Dumb, Stubborn, and bound to end up penniless…….

Post by **coolhandluke** » Thu Nov 19, 2020 2:52 pm

What ABS filler did you use? I bought a set of UKDM tail lights and a post was broken in transit. I wonder if I could try your trick on repairing the post.

aklackner · Post by **aklackner** » Thu Nov 19, 2020 4:59 pm

@coolhandluke I bought a polyvance airless welding kit. Im very happy with it but it does take a bit of practice to get used to and patience to finesse to get acceptably tidy.

I think it will be useful for a lot of repairs like your broken clip and torn plastics that are pretty common on our cars as they get older. I already have a list of minor repairs I know I can do now.

While practicing to weld the replacement section of dash I shaped a bunch of the filler in to the old dash section to see if it could really be used to rebuild a clip. I’m amazed it’s as strong as original even with such a quick sloppy job.

A portion of the clip was entirely broken out before the test, and I just free hand melted the filler into a rough shape to get a sense for the material.

The abs filler material feels very rubbery when it’s warm but once cool feels the same as our interior plastics so don’t judge too quickly, give it a couple minutes once you’re done.

Here’s the link to the kit on Amazon.
Polyvance 5700HT Mini Weld Model... https://www.amazon.com/dp/B00IEX6NME?re ... b_ap_share

aklackner · Post by **aklackner** » Thu Nov 19, 2020 5:15 pm

One of the next things on my to do list for 01-0386 is getting the rear together where I just have things basically hanging in place currently.

The original steel bumper had rust issues so a long time ago I picked up a used replacement in good condition. The replacement was from a green Integra so today I fixed that.

In the next couple days I’ll get the hardware together and shoot to start getting it together properly next week.

aklackner · Post by **aklackner** » Fri Nov 20, 2020 7:29 pm

Pretty successful day
Third taillight and hatch plastics went in.
Ended up doing a bit more plastic welding to repair a torn tab for one of the hatch side covers.

Turns out the plastics are actually polypropylene (which the polyvance unit has a setting for and comes with pp filler too). Repair worked out near perfectly.

Inspired by some momentum, I was able to harvest some mounting hardware for the rear bumper and things just kept going pretty smoothly so....well here’s the finished product.

Hatch plastics on

New license plate lights on

Rear bumper beam mounted

Bumper beam cushions (left was discontinued so is original and pretty disintegrated, right I managed to get new)

Bumper skin and filler

Taillights (need to polish the right some but both are mounted with oem seals)

It was a good day!

Just as good is that this means I’m a few minor things away from starting work on getting side plastics back in!

aklackner · Post by **aklackner** » Sat Nov 21, 2020 3:31 pm

Upper side plastics are in. Yet another broken tab repaired with the plastic welder, so all clip are in place!

Unfortunately the installer that did the glass let the adhesive come up too high for the rubber trims in a couple places so I’ll have to trim the adhesive down with a razor before the rubber trims go into place properly.

aklackner · Post by **aklackner** » Sat Nov 21, 2020 7:11 pm

Ok one more update today

Right side plastic in place!

Post by **coolhandluke** » Sun Nov 22, 2020 10:49 am

aklackner wrote: ↑Fri Nov 20, 2020 7:29 pm ...It was a good day!

Just as good is that this means I’m a few minor things away from starting work on getting side plastics back in!

This sounds like a great feeling! I'm having flashbacks to ~2008 when I was doing final assembly for my rebuild. That's quite a feeling, the home stretch is within sight!

I wasn't aware of the rear bumper foam being discontinued.

aklackner · Post by **aklackner** » Mon Nov 23, 2020 6:21 pm

I feel like I saw this in Disney’s Cars before

Worked though. Our trees got trimmed up, my wife got to drive the ITR, and the ITR and the LS shell are both tucked back away.

I did have to ask her not to shift into gear at 3.5k. The Ogura clutch takes some finesse, or be ready to launch.

Yeah I busted another caster off the dolly. #myweldingsucks but fortunately had the wood furniture dolly on hand, so all’s well.

aklackner · Post by **aklackner** » Mon Nov 23, 2020 6:38 pm

Aaaand
Bits from powdercoating

The shop (powder coat unlimited) did an amazing job, no chipping at the joints, even the backsides look fantastic.

Post by **coolhandluke** » Tue Nov 24, 2020 12:16 pm

Oh wow, those look fantastic! I'm taking notes for my car.

Type R Club of America