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Thread: '86 Aerodeck EX-2.0i

  1. #26
    '86 Aerodeck EX-2.0i
    Dr_Snooz's Avatar
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    Re: '86 Aerodeck EX-2.0i

    I want to see the vids of how you form those custom patch panels.
    Dr_Snooz

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  2. #27
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    Re: '86 Aerodeck EX-2.0i

    Quote Originally Posted by Dr_Snooz View Post
    I want to see the vids of how you form those custom patch panels.
    Sure I can do that. I took a couple days of from work and I was going to have a rust fixing marathon but gf is stuck at home with covid so I have to be home aswell

  3. #28
    '86 Aerodeck EX-2.0i
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    Re: '86 Aerodeck EX-2.0i

    Let me guess, no one is actually sick, right? I'm in the same boat till New Year's.
    Dr_Snooz

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  4. #29
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    Re: '86 Aerodeck EX-2.0i

    Quote Originally Posted by Dr_Snooz View Post
    Let me guess, no one is actually sick, right? I'm in the same boat till New Year's.
    Exactly how it is! She has had headache for a few days and I have no sympthon at all. If we dont have any sympthons we can get out on the 29th.
    I'm starting to get really bored in here. I had planed to be in the garage all winter brake, but that didnt happen.

  5. #30
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    Re: '86 Aerodeck EX-2.0i

    While I'm locked inside I might aswell write about the things I want to get done this winter.

    First of! The rust.. When I first got the car it looked to be in really good condition. A little bubbling on the hatch, a tiny hole in the front right fender and the rear arched being rusted and fixed with bondo. I'm amazed I was so naive...

    The tiny hole in the fender tuned into like 150mm being cut. I found the massive holes in the front right wheel well. I have the same gigantic hole behind the washer fluid tank as on the right side. There is a hole right under the drivers feet. The brackets for the rear bumper are gone aswell.

    Non of the rust i found should be any real issue. I have repaired alot worse on my old Volvo Amazon. It's just a major inconvenience before I can start doing all the fun things.


    Nr 2! The interior.. It's in very good shape still and will stay mostly stock. The only thing I'm thinking I would change is the steering wheel. Maybe put in a MOMO leather wheel or a nice Nard, but thats later down the road. I'm taking out the carpet and seats to clean all of it and to put in some new sound deadening. The old stuff is hard and brittle so it's getting replaced with Silent Coat.

    I have a box of stereo stuff that is going in. I already replaced the front speakers to some old Alpine speakers. In the rear a new set of Alpines 6,5 are going in. And it all is powered with a Hertz HCP4 amp. I also have some random subwoffer I might put in if i can be bothered.


    Nr 3. Wheels, suspension and whatnot. I traded a buch of junk to some dude and got 4 Ronal R8. I think they will suit the car nicely wrapped in 185/60 tires. I would like 15" but for the time being these will do the trick. The tires that are on needs to be repaced anyway (being dry rotted and 20 YEARS OLD ) . I really want some Work Equip 01 or 03 or Ronal R10.

    I'm getting coilovers from Yellow Speed when the time is right. The calipers are getting rebuilt. I'll have to check all the bushings but they feel alright. The swaybar links are getting replaced.


    Nr 4. The exterior. As mentioned....rust, you know all about that. The rest of the car is just getting a lot of little things done to it. A few dings are getting straightened. The left tail light is cracked and getting replaced. A complete polish and waxing and maybe repainting some bits. Maybe taking of the trailer hitch. Replace the plates. I really want some rear mud guards (shoot me a dm if anyone has a pair). And a new layer of undercoating.


    Thats pretty much it. OH One more thing i want. I have this led light bar on now just so I could see something, but it's not very pretty. So I want to replace them with 4 big Cibie (well...knock offs) . I think that would look really fuckin' cool.


    Evening update: I Placed an order from cheddas auto for some shifter bushings! EXCITED
    Last edited by Red_Aerodeck; 12-27-2020 at 12:31 PM.

