1983 KP61 Starlet (lots of pics)

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1983 KP61 Starlet (lots of pics) Empty 1983 KP61 Starlet (lots of pics)

Post by Motax on Sat Aug 11, 2012 11:34 am

So, basicly this is just a copy/paste from kp61.net, as retyping everything would be useless.

Back then i was looking for a project car. I had a slammed GS300 as a daily, and wanted something a bit smaller and lighter to have a little fun with.
Then this starlet came up for sale. This is one of the pics from the previous owner.
1983 KP61 Starlet (lots of pics) Starletstock
So i decided to go check it out, condition was said to be quite rusty.

When i arrived in the barn the car was located, it had a lot of rust, but nothing i couldnt handle, or so i thought. I didnt really take a good look at the underside, cause there wasnt any space to do so. The rear windows where out, the rearfenders cut up, B-pillars had big gaping holes in them. But somehow i liked the car, so we agreed upon a price, and i picked it up a week later. Also, seeing a lot of the projects on this forum, and the bad condition the cars started in, gave me a lot of confidence that i could fix the car.

I decided to drive the car home, as it was only 40km's or so. I had to be a bit carefull on the brakes, as they where quite rusted from standing still. I filled her up with some gas, and off i went. The car didnt actually drive that bad, bar the leaking masterbrake cilinder :-?. About 30km's in i had a flat reartire on the highway, pulled over, called roadassistance, and had the tire replaced at a local tireshop, as i had no spare Sad.

Eventually i got the car to the garage i was working at the time. My employers had allowed me to work on the car during the weekends.
Locked the place up, and started on it about 2 weeks later.

So i began looking over the car, looking at what had been done, and what had to be done. It wasnt long till i figured out that everything that was done to it, was done quite poorly. So i decided to just cut everything out, and redo those parts. On with the pics! Note that i wont post all the pics, cause there are simply too many :p.

1983 KP61 Starlet (lots of pics) IMG_0212
1983 KP61 Starlet (lots of pics) IMG_0213
1983 KP61 Starlet (lots of pics) IMG_0214
1983 KP61 Starlet (lots of pics) IMG_0215
1983 KP61 Starlet (lots of pics) IMG_0216
1983 KP61 Starlet (lots of pics) IMG_0217
1983 KP61 Starlet (lots of pics) IMG_0218
1983 KP61 Starlet (lots of pics) IMG_0222
1983 KP61 Starlet (lots of pics) IMG_0226
1983 KP61 Starlet (lots of pics) IMG_0229
1983 KP61 Starlet (lots of pics) IMG_0235

So, that was i started with. I grinded away some filler around the fuelcap.
As you can see, not pretty.
1983 KP61 Starlet (lots of pics) IMG_0240
So, i started cutting away some of the rot around the rearend.
1983 KP61 Starlet (lots of pics) IMG_0241
1983 KP61 Starlet (lots of pics) IMG_0242
1983 KP61 Starlet (lots of pics) IMG_0243
And then redoing the bit around the fuelcap.
1983 KP61 Starlet (lots of pics) IMG_0244
1983 KP61 Starlet (lots of pics) IMG_0245
1983 KP61 Starlet (lots of pics) IMG_0246

In the meantime, i'd already ordered and received several parts. I bought some fenderflares and a trd replica wing. I then started on repairing the right rear arch. The guy i bought the car from, also gave me some replica reararches, which i used bits from. Fitment was quite bad, and all the lines seemed to be a bit softer than the original.

1983 KP61 Starlet (lots of pics) IMG_0261
1983 KP61 Starlet (lots of pics) IMG_0262
1983 KP61 Starlet (lots of pics) IMG_0264
1983 KP61 Starlet (lots of pics) IMG_0265
1983 KP61 Starlet (lots of pics) IMG_0275
1983 KP61 Starlet (lots of pics) IMG_0278
1983 KP61 Starlet (lots of pics) IMG_0294
1983 KP61 Starlet (lots of pics) IMG_0298
1983 KP61 Starlet (lots of pics) IMG_0332

A friend of mine owns a nice AE86, which he is rebuilding. He needed some parts, and found a donor. We bought the car together, stripped it, and both used the parts we needed. I got the engine/gearbox and rearaxle out of it. Also used the AE86 frontstruts to create coilovers.
I also bought a TA22 rearaxle before we bought the donor, so i still have that laying around aswell Smile.

So we lifted the engine on a cold november day, and left the rest for a later date.

