ADY STIMPSON - MR2 RESTORATION PAGE 1

Back to main page at MR2 MK1 Club

Back to Restorations page on Supercharger Site

The MR2 as purchased

RESTORATION NOTES FOR 1989 TOYOTA MR2 G981 ECK

Rebuilt July 2002 - April 2003

OWNER: ADY STIMPSON

SATURDAY 6 JULY 2002

Found a respectably clean and standard MK1 Toyota MR-2 advertised on the Auto Trader website, the vendor being Nigel Owen of Ashton-in-Makerfield. Contacted the owner via email and received a number of clear digital photographs of the vehicle by return. Decided that the car was worth travelling to the Wigan area to view, and arranged to visit the car the following day.

SUNDAY 7 JULY 2002

Drove 115 miles to Ashton-in-Makerfield to view G981 ECK. Found it to be in quite superb fine original condition, finished in pale Mica Blue with a mere 57,000 miles recorded, all MOT certificates from 1990 and a full main dealer service history which was an unexpected bonus. The vehicle was also complete with the original tool roll (all tools present and correct), and all handbooks including the service history book.

Having taken the car for a 30 minute test drive, and having scrutinised the vehicle documentation, the vendor and I agreed a price of £3,270. I left a cash deposit of £250 and agreed to return the following day to collect the car.

MONDAY 8 JULY 2002

I contacted classic insurance specialists RH and paid £168 for a fully comprehensive policy, with an agreed value of £5000 and an annual mileage limit of 3000 miles. I then drove the 115 miles back up the M6 to collect the car, paying the balance of £3020 in cash. The return journey in G981 ECK was livened up by heavy rain almost all the way home. I found that I was fighting the car through corners due to a severe lack of mechanical grip. Correctly assessed that the tyres as fitted to the car – Korean Woosungs (!!) were dire in wet weather, and therefore the full set must be replaced without delay.

TUESDAY 9 JULY 2002

Took the MR2 out for a drive of about 12 miles to assess and evaluate all systems and functions prior to restoring the car. I gave G981 ECK a thorough check over and made notes to assist in returning the car to near show condition. I quickly established that the external bodywork and interior trim required very little effort to bring it up to standard. However, the body shell underside, inner wheel arches, front bonnet, boot and engine bay areas would require significant re-engineering and refinishing detailing to bring the car nearer to class A1.

SATURDAY 13 JULY 2002

Having parked the MR2 in the garage over a full size footprint of carpet, the car was jacked up onto axle stands and all road wheels removed prior to rebuilding work commencing.

SUNDAY 23 MARCH 2003

Stood back and admired the results of my endeavours over the last 36 weeks. The car is washed, polished, tuned and as close to concourse as I can realistically achieve without throwing absurd amounts of money at it.

Propose to tax the car for 6 months commencing 1 May 2003. Objective achieved.

SERVICE HISTORY – POST RESTORATION WORK 2003

MONDAY 5 MAY 2003 - 57,700 miles

Entered MR2 in the Thoresby Park Classic Car Show, Ollerton, Nottinghamshire. Finished 4th in Best Sports Car category.

FRIDAY 18 MAY 2003 - 58,000 miles

Having covered 350 miles since putting the car back on the road, I ran the engine up to temperature, poured a can of Wynn’s Engine Flush into the cambox, and ran the engine at fast idle for 10 minutes. Dumped all used engine oil, replaced oil filter and sump drain plug gasket. Refilled sump with semi-synthetic 10/40 lubricant.

Found that the new exhaust system was moving around on its mountings. Old mountings were found to be perished. Replaced all 3 mountings with new Toyota genuine parts, exhaust now fitted more securely - £21.50

SUNDAY 30 MAY 2003 - 58,100 miles

Took the MR2 to local Toyota main dealer Farmer and Carlisle at West Bridgford, Nottingham for a cambelt service. Alternator belt found to be very worn and replaced at the same time. Slight oil leak noted coming from distributor drive seal. New ‘o’ ring ordered - £161.14

SATURDAY 31 MAY 2003 - 58,200 miles

Took the MR2 to Tatton Park, Knutsford, Cheshire for the annual Northern Classic Car Show.

Displayed the car on the MR2 Drivers Club stand for the day. Won “Best MR2 in Show” from more than 50 other MK1 MR2s at the show. Received an engraved trophy to mark the award.

WEDNESDAY 11 JUNE 2003 - 58,300 miles

Drove the MR2 to Portsmouth in convoy with other classic cars to catch the Le Havre ferry to 2003 Le Mans 24 hour race. Covered 900 miles from 11 to 16 June with no problems other than a leaking alternator seal. Completed three laps of the Le Mans circuit and achieved a fastest reading of 138mph down the length of the 3 mile Mulsanne straight. Need to uprate the disc pads before I do any more track days. Modifications to engine intake, induction and exhaust systems have given another 15mph on the top speed. Returned home on Monday 16 June with one very dirty MR2…!