  6. #31
    '86 Aerodeck EX-2.0i
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    Re: '86 Aerodeck EX-2.0i

    Just now catching up on this thread. This is going to be a great car. Especially since you are taking care of the rust, everything else is pretty pointless if the rust isn't taken care of first.

    1988 Honda Accord LSDX-I

  7. #32
    '86 Aerodeck EX-2.0i
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    Re: '86 Aerodeck EX-2.0i

    I am really curious to see some testimonials of the ysr coilovers, do keep us updated on that when you decide to pull the trigger

  8. #33
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    Re: '86 Aerodeck EX-2.0i

    Quote Originally Posted by conozo View Post
    Just now catching up on this thread. This is going to be a great car. Especially since you are taking care of the rust, everything else is pretty pointless if the rust isn't taken care of first.
    Thanks! Yeah it is a shit job but it has to be done. I know it will all be worth it in the end.


    Quote Originally Posted by ShiRen View Post
    I am really curious to see some testimonials of the ysr coilovers, do keep us updated on that when you decide to pull the trigger
    I will! I made a YT channel that I'll eventually upload on. A review of the coilovers will go up there when I get them.

  9. #34
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    Re: '86 Aerodeck EX-2.0i

    I had the most productive day ever this weekend. There is not a lot left to do in the front now. The right side is finished, short of a layer of undercoating. The left side is ALL WELDED UP YAAAAAAAAS (almost). One m8 nut needs to be spot welded on, because I forgot that one, then it's finished.

    Picture time. Sorry for the shitty pics but i keep forgetting my good camera at home.


    Rust. Not as bad as the right side.

    '86 Aerodeck EX-2.0i-img_20201230_224430[1]-jpg


    All cut out

    '86 Aerodeck EX-2.0i-img_20201230_231354[1]-jpg


    All welded up and primered. WERI NIIICE

    '86 Aerodeck EX-2.0i-img_4119-jpg


    '86 Aerodeck EX-2.0i-img_4120-jpg

    '86 Aerodeck EX-2.0i-img_4121-jpg


    The new metal

    '86 Aerodeck EX-2.0i-img_4122-jpg

    '86 Aerodeck EX-2.0i-img_4123-jpg

    There we are. As you see I had to make another bit aswell. The metal was too thin and I kept burning through so I had to cut a bit more. I ordered a band grinder just to make grinding inside the engine bay a bit easier (any excuse to buy new tools)
    '86 Aerodeck EX-2.0i-img_4125-jpg

    All that is left to do in the front is make the patch in the enginebay look nice, paint the front end, paint the inside of the frame (if you take of the brackets for the bumper you see straight in, perfect for paint and wax), some undercoating and then put it all back together again. EPIC

  10. #35
    '86 Aerodeck EX-2.0i
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    Re: '86 Aerodeck EX-2.0i

    you make it look so easy.

    1988 Honda Accord LSDX-I

  11. #36
    '86 Aerodeck EX-2.0i

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    Re: '86 Aerodeck EX-2.0i

    Thank you for the pictures!

    I know its a pain but it gives other people places to look for rust. I am going have to look my front parts over now looking at your pictures. I never thought of rust up there.
    1988 Lxi owner since August 1995
    336k miles running strong!
    Now running E85.

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  12. #37
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    Re: '86 Aerodeck EX-2.0i

    Quote Originally Posted by conozo View Post
    you make it look so easy.
    Thanks man. I guess I have at least 150h of just fixing rust so I ought to get decent soon

    Quote Originally Posted by Oldblueaccord View Post
    Thank you for the pictures!

    I know its a pain but it gives other people places to look for rust. I am going have to look my front parts over now looking at your pictures. I never thought of rust up there.
    Yeah everyone who wants to keep their 3g in good shape should at least take of the inner fenders and give it a good clean and some sort of coating. And in the frame aswell.
    I hope this is usefull and other owners can prevent all this missery I'm puting myself in

  13. #38
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    Re: '86 Aerodeck EX-2.0i

    I've been super productive these last few days. The front end is finsihed, just need to put the inner fenders back in place.


