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PostPosted: Wed Jun 10, 2015 9:46 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Yes it's hard to believe but these cars actually need restoring nowadays! My UK spec ST205 with 160k on the clock, would have been broken for parts by most people, but instead I decided to save it. Not the most sensible decision, but when you get your first performance project car you have to stick with it.
I have certainly never been a quitter and nor is the ST205.

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to save scrolling and picture loading, why not check out the Silver Shed Project Thread on Facebook, simply like the page and you'll get updates of my progress in your news feed.
https://www.facebook.com/pages/The-Silv ... ef=tn_tnmn

So straight out the gates after a ropey test drive I bought the car sold as seen…which meant I spent £1500 on a totally ragged 1996 silver ST205, which came with two sets of wheels, no parcel shelf and an HKS Powerflow back box. Not bad I thought!?!
3 weeks into ownership and £800 later, the car had new clutch and rear diff mount. No photos taken as I debated getting rid of the car after that nasty surprise. With no luck finding specialists in my area and not really having the cash drive long distance, I browsed all of the forums and wider web hunting for a set of local experts who could help……… Enter the South Coast Workshop.

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So once at SCW I had a chat with Barry and Mike about getting my cambelts done and also checking for signs of wear and tear to see what else needed to be done to get the car driving well. I assumed cambelt and clutch work would bring an end to the spending and I could get to work on cosmetic improvements and RaceCar bits!!! I was wrong, so very wrong....

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looked OK at first glance. It wasn't

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leaking cover cam seals made for very well lubricated spark plugs and everything else. Also knackered Dizzy cap.

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Cleaned it all out with a turkey baster and blue roll
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Grim and Gopping!...
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After a quick degrease and clean
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Into the parts washer with the cam cover, Yes I got into trouble for doing this, even though i did the dishes first!
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With cam timing done in my absence, the car was put back together over a few nights once I had returned the refurbished parts. The Engine bay ended up looking like this

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A bit tidier and certainly more reliable. Fresh oil and filter, new belts, spark plugs, distributor cap and battery the majority of which had been supplied by TCB. The work turned a sluggish car into a rapid responder. The engine note was much smoother and it started on the button. It was safe to say the car felt better all round. Stage 1 restoration/maintenance complete

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Last edited by BecauseRaceCar on Thu Jun 11, 2015 12:26 am, edited 2 times in total.

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PostPosted: Wed Jun 10, 2015 10:13 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
So after a few months of hard work at uni, I completed my course and nailed a merit grade, so what better way to celebrate than spend the next few weeks covered in rust and oil stripping down the underside of my car for a rebuild!

Yes both front and rear subframes fit in the back of the car- very handy to know that!
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Quick spray with cold galv zinc undercoat to keep it from oxidizing.

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Armed with my spares I headed over to SCW once again ready to do battle with corrosion and dirt, to get my car OCD clean underneath.

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As you can see there is also a silver donor car outside, which is very handy, also I managed to do a swap fro the late spec dark black wheels on the white car-NO MORE TRI-SPOKES!!
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Ok enough outside photos lets get down to business-First order is to knock up a dolly-trolley to allow us to move the wheel-less car if necessary

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Then of course it was time to jack up the car and start removing components.

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Then the drop links started to give me grief, so things had to be CHOPPED!

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Front end done, now to the back end and rear sub frame. lots of rust and many bolt fatalities

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Not to mention a puddle under the passenger seat!
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With the rear assembly off you could really see the damage....check the diff out, looks like and artefact from the Mary Rose!

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Well That, covers the first week of work.

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PostPosted: Wed Jun 10, 2015 11:55 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
OK after making some good progress removing the subframes, now the parts needed to be separated, cleaned and painted - or set aside for powder coating.

This next session, isn't super interesting, but I like to show progress, disassembly and the challenged that seriously corroded parts can present.

Here are some images showing the process for breaking down the hub with a 30 tonne 3 arm pulling claw. We used all 30 tonnes of force, as the hub was fused together with rust. Luckily I have bought new Toyota spherical bushes, and we are likely to DIY media blast the hubs back to metal.

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20 tonnes of pressuer to press out the suspension trailing arm bushes

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Wire wheel work, for superlative super strut suspension spraying.

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meanwhile DEOX-C every single Bolt!

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Tense moments testing the trolley, it was strong enough, but too short, needs modifying.

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Then onto sorting parts for powder coating at a nearby finishers, conveniently 15 minutes down the road.

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The last few shots, show rust areas, that will be wire wheeled/cup brushed back to metal, then Hammerite KURUST will be applied, be fore various preventative primers and finally black paint and under seal. Stay tuned more to come soon.....

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PostPosted: Thu Jun 11, 2015 1:02 am 
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Joined: Wed Jul 13, 2005 12:14 am
Posts: 3222
Location: Camberley, Surrey
Car Model: ST205
Looking really good :)

That rear diff is in a right state, would be interested to deox-c or electrolyse it to see what is actually left of it. :D

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1996 ST205 UK


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PostPosted: Thu Jun 11, 2015 9:04 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Thanks Sirius, it's been hard work so far, but feels like its going to be worth the effort, waiting to make a bit more progress before the next upload of photos. Looking forward to the subframes returning from the Finishers in Portchester. Then everything can go back together, also looks like I will need new brake rotors too. On the look out for a cheap-ish set for all four corners.

