challenges and problem solving. Looking forward to reading more as time allows you to make progress and posting of future updates.

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
5/22/22 1:04 a.m.

Not a huge amount of progress to report; got some more parts blasted and ready for POR15 or powdercoat.

There is a potential plot twist on the horizon for this project; I'll update as soon as things are more solidified! wink

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
5/22/22 1:06 a.m.

In reply to MiniDave :

Thanks for tip! I've used variations on the grind n' chisel in the past, but prefer heat and the proper puller if available...less work and less chance of nicking the hub!

ae86andkp61 (Forum Supporter)
ae86andkp61 (Forum Supporter) Dork
5/23/22 1:04 a.m.

Uh-oh...trouble brewing! Anyone interested in a silver Cappuccino project with a great head-start on the restoration? If so, please PM. wink

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