Well it has been a while since I first posted the GT on here but I had to clear out another project and wait on my panel beater before we could start on the body. That work has now started and I will be posting the rust repair work as we take the GT from start to finish over the next couple of months. First item was the structural work and that has started with the passenger side sill and A pillar. As we went along and opened her up it became evident there was more rust than first thought. To keep the integrity of the car we also had to make sure it did not sag when the sill was cut out hence the frame work you see bolted into the passenger side. The passenger sill is now replaced and the bottom of the A pillar, a lot of fabrication has gone into replacing the rusted sections in the top of the A pillar and these are ready to be welded back in one at a time section by section. Still have to fabricate the top section and weld in. This will be completed next week and the driver side sill will be replaced then also and work will commence on fabricating sections of the driver side A Pillar the same as the passenger side. Hope you like the pictures.

Regards
Peter

Some more pictures of the work

This is the final lot from this week I will post more next week when we have completed the other side.

Keep up the good work - you are making progress...…… looks like it will be a nice (rare) car...…….

well ...now that's what was supposed to be done ….what a great pair of hands the little car is bit by bit day by day then it will be back as it should be great work peter ...cant wait to see the next post cheers davo

Today was the day to do the driver side sill. We welded in the sections of the A pillar on the passenger side and only the top hat section remains to be welded in after it had been fabricated. As we caulked all the sections of the new parts welded in we need to wait for that to dry before putting that on so that will happen next week. We believed the A Pillar on the driver side was not as bad as the passenger side, how wrong we were, you will see from the pictures that we had to take a large section out until we found good metal. this will be finished next week. The driver side sill is all fabricated and welded in including the back section so we are making good progress. During the A Pillar work we discovered more rust in the foot well on both sides, this is very minor and two new sections will be fabricated and welded in next week.

There appears to be more degeneration of the body at the front end so once we have completed the A Pillars it should be relatively easy going. You do not go into a restoration like this without your both eyes open so at this stage there have been no surprises and in fact the body is pretty good for its age. We knew the passenger side suspension tower had rust in it and it was hidden over with filler so it came as no surprise to find a hole when we started digging. What we did find provided a moment where we had a chuckle (when you see the picture you will understand) and I wonder what next this little car will offer up. It just keeps giving and is quite rewarding to work on. When you start digging into the bones of a car like we are you realise just how well these little jiggers were really built, they are very sound structurally it is just the metal was not treated at the time of production hence the rust issues.

Hope you enjoy the pictures

regards
peter

I do not know what happened there but the picture of what we found in the suspension tower did not upload so here it is.

No work on the GT last week as my panel beater had the flu but he has recovered and we were back into it this week. A lot was achieved today, finished off the passenger side A pillar, repaired some more rust found as we moved around the passenger A Pillar area. The driver side A pillar is almost completed, only have to weld the cap on and we can tick that box off. We also fitted the rust repair sections to the quarter panels behind the doors, these are now ready for welding in. Next week we hope to complete the bottom of the rear part of the quarter panels and if time permits the back beaver where we will replace those sections that have been cut out to make the rear look like a teardrop. Here is pictures of todays work.
Regards
Peter

You should make 2 of each part as you go, then you will have enough to build a new GT at the end...…….
(BIG JOB - but making progress!)

Thanks for your comments, much appreciated. Maybe if I do two of everything then I will have rust repair sections ready should anybody else want to repair similar areas. Do not think I will want to build another one after this but there is light at the end of the tunnel. The funny part is that the cabin floor and boot are as solid as a rock and the chassis rails are all good. We believe if we get what we want to do done next week we will have broken the back of it but do not take that too literally.

regards
peter

Things progressing further for the GT. I happened to find genuine Isuzu NOS in original packaging on a site in Japan and purchased some items which arrived today. I cannot thank Jason (prince skyline gt login on the forum) enough for his helpful advice with this. I purchased the following items:
Quarter vent window seals
Handbrake boot
Carburettor air cleaners
It does not stop just because you are working on the body, you need to be alert for items that may pop up to complete the restoration and these were on my bucket list. Also Craig (Claws) was kind enough to lend me a complete set of front brake pipes so I can have two duplicate sets made. To say I am chuffed at the moment would be an understatement.