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PostPosted: Fri Jun 12, 2015 8:58 am 
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Joined: Fri Jan 29, 2010 10:39 pm
Posts: 514
Location: Bournemouth
Car Model: ST205
Looking. good!
May I ask, what paint did you use for your heat shield? (I like it)

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PostPosted: Fri Jun 12, 2015 7:14 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Thanks Niblettr, I use Halfrauds Hi temp metallic black paint. Gives it a nice understated look. £7.99 if I recall, think I used a can and a half for alternator, cam cover and heat shield.

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PostPosted: Sun Jun 28, 2015 2:36 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Well It's been a couple of weeks, since my last update and there has been a lot of progress, with the car almost completely back together, bar a few minor items such as crush tubes etc...

With the subframes away at the powder coaters, I had plenty of time to paint and under-seal the underside of the car, to remove and prevent corrosion, as well as water proof the underside of the car. I also removed the exhaust to try and rescue it from corroding further.

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Just some jacking point markers.
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Lots of Screfix metal paint (like Hammerite only cheaper)
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Then underseal on the arches
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Pipe off!
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Pipe blue!
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Actual Hammerite Smooth Spray on the SSS arms
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Differential too.
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All Done.
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Nearly forgot these
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PostPosted: Sun Jun 28, 2015 4:27 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Wow Photobucket is painfully slow! Anyway here's the next instalment of photos, the subframe arrived back from the finishers ans gets bolted on.

Bushes arrived, probably one of the biggest expenses of the whole build.
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Parts back from the finishers
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Every little detail
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Why not do the bonnet vent too, the whole lot cost £240 inc... some jaguar parts aswell (not mine)
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SHOCKing state of the suspension
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Cusco time!
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The Dust plates/hub plates were pretty shagged, but just wire brushes them and painted them with 2-pac or Tupac as i like to call it black paint. I may add these to the list of new compnents to buy when my wallet has recovered from this session.
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It all looks much better in there now.
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then a final coat of stone chip on some of the more exposed parts of the underside.
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Also applied stone chip to the arches as well.
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PostPosted: Sun Jun 28, 2015 4:33 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Some before and Afters

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PostPosted: Sun Jun 28, 2015 7:51 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
The brakes...
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Base coat of Bronze, hand painted, then flatted.
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Then the handbrake shoes
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Polybushing rear hub
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Nearly back on all fours, just a few more bits and pieces to put back on and sort out.
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PostPosted: Sun Jun 28, 2015 8:59 pm 
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Joined: Sat May 16, 2015 8:21 pm
Posts: 151
Location: Richmond, the southern one
Car Model: ST205
Saw this car today...all looking very neat and tidy underneath, cannot believe what it used to look like!

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"Have to say this is one of the nicest ST205's I have ever seen. Certainly the nicest I have seen in a long while" Mr Sirius, South Coast Workshop & general all round nice bloke


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PostPosted: Sun Jun 28, 2015 9:42 pm 
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Joined: Wed Jul 13, 2005 12:06 am
Posts: 4741
Location: Perth, Western Australia
Car Model: ST205
Great photo diary! :D

One more thing I'd recommend doing is VHT paint the centre hubs of your new discs to stop them rusting. This has worked well on my ST205 to stop them rusting.

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1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2012 Van Diemen JL12 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp


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PostPosted: Mon Jun 29, 2015 1:29 pm 
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Joined: Wed Dec 17, 2014 6:17 pm
Posts: 166
Location: Portsmouth
Car Model: ST205
Thanks Coldel, appreciate the kind words, will hopefully bump into you at SCW in the future. I'd like to check out your ST205 in the metal, it really is in fantastic shape.

Good tip Don, I will indeed paint the discs-hubs and vents too, as it looks great whilst adding protection. I will also need drive the car for a bit in the dry to shake loose the remaining blast media from inside the frames, before I do a cavity wax.

I also need to work out whether or not I need to declare the Polybushes, as they are not OE, but they have been used as the next best replacement....The main issue is I am with admiral, so no real specialist knowledge/understanding on the end of the phone. I only have 2 months left on my current policy too, which makes me wonder if it's worth cancelling and taking out a policy with a specialist.

The main thing I can look forward to after this underside overhual is sorting out my radiator/cooling system and bodywork.... especially the bodywork!

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PostPosted: Mon Jun 29, 2015 2:20 pm 
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Joined: Sat May 16, 2015 8:21 pm
Posts: 151
Location: Richmond, the southern one
Car Model: ST205
I would declare it, it shouldn't make a difference and will ensure that any insurance claim goes as hassle free as possible. Just explain they do the same thing, no performance upgrade in terms of speed and the items they replaced had perished.

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"Have to say this is one of the nicest ST205's I have ever seen. Certainly the nicest I have seen in a long while" Mr Sirius, South Coast Workshop & general all round nice bloke


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