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Project AE86, Repairing the Chassis

  • Mike Kojima

After fitting Zack drilled and sanded the ecoat off the new parts to prep them for welding.

The new quarter panels have 2x the number of spot welds than the factory had.  This will make the repair stronger than stock.  The new quarter panels are made out of higher quality and thicker metal than the stock parts as well.  The new reproduction parts fit very well.  Frankly, we were surprised with the quality.

After applying weld through primer for rust resistance, Zack welded the quarter panels in place.

The entire bottoms of the rear panels were rusted all the way through.

Surprisingly, the floor panel was still in ok shape.  The rust was sanded off, rust deactivator was applied, then holes were drilled for new welds.  Finally, weld through primer was applied before welding.

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Related Topics
  • toyota
  • Fabrication and Safety
  • Paint and Bodywork
  • AE86
  • Fabrication
  • Toyota 86
  • restomod
  • Rust Repair
  • Restoration
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2 comments
  1. James says:
    March 11, 2025 at 4:32 am

    That is super cool that good quality repair parts can still be found for that chassis. Rust and bondo are the absolute worst thing to find when trying to modify any car.

    Reply
  2. Rachel 😉 says:
    April 15, 2025 at 11:14 am

    Zach is the best!! I wish I lived closer cause I’d love for him to do my roll cage!

    Reply

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