A good days work today and I can say we have now completed the drivers side with rust repair work. Next week we will complete the passenger side rear quarter and then move onto the tail lights in the back beaver section.

Hi Peter,
The progress is looking fantastic!
It’s going to be one solid PR90 once complete.

Hi Lewis,
Thanks for your comments. Yes it will be solid but still a ways to go yet. Next week we hope to complete the passenger side rear quarter, that will take some time as we do not have a donor piece so it will have to be fabricated by hand but my panel beater is very good at that and if time permits we will try and complete the back tail light section and return that to how it should be. Once that is all completed then we have the gutter railing in the roof section on both sides, no rust originally evident there but with a little tapping we found it. Last major piece is the passenger side suspension tower but I will move it into the shed and up on the hoist for that as we will need to drop the front end out to get a clear go at it. Finally we will do the windscreen surrounds and any other little bits and pieces then work the panels along with guards, doors, bonnet and boot in preparation for painting. We hope to have it in colour by the end of the year or early next year then off to the trimmers whilst I try and source engine bits for my original G160 like pistons etc. I am enjoying this car and it is making me think outside the square so the old grey cells are getting a good work out.

I am sure I will be picking your brain as we get deeper into it.

Regards
Peter

Most GT engine builders use Gemini pistons and rods in an engine rebuild. I did this in my (now Dave's) 68 1/2 GT. ( I don't have direct knowledge of early GT engines)

While Gemini stuff used to be very common, it should still be possible to come up with good s/h rods and new pistons. Certainly easier than original Bellett parts. Bellett GT pistons crowns are different to Gemini so you will end up with a lower compression ratio. In my GT engine, the head was milled also to get back some of that CR.

Glenn

Hi Glenn,

Thanks for your input.

I have read on the forum about Gemini pistons and rods for these engines but as you say they are not that common anymore either. My car has the 160 engine which is 3 bearing crank and it has standard bore with original pistons that have no crown but are flat top. From what I can find out they appear to have changed the pistons for the 161 motor different stroke and bore for the 160 to the 161 so there will probably be issues like piston pin height etc as I look for substitutes. Also I believe from reading on this forum that there is a problem with cam bearings so that is an issue that will have to be resolved as well. I have decided to go with the original motor so it has not escaped me that I may have to have some things made like pistons and cam bearings, I understand this can be expensive but if you work out the cost of finding a 161 motor and then equipping it I think the motor I have will be the more cost effective way to go.

My mind is not closed on this and will appreciate the views of others as I do not want to reinvent the wheel unfortunately I have chosen the rarer of the GT's to restore and parts are going to be difficult.

Regards
Peter

I'm sure somebody here will pop up with the word on 3 bearing engines re what can be done.. There was a place called Special Engine Services in Dandenong area I believe that could have pistons made or adapted to most applications. Not sure if they still exist.

For later engines, anybody on this group who are thinking of the gemini route in future might well pay to get the parts asap.
There were a few posts in this group with part numbers for cam bearings. Still available, may have to do some hunting. I am referring to the latter engines but it might be that they suit early engines also?

I hope it all works out well for your car.
glenn

Thanks Glenn
A forum member has given me a lead to a Engine Reconditioning firm in Ballarat called M and W that specialises in vintage and classic engines. They will manufacture parts or adapt existing items that can be re-worked. I will contact them in the near future and see what can be done.

I also have a very good friend in Bendigo who has done a lot of engine work for me in the past called Lyndon Little from Little race engines and I am sure he could source items for me but he is just so busy and I do not want to wait 12-24 months for an engine.

I will keep you all posted on how that progresses in the meantime back into the panel work tomorrow.

cheers

Peter

Peter,
Don’t forget that JP PISTONS is a local (to Adelaide) firm and may be worth talking to to find out what possibilities and cost.
A.J.

Thanks AJ I will check them out.