1983 KP61 Starlet (lots of pics) IMG_0302
1983 KP61 Starlet (lots of pics) IMG_0304

With the 4age in my possession, i bought some mounts from TechnoToyTuning, and found a set of itbs on ebay Smile.
1983 KP61 Starlet (lots of pics) IMG_0306
1983 KP61 Starlet (lots of pics) IMG_0307
Also found a good, rustfree driversside door Smile.
1983 KP61 Starlet (lots of pics) IMG_0344

I then set on repairing the inner arch on the right side. Someone had already bodged something there, and it didnt look good. So i cut it all out, and put some fresh metal in there.

1983 KP61 Starlet (lots of pics) IMG_0333
1983 KP61 Starlet (lots of pics) IMG_0336
1983 KP61 Starlet (lots of pics) IMG_0337
1983 KP61 Starlet (lots of pics) IMG_0348
1983 KP61 Starlet (lots of pics) IMG_0349

In my everlasting search for parts, i came across a lower lip on ebay, so i bought it.
1983 KP61 Starlet (lots of pics) IMG_0354
1983 KP61 Starlet (lots of pics) IMG_0355

As the pockets on the rear where completely vanished, i had to create something of my own. I had been thinking alot about this part, and i didnt know how to tackle it. This is my first attempt, which i have now removed and redone.
1983 KP61 Starlet (lots of pics) IMG_0360
1983 KP61 Starlet (lots of pics) IMG_0361
1983 KP61 Starlet (lots of pics) IMG_0363
1983 KP61 Starlet (lots of pics) IMG_0364
It wasnt too bad, but my new plans required something a little bit more like the original.

In the meantime i bought some SSR MKIII's from the motherland, made a big order with T3, and ordered some more stuff on ebay.
1983 KP61 Starlet (lots of pics) IMG_0369
1983 KP61 Starlet (lots of pics) IMG_0370

Then it was time to put the engine in.
Fridaynight i removed the old 4k, Saturday i cleaned and painted the enginebay, and serviced the engine (new timingbelt, waterpump, sparkplugs, rotor/distributorcap), and on Sunday the engine was in.

1983 KP61 Starlet (lots of pics) IMG_0379
1983 KP61 Starlet (lots of pics) IMG_0380
1983 KP61 Starlet (lots of pics) IMG_0384
1983 KP61 Starlet (lots of pics) IMG_0391
1983 KP61 Starlet (lots of pics) IMG_0397
Had to make up my own gearboxmount, not the prettiest, but it works.
1983 KP61 Starlet (lots of pics) IMG_0405

Someone had already made an attempt at fixing the floor on the drivers side, without succes. They did it without removing the interiortrim obviously, as some of it was melted.
1983 KP61 Starlet (lots of pics) IMG_0438
1983 KP61 Starlet (lots of pics) IMG_0439
1983 KP61 Starlet (lots of pics) IMG_0440
Wasnt too happy about that, or the other side, which was worse.
1983 KP61 Starlet (lots of pics) IMG_0473
I then did some cutting on the b-pillar, but go any further than that at the time, as i still had no idea how to fix this.
1983 KP61 Starlet (lots of pics) IMG_0474

Because the stock gaugecluster didnt have a tacho, i went on the look for something else. I wanted something that would fit in the stock position, and held as much information as possible. I found this:
1983 KP61 Starlet (lots of pics) IMG_0446
And modified the stock cluster to fit it in.
1983 KP61 Starlet (lots of pics) IMG_0461
1983 KP61 Starlet (lots of pics) IMG_0462


Last edited by Motax on Sat Aug 11, 2012 11:41 am; edited 1 time in total

Motax
125cc single cylinder

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Post by Motax on Sat Aug 11, 2012 11:35 am

So with almost all the welding done, there where 2 spots that still needed to be done. These are the ones i've been dreading since the day i bought the car. In the end it wasnt too bad. Sometimes you just need to start and see where you end.
1983 KP61 Starlet (lots of pics) IMG_0776
1983 KP61 Starlet (lots of pics) IMG_0777
1983 KP61 Starlet (lots of pics) IMG_0778
1983 KP61 Starlet (lots of pics) IMG_0779
1983 KP61 Starlet (lots of pics) IMG_0780
1983 KP61 Starlet (lots of pics) IMG_0781
1983 KP61 Starlet (lots of pics) IMG_0784
1983 KP61 Starlet (lots of pics) IMG_0785
1983 KP61 Starlet (lots of pics) IMG_0786
1983 KP61 Starlet (lots of pics) IMG_0787
1983 KP61 Starlet (lots of pics) IMG_0788
1983 KP61 Starlet (lots of pics) IMG_0789
1983 KP61 Starlet (lots of pics) IMG_0790
1983 KP61 Starlet (lots of pics) IMG_0791
1983 KP61 Starlet (lots of pics) IMG_0792
1983 KP61 Starlet (lots of pics) IMG_0793
1983 KP61 Starlet (lots of pics) IMG_0794
1983 KP61 Starlet (lots of pics) IMG_0795
1983 KP61 Starlet (lots of pics) IMG_0796
1983 KP61 Starlet (lots of pics) IMG_0797
1983 KP61 Starlet (lots of pics) IMG_0798
1983 KP61 Starlet (lots of pics) IMG_0799
1983 KP61 Starlet (lots of pics) IMG_0800
1983 KP61 Starlet (lots of pics) IMG_0816
1983 KP61 Starlet (lots of pics) IMG_0818