FRIDAY 20 JUNE 2003 - 59,200 miles

Collected a new distributor drive shaft oil seal from Toyota dealer Farmer and Carlisle - £3.30

SATURDAY 16 AUGUST 2003 - 59,363 miles

Fitted new distributor drive shaft oil seal, and degreased rear of engine block. Fitted 2 off front “blue tinted” sidelight bulbs. Rubbed down flaking exhaust manifold, and repainted in high temperature satin black finish.

Fitted new genuine Toyota cable clamp to distributor housing. Original part broke during distributor removal.

Fitted new door lock screws to both door trailing edges – 6 off – to replace badly corroded originals. Drove MR2 over to Trowell Repair Services for MOT test. Passed with no problems whatsoever - £43.24

RESTORATION WORK 13 JULY 2002 – 23 MARCH 2003

Removed front wheels and spare wheel from front bonnet bay - 0.25hrs

Cleaned wheels of all road dirt and brake dust - 1.0hrs

Replaced worn Woosung tyres with “Continental Premium Contact” 185/60/H14’s - 2.0hrs

Stripped out front wheel arches, both arch liners and front radiator hose covers - 2.0hrs

Washed bare metal wheel arches out, removing some 2kg of debris, which had become trapped behind the trailing edge of the wheel arch liners - 2.0hrs

Cleaned and prepared both plastic wheel arch liners before refinishing with 4 coats of PJ satin black aerosol paint finish - 3.0hrs

Stripped down front disc brake assemblies. Found front disc wear to be excessive and rebuilt the stub axle assemblies with new discs, pads and shims, correctly lubricated with Copper grease - 3.5hrs

Masked off rebuilt stub assemblies and refinished inner wheel arch metalwork with Hammerite Smooth Gloss Black paint finish - 5.5hrs

Brass brushed all corroded front suspension and steering components to remove debris and flaking paint finish. Washed down all components, having used a vacuum cleaner to remove all loose debris and particles, prior to re-finishing steering and front suspension with Hammerite Smooth Gloss Black - 8.0hrs

Using abrasives, stripped the finish off the inside of the front and spare wheels, removing all traces of road dirt and brake dust, taking the surface back to bare alloy - 4.5hrs

Masked off tyres, and refinished the inner wheels with 4 coats of acrylic primer - 4.0hrs

Refinished the inner wheels with 4 coats of acrylic alloy wheel silver paint finish - 2.0hrs

Completed the wheels by applying 4 coats of clear acrylic lacquer - 1.0hrs

Using Solvol Autosol metal polish, restored the chrome front wheel nuts - 0.5hrs

Refitted the plastic wheel arch liners using new fixings - 1.0hrs

Refitted both front road wheels, and checked and adjusted the tyre pressures - 0.5hrs

Removed front no plate, support bracket, radiator grille and front spoiler assembly - 1.5hrs

Removed front radiator trim panel from under front bonnet - 0.5hrs

Removed front radiator twin cooling fan assembly - 2.0hrs

Washed out underside to front of car, washed grille, twin fans and spoiler assy - 4.5hrs

Brass brushed front radiator brackets and refinished in black enamel - 2.5hrs

Brass brushed front spoiler brackets and refinished in black enamel - 1.5hrs

Dismantled badly corroded front radiator twin fan assembly - 3.0hrs

(Running Total 56.25hrs)

Brass brushed twin fan housing and refinished in PJ1 satin black - 2.0hrs

Degreased both nylon fan impellers and re-assembled twin fan assembly - 1.0hrs

Washed out front radiator area and removed all road dirt and deposits therein - 2.0hrs

Re-installed twin fan assembly and reconnected to electrical circuits - 1.0hrs

Brass brushed front radiator housing and refinished in PJ1 satin black - 1.0hrs

Stripped out front bonnet area totally - 1.5hrs

Removed and cleaned screen wash reservoir - 0.5hrs

Cleaned and polished front radiator panel - 0.5hrs

Refinished all brackets in PJ1 satin black - 1.0hrs

Stripped out retractable headlight assemblies from car - 4.0hrs

Brass brushed mechanical headlamp structures and refinished in gloss black - 2.0hrs

Refinished front bonnet stay in gloss black - 0.25hrs

Washed out headlamp retraction pockets and removed all road dirt - 0.5hrs

Re-assembled headlamp units with new “Cool Blue” quartz bulbs, and re-installed - 0.5hrs

Replaced broken nylon front bonnet stay clip with new and refitted bonnet stay - 0.25hrs

Refitted front radiator cover using new fixings - 0.25hrs

Refitted screen wash reservoir with new fixings - 0.25hrs

Refilled screen wash bottle with Toyota brand blue screen wash

Polished all painted surfaces under front bonnet using Autoglym - 0.25hrs

Washed out spare wheel well - 0.25hrs

Refitted refurbished spare wheel into it’s location under the front bonnet - 0.25hrs