    Ground the welds on the patch nice and flat

    '86 Aerodeck EX-2.0i-img_4145-jpg

    A little bit of filler

    '86 Aerodeck EX-2.0i-img_4146-jpg

    And some paint! Looks pretty decent if I may say so myself. I'll try to polish the original paint a little to see if they match better, you can see the joint pretty well even tho the paint is supposed to be matched.

    '86 Aerodeck EX-2.0i-img_4149-jpg


    The front end was looking a bit sad, so it to got a lick of paint aswell

    Before
    '86 Aerodeck EX-2.0i-img_4128-jpg

    And after!
    '86 Aerodeck EX-2.0i-img_4136-jpg


    Regarding the videos I have filmed. I'm trying to edit the first one, introducing the car and just rambling on about it, but my computer is a bit too weak so it takes it sweet time. But it's coming! Eventually...

  14. #39
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    Re: '86 Aerodeck EX-2.0i

    Finally got the first video uploaded. It's just me talking a bit about the car and showing it off


  15. #40
    '86 Aerodeck EX-2.0i

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    Re: '86 Aerodeck EX-2.0i

    Great job its gonna turn out great!
    1988 Lxi owner since August 1995
    336k miles running strong!
    Now running E85.

    My Acura Type R front brake thread

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  16. #41
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    Re: '86 Aerodeck EX-2.0i

    The front end is done! Now we are tearing in to the ass end of the car.
    I have removed the bumper, it's not too bad but there is alot of surface rust and one of the brackets for the bumper is totaly rusted away.

    I had to take off the tow hitch to take of the bumper and yeah, it's staying of. The car looks alot alot nicer without it.

    My girlfriend calls the car "Coi", can you see why?
    '86 Aerodeck EX-2.0i-img_20210119_162340[1]-jpg

    I had to take it for a little spin while it was all put together.
    '86 Aerodeck EX-2.0i-img_20210118_153045[1]-jpg

    And a bonus pic of my other red rusty car!
    '86 Aerodeck EX-2.0i-img_20210119_143748[2]-jpg

    I uploaded a video showing s bit of the rust repairing for anyone intrested.

  17. #42
    '86 Aerodeck EX-2.0i
    Dr_Snooz's Avatar
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    Re: '86 Aerodeck EX-2.0i

    Cool! Thanks. I want to see you forming one of those curvy, intricate pieces on your forming tools.

    (Your camera is the tool of the devil, BTW).
    Dr_Snooz

    "I like to take hammers, and just break stuff, just break stuff." - Beavis


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  18. #43
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    Re: '86 Aerodeck EX-2.0i

    Quote Originally Posted by Dr_Snooz View Post
    Cool! Thanks. I want to see you forming one of those curvy, intricate pieces on your forming tools.

    (Your camera is the tool of the devil, BTW).
    I'll see what I can do. I have ordered rear arch repair panels and I'll show that of a bit.

    Yeah I know. I think I will film with my phone instead. The quality might be a little worse, but hopefully more than 50% of the video will be in focus.

  19. #44
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    Re: '86 Aerodeck EX-2.0i

    Rust upate!

    I have taken of the rear bumper. At first glance it looks like just surface rust, but it has gone through in alot of places. Alot of teeny tiny holes with thin metal around them. I know what I'll be doing for the next couple of weeks .

    '86 Aerodeck EX-2.0i-img_20210129_151158[1]-jpg

    '86 Aerodeck EX-2.0i-img_20210129_151141[1]-jpg

    And the interior is getting thrown out! Well, for now. It's all going back in eventually. The whole inside is getting the rust-eze treatment, paint, cleaning and sound deadening with silent coat. And I found 2 swedish crowns in the carpet! Money!!