So right after easter, i took a week off work to work on the starlet. I basicly started bolting back the front suspension, subframe, and put the engine back in. Painted some of the parts black before mounting them
1983 KP61 Starlet (lots of pics) IMG_0826
1983 KP61 Starlet (lots of pics) IMG_0827
1983 KP61 Starlet (lots of pics) IMG_0828
1983 KP61 Starlet (lots of pics) IMG_0834
1983 KP61 Starlet (lots of pics) IMG_0835
1983 KP61 Starlet (lots of pics) IMG_0836
1983 KP61 Starlet (lots of pics) IMG_0837
1983 KP61 Starlet (lots of pics) IMG_0839
1983 KP61 Starlet (lots of pics) IMG_0840
1983 KP61 Starlet (lots of pics) IMG_0841
1983 KP61 Starlet (lots of pics) IMG_0842
1983 KP61 Starlet (lots of pics) IMG_0846
1983 KP61 Starlet (lots of pics) IMG_0847
1983 KP61 Starlet (lots of pics) IMG_0848
1983 KP61 Starlet (lots of pics) IMG_0850
1983 KP61 Starlet (lots of pics) IMG_0851

One of my mates had the enginelift in his garage, only problem was, that he got off work at 6, and it was still 3 o clock. Also, there was an S15 in the way, so i wasnt even sure if we could get the damn thing out of his garage.
So i decided to get the engine in without the lift. I lowered the front of the car on the ground, and slowly lifted the engine into place.
1983 KP61 Starlet (lots of pics) IMG_0853
1983 KP61 Starlet (lots of pics) IMG_0854
1983 KP61 Starlet (lots of pics) IMG_0855
1983 KP61 Starlet (lots of pics) IMG_0865
1983 KP61 Starlet (lots of pics) IMG_0868

Next day i modified the AE86 rearaxle to fit.
1983 KP61 Starlet (lots of pics) IMG_0899
Still using the ae86 springseats, as the KP springseats where rotten, and i had also gotten ae86 springs, which are slightly larger than the KP springs.
1983 KP61 Starlet (lots of pics) IMG_0908
1983 KP61 Starlet (lots of pics) IMG_0909

With that all bolted together, i just had to put one of the SSR's on Smile
1983 KP61 Starlet (lots of pics) IMG_0910
1983 KP61 Starlet (lots of pics) IMG_0911
1983 KP61 Starlet (lots of pics) IMG_0912
1983 KP61 Starlet (lots of pics) IMG_0913

And after that, its back on its wheels for the first time in 5 months Smile.
1983 KP61 Starlet (lots of pics) IMG_0916

I still dont have a fueltank, but i took some measurements of the one i will buy, and made a frame using that.
1983 KP61 Starlet (lots of pics) IMG_0923
1983 KP61 Starlet (lots of pics) IMG_0925
1983 KP61 Starlet (lots of pics) IMG_0930
1983 KP61 Starlet (lots of pics) IMG_0935
1983 KP61 Starlet (lots of pics) IMG_0937
Strong enough i hear you ask?
1983 KP61 Starlet (lots of pics) IMG_0938
1983 KP61 Starlet (lots of pics) IMG_0939
1983 KP61 Starlet (lots of pics) IMG_0940

Then i did some bodyfiller/sanding/primer etc.
1983 KP61 Starlet (lots of pics) IMG_0948
1983 KP61 Starlet (lots of pics) IMG_0953
1983 KP61 Starlet (lots of pics) IMG_0983
1983 KP61 Starlet (lots of pics) IMG_0973
1983 KP61 Starlet (lots of pics) IMG_0974
1983 KP61 Starlet (lots of pics) IMG_1006
1983 KP61 Starlet (lots of pics) IMG_1007
1983 KP61 Starlet (lots of pics) IMG_1008
1983 KP61 Starlet (lots of pics) IMG_1009
1983 KP61 Starlet (lots of pics) IMG_1011
1983 KP61 Starlet (lots of pics) IMG_1014