Degreased and cleaned tool kit and roadside jack - 0.25hrs

Polished front spoiler assembly and rebuilt using new fixings - 1.0hrs

Refitted front spoiler assembly using new fixings - 0.5hrs

Refinished front grille screws in PJ1 satin black - 0.25hrs

Refitted front grille assembly - 0.25hrs

Removed both offside and nearside body skirt assemblies - 1.0hrs

Cleaned out all debris from both body skirt assemblies - 2.0hrs

Cleaned obscured bodywork where side skirts are located, applied Autoglym - 0.5hrs

(Running Total 81.25hrs)

Removed front windscreen wiper arm assemblies for refinishing - 0.25hrs

Dismantled both wiper arm assemblies - 0.25hrs

Flatted back paint and refinished both wiper arms in PJ1 satin black finish - 0.5hrs

Removed front scuttle panel air intakes and cleaned out accumulated debris - 0.5hrs

Cleaned and polished scuttle panel using Autoglym paint restorer - 0.25hrs

Cleaned and polished scuttle panel air intakes and refitted to their locations - 0.25hrs

Re-assembled both wiper arms using 4 new fixings, and refitted to the car - 0.5hrs

Removed both door mirrors to address severe corrosion to alloy mountings -1.0hrs

Stripped down both mirror assemblies to their component form - 2.0hrs

Paint stripped the door mirror alloy mountings with Nitromors, back to bare alloy - 1.0hrs

Brass brushed up the alloy castings to remove all trace of corrosion - 0.5hrs

Refinished alloy mirror castings with 6 coats of PJ1 satin black paint finish - 1.0hrs

Cleaned up all mirror components and reassembled the pair ready for refitting - 2.0hrs

Cleaned down mirror mounting faces on both doors, and refitted mirrors - 1.0hrs

Removed offside rear air intake scoop - 0.25hrs

Cleaned out debris, washed and polished exposed body side - 0.25hrs

Refinished air intake scoop with PJ1 satin black paint finish - 0.25hrs

Washed and polished rear air intake scoop and refitted to car - 0.25hrs

Removed rear road wheels - 0.25hrs

Stripped down rear brake caliper and disc assemblies - 1.0hrs

Stripped out fuel filler hose plastic shroud from rear nearside wheel arch - 0.5hrs

Removed both rear mud flaps - 0.5hrs

Washed out both rear wheel arches and removed all debris and road dirt - 2.0hrs

Refinished the insides of both rear wheel arches with gloss black Hammerite - 2.0hrs

Degreased rear calipers and rear discs - 2.0hrs

Brass brushed both rear brake calipers to remove all traces of corrosion - 1.0hrs

Re-finished both rear brake calipers in gloss silver smooth Hammerite - 1.0hrs

Rear discs were found to be new, and were brass brushed to remove all corrosion from centers - 0.5hrs

Rear discs were masked up and centres refinished in acrylic silver paint finish - 1.0hrs

(Running Total 105.0hrs)

Washed and degreased fuel filler hose shroud, and refinished in PJ1 satin black - 1.0hrs

Washed and cleaned out all debris from rear mud flaps - 0.5hrs

Refinished interior faces of rear mud flaps with PJ1 satin black paint finish - 0.5hrs

Brass brushed rear suspension and drive train to remove all traces of corrosion - 16.0hrs

Washed down rear suspension and drive train components - 6.0hrs

Re-finished the rear suspension components with two coats of Hammerite - 8.0hrs

Refinished drive train components with two coats of silver smooth Hammerite - 2.0hrs

Reassembled rear wheel arches with new genuine Toyota fixings - 3.0hrs

Removed badly corroded rear offside brake disc stone guard and discarded - 1.0hrs

Fitted new rear offside brake disc stone guard - 1.5hrs

Re-assembled rear brake discs and calipers, checked pads and copper greased - 2.0hrs

Refitted rear mud flaps using new genuine Toyota fixings - 0.5hrs

Washed clean both rear wheels - 0.5hrs

Using abrasive materials, stripped the finish off the inside of the rear wheels, removing all traces of road dirt and brake dust, taking the surface back to bare alloy - 2.0hrs

Masked off tyres, and refinished the inner wheels with 4 coats of acrylic primer - 2.0hrs

Refinished the inner wheels with 4 coats of acrylic alloy wheel silver paint finish - 1.0hrs

Completed the wheels by applying 4 coats of clear acrylic lacquer - 2.0hrs

Using Solvol Autosol metal polish, restored the chrome rear wheel nuts - 0.5hrs

Refitted both rear road wheels, and checked and adjusted the tyre pressures - 0.5hrs

Refitted both body skirt assemblies with new fixings to the wheel arch locations - 1.5hrs