    '86 Aerodeck EX-2.0i-img_20210129_140601[1]-jpg

  20. #45
    '86 Aerodeck EX-2.0i
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    Re: '86 Aerodeck EX-2.0i

    Hoowhee! Somebody has a PROJECT!
    Dr_Snooz

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  21. #46
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    Re: '86 Aerodeck EX-2.0i

    I bought a box with things in it. Lots of boxes with lots of things acctually, but this is the most fun one

    '86 Aerodeck EX-2.0i-img_20210212_180557[1]-jpg

  22. #47
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    Re: '86 Aerodeck EX-2.0i

    Hello, it's me again. I have been super unproductive this week. I have just wanted to stay in bed when I don't work. But today I hauled my skinny butt down to the garage while the girlfriend was at work.


    I started on this little hole last week. "Hell, I'll have this finished in 1h", i thought.... WRONG
    Because this...
    '86 Aerodeck EX-2.0i-img_20210129_122714[1]-jpg


    Turned into this...
    '86 Aerodeck EX-2.0i-img_20210204_200645[1]-jpg


    Turned into thissssssss
    '86 Aerodeck EX-2.0i-img_20210205_151516[1]-jpg

    And I finished it of today. All welded up and primed with epoxy aaaaaand I see that I forgot the weld on nut for the seatbelt

    For those who wonder why I did this. When i tried welding in the smaller patches I kept burning through because the surrounding metal had rusted. While it hadn't rusted so bad it had turned into a hole, it had made the metal so thin that it just melted as soon as I stared welding. The undercoating in the wheel well hid all the rust, and I could not see it until I took of the coating.
    '86 Aerodeck EX-2.0i-img_20210214_163327[1]-jpg


    Then i cut this off
    '86 Aerodeck EX-2.0i-img_20210214_204713[1]-jpg

    And started to make a patch.
    '86 Aerodeck EX-2.0i-img_20210214_204811[1]-jpg


    And that's all I could take in just one day. I am pretty happy with the progress (except for just now when i saw i forgot that dang nut).

  23. #48
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    Re: '86 Aerodeck EX-2.0i

    Progress! Lots of work is getting done but we are still a long way from done.

    I found new sheet metal for the rear arches from some random website in like Estonia. I was a bit skeptical when i bought them but they look great! At least the left side that i have messed around with the most so far. They are made by Klokkerholm for anyone wondering.

    '86 Aerodeck EX-2.0i-img_20210219_153128[1]-jpg

    My dad had a really neat trick on how to make the new arches fit perfectly.

    First you clamp down the new panel on top of the old sheet metal. Mark where you want to cut.

    '86 Aerodeck EX-2.0i-img_20210219_155038[1]-jpg

    Use a thin cutting disc (I use 1.25mm thick ones for sheet metal) and cut through both of the panels. What will happen is, when you clamp the new panel on top of the old one it will sit about a millimeter or so lower than intended. When you then make your cut you remove that millimeter (the thickness of your disc) and the new panel will sit exactly were the old one was.

    I put a few spot welds just to hold it in place.

    '86 Aerodeck EX-2.0i-img_20210219_163306[1]-jpg

    All gone. Hey look! More rot. Yay!

    '86 Aerodeck EX-2.0i-img_20210219_173936[1]-jpg

    And this is how it fits! Very nice if a may say so myself. It was easier than I expected.
    This will later on be butt welded to the quarter panel (slowly to not warp it too much) and plug welded to the inner lip of the wheel arch.

    I had to make a new lip myself aswell. I didn't take any pictures but I'll take some during the week and maybe film some of it.

    '86 Aerodeck EX-2.0i-img_20210219_183944[1]-jpg

  24. #49
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    Re: '86 Aerodeck EX-2.0i

    Ooh, very, very nice. I need something like that for my accord.

  25. #50
    '86 Aerodeck EX-2.0i
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    Re: '86 Aerodeck EX-2.0i

    New body panels??? Were they selling unicorns too? Dodo birds? $1400 COVID stimulus checks? OMG!
    Dr_Snooz

    "I like to take hammers, and just break stuff, just break stuff." - Beavis


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