And last thursday i put the windows back in.
1983 KP61 Starlet (lots of pics) IMG_1015
1983 KP61 Starlet (lots of pics) IMG_1018
1983 KP61 Starlet (lots of pics) IMG_1012
1983 KP61 Starlet (lots of pics) IMG_1013

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Post by Motax on Sat Aug 11, 2012 11:41 am

So basicly after that, i picked the car up. Rented a transporter, drove the car home. I really hadn't touched the car since i put it on the trailer, and it has been sitting for about 2 months, due to various reasons (mainly bad weather, and lack of time).

Last week i've done some small things. I've been busy shortening, and thinning out the engine loom. As i'll be using MegaSquirt, a lot of oem sensors will not be used.
1983 KP61 Starlet (lots of pics) IMG_1131
1983 KP61 Starlet (lots of pics) IMG_1138
As you can see, not a whole lot of wires left Smile.

I've ordered some supplies to finish the loom, and i was hoping to get them in the mail today, but i'll have to wait a few more days Suspect. Yesterday i've also converted one of my bathrooms into a spraying booth so i could spray some of the smaller interior bits.
1983 KP61 Starlet (lots of pics) IMG_1167

Thats it for now, i'll have to wait till the end of the month to order some new stuff, but the good thing is that i've started working on the car again Smile.

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Post by john on Sat Aug 11, 2012 12:32 pm

This is AWESOME!!! Very Happy do you have any idea when this will be painted?
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Post by Motax on Sat Aug 11, 2012 1:47 pm

Paint is absolutely dead last on my list. It's been too long since i've driven something fun, so i'll probably get some seat time before it's sent of to paint.

First things first tho. I need to get it running first. And for that i need the intake finished, exhaust, fuelsystem, ecu, and all the wiring done.

I have to find a solution for the exhaust manifold. I bought one on ebay, but its not going to fit due to the changes i've made in the firewall for the pedalbox. So either modify a turbomanifold, or buy one of those kits they use on kitcars, to create it myself.

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Post by martyn on Sun Aug 12, 2012 3:48 am

super skills i think mine would have been nearly done if i had some of them skills im poo at fab work lol

are you going to drift it ?

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Post by Motax on Sun Aug 12, 2012 4:53 am

Not sure yet. The driftscene in holland doesnt have much life in it, so it probably won't see a lot of sideways action.

The build started as a restoration, but slowly evolved into something resembling a racecar, with intentions to use it on the nordschleife.

I just want to have some fun with the car, on the street, on the track. I've only driven it for 40-50km's, in stock form, so i'm realy curious to see what it's capable of.

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Post by Steve on Sun Aug 12, 2012 5:46 am

Give the drift scene some life with it Smile

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Post by finch on Sun Aug 12, 2012 11:47 am

Wow! Shocked Cool so much good work going into this!
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Post by Ian on Mon Aug 13, 2012 4:50 am

thats an epic build...cant wait to see the finished product! Very Happy

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Post by john on Tue Aug 14, 2012 12:09 am

I think you should make a manifold Smile
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Post by Motax on Tue Aug 14, 2012 10:31 am

Yeh, thats also probably the cheapest option. But instead of buying a kit, i can also just chut up the ebay manifold i already have. I've already chopped a bit off to see if it would fit. I think i'll be breaking my head on that next weekend.

In the mean time, my wiring supplies have finally arrived.
1983 KP61 Starlet (lots of pics) IMG_1172
So i got something to do now Smile.

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Post by Si on Wed Aug 15, 2012 12:01 am

awesome project there mate alot of work has gone into that i will keep an eye out for updates Very Happy
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Post by Motax on Sun Aug 19, 2012 9:18 am

So today i've started on the engine loom. It was hot as hell, it took forever, i'm not 100% satisfied with it, but it will have to do. It went from 40 to 20 wires. TPS plug still needs to be hooked up, but other than that, the engine side is pretty much done. Almost all the wiring is new, except for the last few cm's leading to the plug, as i dont have the tools to take that stuff apart.
1983 KP61 Starlet (lots of pics) IMG_1175
1983 KP61 Starlet (lots of pics) IMG_1176
1983 KP61 Starlet (lots of pics) IMG_1177
1983 KP61 Starlet (lots of pics) IMG_1173

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Post by john on Tue Aug 21, 2012 3:05 am

Looks awesome mate, nice little loom you have made yourself Smile
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