Removed the complete exhaust system and discarded due to severe corrosion - 2.0hrs

Removed both floor mounted exhaust heat shields - 1.5hrs

Washed and cleaned out debris from exposed areas of body shell underside - 2.0hrs

Brass brushed both exhaust heat shields to remove all traces of corrosion - 1.0hrs

Refinished exhaust facing side of heat shields with VHT silver spray paint - 1.0hrs

Refinished rear under bumper vent panel face of heat shield with satin black paint - 0.5hrs

Removed rear bumper skin panel bracket and brushed to remove loose flaking - 1.0hrs

Refinished rear bumper skin panel bracket in PJ1 satin black paint finish - 1.0hrs

(Running Total 167.0hrs)

Removed all exhaust system brackets for cleaning and refinishing - 1.0hrs

Removed 2 off exhaust flange ‘O’ ring gaskets from manifold down pipe - 0.25hrs

Removed 4 off rear bumper bolts from inside rear boot area - 0.5hrs

Removed complete rear bumper assembly - 0.25hrs

Found rear bumper inner structure to be badly corroded.

Brass brushed rear bumper inner structure and vacuumed out loose corrosion - 2.0hrs

Washed down rear bumper and removed all trace of road dirt - 0.5hrs

Laid rear bumper face down, refinished rear bumper with black Hammerite - 1.0hrs

Brass brushed and washed exhaust system brackets prior to refinishing - 0.5hrs

Refinished exhaust system brackets with 2 coats of black smooth Hammerite - 1.0hrs

Removed all 3 body shell louvred plastic under floor panels - 2.0hrs

Washed and degreased all under floor panels prior to refinishing - 2.0hrs

Refinished all 3 under floor panels with 4 coats of PJ1 satin black paint finish - 2.0hrs

Washed down exposed underside body shell and removed all debris - 1.5hrs

Refinished rear body shell underside with smooth black Hammerite - 2.5hrs

Drilled out 4 off broken M6 studs for the floor panel fixing points, and re-tapped - 2.0hrs

Washed and degreased floor panel steel bracing brackets - 0.5hrs

Refinished floor panel bracing brackets with smooth gloss black Hammerite - 0.5hrs

Drilled out 3 broken rear bumper skin fixings on underside of rear bumper - 0.75hrs

Tapped out new M6 threads in 3 positions and fitted new genuine Toyota fixings - 0.25hrs

Removed rear boot mounted spoiler panel, and discarded 7 off corroded fixings - 0.5hrs

Reassembled rear bumper, washed and polished using Autoglym - 0.5hrs

Found 2 off M6 fixing studs in the rear spoiler panel to be seized solid - 0.25hrs

Left studs soaking in WD40 and freed off - 0.25hrs

Fitted all fixing studs back into rear spoiler panel - 0.25hrs

Washed and polished rear spoiler panel using Autoglym - 0.5hrs

Removed small areas of corrosion on inside of rear boot cover, and painted - 1.0hrs

Polished inside of rear boot lid with Autoglym - 0.25hrs

Refitted rear spoiler panel to boot lid using 7 off new genuine Toyota fixings - 0.5hrs

(Running Total 192.0hrs)

Removed rear number plate - 0.25hrs

Washed and cleaned down rear black number plate panel area - 0.25hrs

Using Solvol Autosol, I polished the rear number plate panel to a gloss finish - 0.25hrs

Used clear silicone sealant to seal rear no plate fixing holes in rear black panel - 0.25hrs

Fitted new cherished no plate “ADY 2V” to rear panel using self adhesive tapes - 0.25hrs

Fitted new “ADY 2V” no plate to front bumper bracket using concealed fixings - 0.25hrs

Drilled out 4 off broken fixings for exhaust system heat shield on body underside - 1.0hrs

Tapped out M6 thread in 4 off positions - 1.0hrs

Refitted 3 off louvred plastic under floor panels using new genuine Toyota fixings - 0.5hrs

Refitted 2 off exhaust system heat shields using new genuine Toyota fixings - 0.5hrs

Washed down exposed rear bodywork behind rear bumper assembly - 0.25hrs

Polished exposed rear bodywork with Autoglym - 0.25hrs

Refitted rear bumper assembly to car - 0.5hrs

Re-assembled and refitted 3 exhaust mounting brackets to body shell underside - 0.25hrs.

