The shell was in pretty good shape, given the fact it was sat in a compound for 2 years untouched.
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The rear exhaust grill was cut off high up, before the rear bumper was refitted.
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The section the rear grill was cut off from was given the waxoyle protection treatment.
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![Image](http://i.imgur.com/cvt83Om.jpg)
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Welding to the drivers side sill was required, as it had a hole in it:
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![Image](http://i.imgur.com/xteeEVn.jpg)
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The paint was rubbed down to bare metal to make sure all the affected metal was removed.
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The affected section was cut out, and a new piece cut to suit:
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![Image](http://i.imgur.com/3CzT4qf.jpg)
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Then welded in:
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![Image](http://i.imgur.com/qGFsXxx.jpg)
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In addition, a brand new radiator support bracket was fitted:
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![Image](http://i.imgur.com/eWHQR9X.jpg)
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The passenger sill required no work, as it was perfect.
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With both sills solid, the car was transported on a trailer to the body shop for a full respray in non standard jet black paint.
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One tired looking
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'94 turbo in its original 202 paint on its way to the bodyshop:
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![Image](http://i.imgur.com/ZAx7XR6.jpg)
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The respray is a full bare shell respray.
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No glass or trim was left on the shell when it was painted.
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The result
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- zero lacquer lines.
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Once the shell had been resprayed, it was loaded back onto the trailer and on its way back to Sbits:
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![Image](http://i.imgur.com/APw9VoC.jpg)
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![Image](http://i.imgur.com/KRP2biV.jpg)
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Back at sbits, the T bar and my donor tin top side by side, ready to start swapping everything over and rebuilding the T bar:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/53Ty4Fl.jpg)
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The sills, rear grill area and inner arches have been protected with waxoyle, and the outer sills rubber coated for maximum protection against the elements:
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Rear grill removed and waxoyled:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/yorwyyO.jpg)
![](./images/smilies/spacer.gif)
Arches waxoyled:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/ZpJotrb.jpg)
![](./images/smilies/spacer.gif)
Sills rubber coated:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/SqdAZ7V.jpg)
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As the windscreen was transferred from the tin top, a new windscreen seal was ordered from Toyota and fitted:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/8ATy4LL.jpg)
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With all the rest of the body panels from the tin top painted, it was time to look at what could be done to the engine whilst it was out of the car.
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The following work was carried out on the engine:
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-Cam cover painted silver.
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Inlet manifold also painted silver, along with new sticker from Toyota:
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![Image](http://i.imgur.com/W1CkyL0.jpg)
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-Throttle body painted silver:
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![Image](http://i.imgur.com/sLIpMwg.jpg)
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-Custom wrapped exhaust heat shield in NimbusII:
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![Image](http://i.imgur.com/dceDV2T.jpg)
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-New head gasket
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-New cambelt
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-New water pump
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-Freshly refurbished CT26 hybrid turbo
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-Goodridge fuel line:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/VcpvGff.jpg)
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-Block casing painted black
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-New hose from hell
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-New oil cooler
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-HKS SSQV separated and painted gloss black with new bolts and printed HKS decal:
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![Image](http://i.imgur.com/VTndH5v.jpg)
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-Gear box steam cleaned
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-Fuel rail cleaned:
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![Image](http://i.imgur.com/Kfv6IK5.jpg)
![](./images/smilies/spacer.gif)
-Walbro 255l/h fuel pump:
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![Image](http://i.imgur.com/TMKUoe8.jpg)
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-Excedy uprated clutch:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/utYqrY0.jpg)
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/UUF4yoy.jpg)
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![Image](http://i.imgur.com/whe94Ux.jpg)
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Firewall heat shield painted silver:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/EyYt7Pl.jpg)
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The chargecooler was previously connected to a Celica GT4 ST205 stock pump.
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This was removed and replaced with a new Bosch pump as fitted to the Audi TT.
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:
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![Image](http://i.imgur.com/TMKUoe8.jpg)
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Anything else that could be degreased and cleaned, was done.
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All brackets visible from the top side of the engine were prepped and painted black.
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Coolant junction pipework was painted silver.
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A pic of the engine about ready to go back into the car:
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![Image](http://i.imgur.com/OMxGk4z.jpg)
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Engine refitted:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/4FAehQ7.jpg)
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In addition to the above, the car's aircon system has been fully overhauled:
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-New OEM dryer
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-New OEM aircon radiator
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-Refurbished air con compressor with 2 year warranty
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-Pressure tested
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-Gassed up
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One of the few MK2s with an aircon system as good as the day it rolled out of the Toyota factory in 1994!
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I also purchased a Speedhut rhd twin 52mm A pillar pod and 2 Stack gauges:
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-Oil Temp
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-Clock
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Reason for the clock, is that I have the Blitz boost controller fitted in the stock clock housing, for a snug fit in the dash:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/Yj4rYy8.jpg)
![](./images/smilies/spacer.gif)
A fully plumbed in Lifeline 2000 fire extinguisher has been fitted:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/nxuC2ZK.jpg)
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This is connected to 4 nozzle jets positioned in all 4 corners of the engine bay.
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This is controlled via a 2 stage process.
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Other additional bits that have been fitted:
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Gentex auto dimming electronic rear view mirror:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/YsAFboQ.jpg)
![](./images/smilies/spacer.gif)
TPMS
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(Tyre pressure monitoring system):
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/KxklWDr.jpg)
![](./images/smilies/spacer.gif)
Auto dimming dome light control module
Full rev 1 black roof lining, lights and sunvisor conversion:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/p6jaV1E.jpg)
![](./images/smilies/spacer.gif)
In addition to the black headlining, a brand new set of T bar seals were ordered from the US, and fitted, along with new rod guides:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/qfikTEc.jpg)
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/gGGOzM2.jpg)
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Stainless steel cancer bars
Stebel Nautilus horn
![](./images/smilies/spacer.gif)
Honda S2000 start button in factory cig lighter location
Additional auxiliary port in place of coin trays
![](./images/smilies/spacer.gif)
Goodridge braided brake lines
Goodridge braided clutch hose
Carbotech Panther Plus brake pads with Motul RBF600 brake fluid
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With the engine refitted to the car, and the car built back up, it looked like this:
![](./images/smilies/spacer.gif)
![Image](http://i.imgur.com/segYtPT.jpg)
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![Image](http://i.imgur.com/2ryDfB5.jpg)
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