Builds Ikarus' HDJ81 Aussie-Style Build

[ikarus]

Continued disassembling the interior. Pulled the steering wheel, instrument cluster and steering column:

I was glad to see that the captured nut for the top of the clutch pedal is already there, as well as a pre-cut section of the firewall insulation for the clutch mount.

Just need to get in there with a dremel and remove that stud to the top right of the clutch MC hole.

 

[ikarus]

Dashboard out. I swear I had 2x the amount of screws and bolts to remove than the FSM's instructions.

Pulled off the foam/cracked section. Need to figure out how I'm going to reupholster the dashboard and fix the cracks.

 

[Mag71k5]

For some reason an image of the dash being out just terrifies me. lol.

 

[Beach80]

Dashboard out. I swear I had 2x the amount of screws and bolts to remove than the FSM's instructions.

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Pulled off the foam/cracked section. Need to figure out how I'm going to reupholster the dashboard and fix the cracks.

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Cosmetic repair shops do exist that can repair your dash. I know it can be done.

 

[ikarus]

Cosmetic repair shops do exist that can repair your dash. I know it can be done.

I was thinking about sending it here:

Classic Car Interior Restoration | Just Dashes

We specialize in Classic Car Interior Restoration more than just the dash pads and instrument clusters. Check our works to know what other parts we restore.

www.justdashes.com

 

[ikarus]

Built the clutch pedal tonight. The pedal isn't covered in any FSM I could find so I had to go off the EPC diagram, and I kept a spare clutch pedal assembled to use as a reference.

The pedal and bucket are NLA but all the other parts are available new:

Here's a few photos mid-assembly:

I used Toyota body grease on the moving parts based on the places I saw with grease on the assembled pedal.

One thing to note is there are non-cruise and cruise control clutch pedals. The old pedal on the left is from an earlier 80 with no cruise control. The pedal stop adjustment is a bolt on the left side of the bucket. This bolt is smaller in diameter than the cruise control cancel switch.

The pedal I built is from a later 80 and uses a clutch switch (88280-14030) as the pedal stop.

I need to dig into the EWD and double check but I think I found the cruise control cancel switch connector taped up here behind the instrument cluster:

 

[ikarus]

Local junkyard had a '91 so I grabbed the AC hard lines, drier bracket and pressure switch to relocate my AC drier to the battery box.

 

[efjayatee]

Local junkyard had a '91 so I grabbed the AC hard lines, drier bracket and pressure switch to relocate my AC drier to the battery box.

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Grab the hood and graft yourself a 79 hood scoop

 

[ikarus]

Grab the hood and graft yourself a 79 hood scoop

I honestly might. Once all these projects are done.

 

[efjayatee]

I honestly might. Once all these projects are done.

Got the quote of $500 shipped to my door for the 79 hood-80 series model

 

[logicbyondreaso]

Got the quote of $500 shipped to my door for the 79 hood-80 series model

Where from?

 

[ikarus]

Got the quote of $500 shipped to my door for the 79 hood-80 series model

Shipping alone was $500, or the whole thing shipped was $500 total?

 

[Mag71k5]

The 80/79 hoods look cool, but I thought top mount intercoolers perform worse, love the look.

Id just be afraid of a performance hit.

 

[ikarus]

The 80/79 hoods look cool, but I thought top mount intercoolers perform worse, love the look.

Id just be afraid of a performance hit.

Yeah mainly the look in this case. Though if the performance hit wasn't too bad it would be nice to simplify the engine bay with a top mount and get rid of all the PDI pipes.

 

[efjayatee]

Sh

Shipping alone was $500, or the whole thing shipped was $500 total?

Shipping alone $500 + the hood (>$1200 usd). From Ultimate4x4, Thread #756

 

[efjayatee]

I'm tr

I like the PHAT option with OEM parts. Relatively expensive, would like use case from someone for QC and peace of mind.

I think a quality hood with genuine components won’t be cheaper than a couple of G’s from across the pond. BUT, I suppose you never know. @efjayatee, time to step up and take one for the team!

Their communication is non existent. Took 2 weeks to get a reply for the shipping cost. I've ask to formally quote/invoice me 2 weeks ago aswell.

 

[ikarus]

I'm tr

Their communication is non existent. Took 2 weeks to get a reply for the shipping cost. I've ask to formally quote/invoice me 2 weeks ago aswell.

Not a bad price but that would make me hesitant to deal with them

 

[efjayatee]

Not a bad price but that would make me hesitant to deal with them

Don't forget another added cost is to color match the paint

 

[ikarus]

Small update. Had a mobile AC guy stop by to drain the AC refrigerant. I had 8 oz in there.. explains why the AC wasn't feeling so good the last few months. FSM says it takes 30 oz or so.

 

[Beond77]

Small projects this weekend. Removed the old steering wheel cover:

Popped off the wheel:

I was talking to an upholsterer I know and he recommended trying to sand down the original steering wheel because it was so degraded and uneven. It's not perfect, but it worked out pretty well:

The cover I bought is a Loncky. I installed one in my 100 years ago. The color match for the brown is ok. It's lighter than stock.

Amazon product ASIN B00QLYA3XS

I wrestled it on, took a good amount of stretching, and added double sided tape all around.

Then got to work sewing. The Loncky kit comes with 5x as much thread as you'll need and a couple needles.

Loncky has videos on youtube that are ok, but I followed this method of sewing:



I would say it's not necessarily difficult but it is time consuming to make sure you get everything lined up right, stretch it together properly, make sure you're not pulling too hard etc. Once you get the technique down to start with a knot, figure out your pattern, and how to tie it off, it turns into a nice meditative exercise.

4-6 hours later:

I give the kit a 3.5 / 5 stars. It's nice enough, the material feels good and it generally goes on well but there were a few parts that just didn't have the right amount of material:

But having said that it's a huge upgrade over an old steering wheel cover. Feels great in your hands. If you just want to spend $60 and a half a day of your time, go for it. Next time I might try one of those Saudi eBay specials or have a shop do it since my steering wheel is a little lumpy underneath.

Wheel back on, no airbag accidents... (don't forget to disconnect the battery before doing any of this)

Looks amazing