Replaced worn rear Woosung tyres with 2 OE “Continental Premium Contact” 185/60/H14’s - 2.0hrs

Stripped out rear window aerofoil, air vents and rear flying buttress trims - 2.0hrs

Cleaned out debris from trims and exposed bodywork - 1.0hrs

Refitted rear window aerofoil, air vents and rear flying buttress trims - 1.0hrs

Removed rear engine cover side trim panels - 0.25hrs

Washed and cleaned rear engine cover trim panels, and re-finished fixings in black - 1.0hrs

Polished rear engine cover trim panels using Autoglym - 0.25hrs

Removed and cleaned rear engine cover rubber seal - 0.25hrs

Removed all 3 alarm contact switches to front and rear boots, engine bay cover - 1.0hrs

Cleaned all 3 off switches, and cleaned and polished exposed bodywork - 1.0hrs

Repaired paint finish to bodywork, and refitted 3 switches with new fixings - 1.0hrs

Washed debris from exposed bodywork areas beneath engine trim panels - 0.5hrs

Disconnected coolant system header tank and removed completely from car - 1.0hrs

Drained expansion bottle and left to soak in a bleach solution for 10 days to remove discolouring - 0.25hrs

Used cutting compound to restore finish of expansion bottle - 0.25hrs

(Running Total 210.5hrs)

Replaced old tired tool roll under front bonnet with new Toyota item - 0.25hrs

Cleaned and refinished overflow trim to header tank in PJ1 satin black - 0.5hrs

Refitted overflow trim to header tank using new genuine Toyota fixings - 0.25hrs

Removed all rear boot trim panels and carpet for cleaning - 0.5hrs

Shampooed all rear boot trim panels and carpet - 1.0hrs

Cleaned out exposed rear boot area of dirt and debris - 0.5hrs

Refitted rear boot trim panels and carpet using new genuine Toyota fixings - 0.25hrs

Stripped out fuel filler area. Removed flap, and removed over spray damage - 0.5hrs

Polished corrosion off filler cap and refitted. Refitted flap using new fixings - 0.25hrs

Refinished 4 off fuel hose fixings in PJ1 satin black - 0.25hrs

Fitted 2 off new fuel flap stop rubbers - 0.25hrs

Stripped out both rear light clusters from boot area for cleaning - 0.25hrs

Cleaned out, replaced defective bulbs and refitted - 0.5hrs

Replaced 6 off front bumper trim fixings under front bonnet - 0.25hrs

Removed and cleaned sunroof glass panel - 0.5hrs

Removed and cleaned stainless steel aero deflector from sunroof recess - 0.5hrs

Cleaned out dirt in sunroof recess of body shell and found some corrosion - 0.5hrs

Treated corrosion with Cure-Rust and left to dry - 0.25hrs

Filled corrosion area and repainted in Toyota pale Mica Blue - 0.5hrs

Removed and cleaned sunroof seals and trim panels - 0.25hrs

Polished sunroof recess and whole roof of car twice with Autoglym - 0.25hrs

Refitted roof seals, aerofoil and sunroof assemblies - 0.5hrs

Removed dash trim panels and audio systems to access alarm system LED - 1.5hrs

Removed and old red LED and replaced with wide angle high intensity blue type - 2.0hrs

Removed both door air vents in body shell structure for refurbishing - 0.25hrs

Stripped both air vents down to component form - 0.5hrs

Cleaned all components and re-assembled both air vents - 1.5hrs

Cleaned exposed air vent recesses in body shell, refinished both fixings in black - 0.5hrs

Refitted both air vents to car - 0.25hrs

(Running Total 225.75hrs)

Removed both seats for cleaning - 1.0hrs

Removed centre console trim and cassette storage box assemblies - 1.0hrs

Removed both seat belts and anchorage points for cleaning - 0.5hrs

Removed rear view mirror and both sun visor assemblies - 0.5hrs

Shampooed headlining and removed all stains and dirt marks - 0.5hrs

Vacuumed all carpets and trim panels - 0.25hrs

Shampooed carpets and trim panels - 1.5hrs

Scrubbed and shampooed both seats, removing all marks and stains - 2.0hrs

Cleaned dashboard and plastic trims - 0.5hrs

Cleaned all glass on both sides - 0.5hrs

Removed old gear lever gaiter and discarded - 0.25hrs

Cleaned centre console trim panel and fitted new blue Toyota gear lever gaiter - 0.25hrs

Fitted new driver’s door mirror trim panel -

Scrubbed and shampooed both carpet mats - 0.25hrs

Scrubbed and shampoo’s sun visors - 0.25hrs

Refitted both sun visors and rear view mirror - 0.25hrs

Cleaned both seat runner rails - 0.25hrs

Refitted seats using copper grease to ease the fixings through the floor threads - 0.5hrs

Refitted centre console and cassette storage unit - 0.5hrs

Refitted floor mats -

Worked on fine detailing under front bonnet, replacing various fixings etc - 2.0hrs

Cleaned up audio unit and refitted - 0.5hrs

Refitted final dash fascia trims - 0.25hrs

Stripped out throttle cable bracket from engine bay area - 0.5hrs

Removed camboxes and paint stripped with Nitromors, back to bare alloy - 2.5hrs

Left camboxes soaking in degreaser overnight, badly clogged with old oil - 0.5hrs

Dried and prepared camboxes for repainting - 1.5hrs

Refinished both camboxes with 4 coats of acrylic primer - 1.0hrs

Refinished both camboxes with 4 coats of acrylic silver paint - 1.0hrs

(Running Total 246.75hrs)

Refinished both camboxes with 4 coats of acrylic lacquer - 1.0hrs

Removed old spark plugs which were rusted in solid into their threads - 1.0hrs

Vacuumed out the valley between the cams to remove all debris - 0.25hrs

Poured 50ml of Redex fluid into each cylinder - 0.25hrs

Fitted 4 off new NGK-R spark plugs using copper grease - 0.25hrs

Removed HT leads and distributor cap for cleaning - 0.25hrs

Removed distributor unit complete with heat shield - 0.25hrs

Removed airbox assembly - 0.5hrs

Replaced all cross head fixings in all 4 wheelarches with new Toyota fixings - 1.0hrs

Disconnected and removed battery and tray - 0.25hrs

Discarded battery as it was the wrong type of unit and was some 7 years old - 0.25hrs

Degreased and cleaned up cambox fixings - 0.25hrs

Repainted “TWIN CAM 16 VALVE” lettering on camboxes in Ford Radiant Red - 1.0hrs

Inserted new Toyota rubber gaskets into camboxes and refitted to the engine - 1.0hrs

Used new compression washers and chrome domehead fixings to secure camboxes. Nitromorsed spark plug trim plate to remove black crackle finish - 0.25hrs

Degreased and cleaned up trim plate. Used emery paper to remove surface rust - 0.25hrs

Refinished trim plate with 4 off coats of PJ1 satin black paint finish - 1.0hrs

Removed and brass brushed up the speedo cable support bracket - 0.25hrs

Refinished speedo cable bracket with 4 coats of acrylic primer - 0.25hrs

Refinished speedo bracket with 4 coats of “Ardennes Green” to match original - 0.25hrs

Degreased and dismantled HT leads from distributor cap - 1.0hrs

Polished HT leads and distributor cap back to their original red finish - 0.5hrs

Brass brushed and degreased distributor cable clamp - 0.25hrs

Refinished distributor cable clamp in acrylic silver paint - 0.25hrs

Refitted throttle cable bracket using new Toyota fixings - 0.25hrs

Refitted spark plug trim plate cover with a new rubber gasket and Toyota fixings - 0.5hrs

Refitted newly refurbished HT leads and distributor cap - 0.25hrs

Nitromorsed battery clamp and degreased and cleaned off corrosion - 0.5hrs

(Running Total 260.0hrs)

Refinished battery clamp with 4 coats of acrylic primer - 0.5hrs

Refinished battery clamp with 4 coats of acrylic gloss black - 0.5hrs

Degreased and brass brushed throttle cable link bracket assembly - 1.0hrs

Masked off springs and pivots and refinished with 4 coats of acrylic primer - 1.0hrs

Refinished assembly with 4 coats of “Ardennes Green” to replicate original finish - 1.5hrs

Removed both door weather seals and both front windscreen trim panels - 1.5hrs

Prepared trims and refinished in 4 coats of PJ1 satin black - 2.0hrs

Cleaned down exposed A pillars and bodywork, and refitted front screen trims - 1.5hrs

Cleaned out rebates and refitted both door weather seals - 0.5hrs

Removed both rear buttress glass trims - 0.5hrs

Refinished glass trims in PJ1 satin black - 0.25hrs

Refitted buttress glass trims - 0.5hrs

Touched in with blue touch in stick, bottom rear edge of rear valance panel - 0.25hrs

Cleaned out door jam and degreased mechanisms in passenger door area - 0.5hrs

Brass brushed and refinished throttle link bracket bolts in “Ardennes Green” - 0.25hrs

Disconnected and removed engine bay cooling fan for renovation - 1.0hrs

Cleaned up and degreased engine bay cooling fan assembly - 2.0hrs

Refinished fan housing and motor casing in PJ1 satin black - 1.5hrs

Cleaned exposed body area in engine bay and refitted fan assembly - 1.5hrs

Removed ignition coil assembly and various other electrical parts from engine bay - 1.0hrs

Washed out entire engine bay and major components using 25 gallons of sugar soap and water-soluble degreaser - 12.0hrs.

Degreased and serviced distributor unit and refitted cable clamp - 1.0hrs

Refitted distributor to engine block with the timing checked at No.1 TDC - 0.25hrs

Refitted cooling header tank and refilled with Toyota red coolant - 0.25hrs

Disconnected, cleaned thoroughly and reconnected all electrical connectors within reach in the engine bay area - 3.0hrs

Removed engine bay cover catch and degreased - 0.25hrs

Brass brushed corrosion off catch mechanism and refinished with 4 coats of gold cadmium plate effect paint finish - 1.0hrs

Refitted engine cover catch with 3 off new genuine Toyota fixings - 0.25hrs

(Running Total 297.25hrs)

Removed front bonnet catch and degreased - 0.25hrs

Brass brushed corrosion off bonnet catch and removed both springs for cleaning - 0.5hrs

Refinished bonnet catch and springs with 4 coats of gold cadmium plate paint - 1.0hrs

Removed hooter and bracket from inside front bonnet - 0.25hrs

Degreased and polished hooter, bracket and connector, refitted using new fixing - 0.5hrs

Removed throttle return linkage and discarded as it was totally worn out - 0.25hrs

Degreased throttle linkage assemblies and springs, brushed all corrosion off - 2.0hrs

Brass brushed all corrosion of the fuel injection housing - 0.5hrs

Polished fuel injection housing using Solvol Autosol - 0.25hrs

Replaced all fixings on fuel injection housing - 0.25hrs

Refitted throttle support bracket assembly and reconnected throttle cable - 1.0hrs

Replaced 18 various fixings in the engine bay with new genuine Toyota parts - 2.5hrs

Fitted new stainless steel Mongoose exhaust system - 2.0hrs

Refitted and reconnected battery

Fired engine up for the first time in almost 8 months. Started on 1st turn of the key Engine roared into life and settled down to an uneven tick-over.

Disconnected and removed battery - 0.25hrs

Removed all air intake piping from the injection system for cleaning - 0.5hrs

Cleaned and polished all air intake piping - 1.5hrs

Found lower metal induction tube fitted with 2 off air temp sensors to be corroded

Brass brushed corrosion from intake tube and prepared for refinishing - 1.0hrs

Refinished intake tube with 4 coats of PJ1 satin black paint finish - 1.0hrs

Refitted 2 air intake sensors to intake tube, refitted to car with all air intake piping - 0.5hrs

Refinished exposed front and rear suspension fixings (16 off) with 2 coats of paint - 1.0hrs

Refinished exposed suspension mountings with 2 coats of satin black paint finish - 0.5hrs

Removed and degreased rearmost throttle cable support bracket back of engine - 0.25hrs

Brushed corrosion from bracket and removed sensor prior to refinishing - 0.25hrs

Refinished bracket with 4 coats of acrylic primer - 0.25hrs

Refinished bracket with 4 coats of “Ardennes Green” paint to replicate original - 0.25hrs

(Running Total 315.75hrs)

Degreased and polished electrical sensor and refitted to bracket - 0.25hrs

Refitted battery and reconnected - 0.25hrs

Ran engine until normal operating temperature was achieved - 0.25hrs

Poured a can of Wynn’s Engine Flush into the cambox filler and replaced cap.

Ran the engine at 1800rpm fast idle for 10 minutes.

Switched engine off and removed sump drain plug, used oil into catch bowl - 0.25hr

Removed old oil filter, which had seized on solid and discarded - 0.25hrs

Found sump drain bolt to have a badly damaged thread.

Tapped out damaged thread in sump pan with an M12 tap, using copper grease - 0.25hrs

Replacement sump bolt from Toyota and refitted using a new sump bolt gasket - 0.25hrs

Fitted a new Toyota oil filter and lubricated the sealing gasket.

Refilled the sump with 10/40 grade semi-synthetic oil - 0.25hrs

Ran the engine again and topped up the oil level accordingly - 0.25hrs

Refinished various electrical engine bay brackets in either gold or BZP paint finish - 1.0hrs

Removed Scorpion alarm sounder unit and thoroughly cleaned - 0.25hrs

Refinished alarm mounting bracket in BZP paint and refitted using Toyota fixings - 0.5hrs

Removed nearside luggage boot trim panel and removed air filter assembly - 0.5hrs

Fitted new Ramair induction unit and connecting pip in place of the original air filter - 0.5hrs

Replaced luggage boot trim panel and ran engine for 15 minutes - 0.25hrs

Fitted new Jap specification heavy duty battery and cleaned up all connections - 0.25hrs

Removed offside rear wheel and tightened stub axle assy, fitted new split pin - 0.25hrs

Checked and adjusted all 5 off tyre pressures - 0.25hrs

Refitted rear exhaust box fixing clamp to stop exhaust gases blowing at slip joint - 0.25hrs

Fitted new Toyota fixings to front spoiler joint on centre line of front panel - 0.25hrs

Checked operation of all electrical functions.

MRB Tuning calibrated the engine to suit the revised induction and exhaust systems and found the engine to be in excellent mechanical condition. The compression test of the cylinders and valve gear gave an incredible reading of 21.9 compared to the manufacturers figure for a new engine as 22.0 - 1.5hrs

Road tested the car for first time since buying the car and checked all operations - 0.25hrs

Polished the engine bay components using Armorall to restore the factory finish - 1.5hrs

(Running Total 325.5hrs)

Polished the bodywork with 2 coats of Autoglym Super Resin polish - 1.5hrs

Polished the bodywork with 4 coats of Autoglym Extra Gloss Protection - 2.0hrs

Polished all black trim and tyres with Armorall - 1.0hrs

Covered MR2 over with tailored car cover. Restoration completed on Sun 23 March 2003 - TOTAL HOURS SPENT ON RESTORATION: 330.0 HOURS

RESTORATION SUMMARY

Total time elapsed during the restoration of G981 ECK: 36 weeks

Total number of new parts fitted during restoration period: 202 parts

Total quantity of new paint finish used to restore G981 ECK: 11 litres

Total man-hours spent restoring G981 ECK: 330.0 hours

Total expenditure spent during the restoration: £1,338.75

POST RESTORATION WORKS 2003

Service and Maintenance Costs For 2003: £229.18

NEW PARTS FITTED TO G981 ECK

QTY   DESCRIPTION                                    SUPPLIER                 COST
2        Paints                                                      Kens Autos                £6.49
8        Paints                                                      Kens Autos              £34.28
5        Paints                                                      Kens Autos              £15.75
2        Continental Premium Contact tyres      Big City Tyres        £139.75
1        Screen wash                                          F and C Toyota           £2.66
8        Genuine Toyota parts                            F and C Toyota         £13.17
2        PJ1 Satin black aerosol paint               2 Wheel Centre         £13.00
1        Alloy Wheel aerosol paint                     Kens Autos                  £3.99
3        Masking tape rolls                                  Wilkos                          £3.28
3        Paint brushes                                         Wilkos                          £0.99
1        Hammerite Smooth Black 1 litre           Wilkos                        £13.99
1        Cellulose Thinners                                 Wilkos                          £1.49
7        Genuine Toyota parts                             F and C Toyota           £6.59
11      Genuine Toyota parts                             F and C Toyota           £9.38
1        Acrylic grey primer aerosol                    Kens Autos                  £2.49
1        Acrylic Clear Lacquer                             Kens Autos                  £3.00
2        Masking Tape rolls                                  Wilkos                          £2.00
1        VHT silver paint                                       Kens Autos                  £4.99
2        4mm drill bits                                           Wilkos                          £1.38
2        PJ1 Satin black aerosol paint                 2 Wheel Centre         £13.00
18      Genuine Toyota parts                             F and C Toyota          £26.52
1        0.5kg Copper Grease                            Kens Autos                   £4.99
2        4.8mm drill bits                                       Wilkos                           £1.38
1        5mm wide angle high intensity LED      Maplin                           £3.08
3        Continental Premium Contact Tyres     Big City Tyres            £93.94
2        ADY 2V number plates                          Tennants UK Ltd       £24. 09
56      Genuine Toyota parts                             F and C                     £92. 88
3        Paints                                                       Wilkos                          £9.99
6        Genuine Toyota parts                             F and C                         £3.17
1        Soft bodywork dust cover                       NEC Classic Show    £25.00
1        MR2 Key fob                                            MR2 DC                       £3.00
2        Acrylic silver and clear lacquer paints    Wilkos                           £5.00
1        Heavy duty carpet shampoo                   JTF                                £1.88
1        Genuine Toyota parts                              F and C                         £2.22
2        Front brake discs                                     Kens Autos                 £58.00
4        Front disc pads                                        Kens Autos                 £10.00
2        “Cool Blue” headlamp bulbs                   Kens Autos                 £15.98
4        NGK-R high performance spark plugs   Kens Autos                 £10.00
1        500ml Redex Injector Cleaner               JTF                                 £3.29
1        500ml Wynns Engine Flush treatment   JTF                                 £1.70
31      Genuine Toyota parts                             F and C                         £50.16
1        Ardennes Green paint                             Kens Autosan                £2.50
2        Ardennes lacquer paints                         Kens Autos                   £5. 98
2        PJ1 Satin black aerosol paint                 Granby Motors            £11. 00
1        Sugar Soap                                              Wilkos                           £1. 15
1        Silver BZP chrome paint                         Wilkos                           £2. 19
1        Sugar Soap                                              Wilkos                           £1. 15
3        Silver BZP and Primer paints                  Wilkos                         £11. 97
8        Genuine Toyota Parts                              F and C                       £14. 35
7        Mongoose performance exhaust            Fensport                   £334. 88
4        Ramair induction kit                                  Fensport                   £108. 63
1        Silver BZP chrome paint                          Wilkos                           £3. 99
20      Genuine Toyota parts                              F and C                       £14. 52
1        5 litres 10/40 Semi-synthetic oil              Kens Autos                 £12. 99
1        Genuine Toyota parts                              F and C                          £2. 41
1        Japanese specification battery               Kens Autos                  £48. 00
1        MRB Electronic Dynamic Engine Tune  MRB Tuning                 £25. 00

TOTAL RESTORATION EXPENDITURE                                       £1,338. 75