Thanks Nial , I have more pics to post up but didn't want to spoil everyone by posting them all at once!

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Oh go on......spoil us

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ST205

What do you think is the best thing to do with the doors to protect them against rust?

I have two doors for my rebuild, both are mint and rust free, I was going to remove all the standard seam sealer and grind around it back to bare metal, then POR15 the door around the seams and on the inside of the door at the bottom. Or should I leave we'll alone?

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ST205

Well just about every ST205 I've seen has this problem. Even my mollycoddled JDM ST205WRC is showing the signs despite being kept under cover and driven sparingly during the winter.

If there are no signs of corrosion along the lower door seam I'd be tempted to simply clean it up and waxoyl the interior. If you do notice ANY sign of rust then I'd strip it back to the bare metal like you see in my pics. This should reveal the extent of any damage, particularly if you use the 'special tool' shown in the pics Good to see the time-honoured approach of giving suspicious areas a good poke with a screwdriver is alive and well

If it's really bad then you could cut the section out like you see in the pics or if it looks like its not too far gone then try to stabilise it with POR15 or similar. before priming, painting and sealing.

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

thinking that approach is going to be needed with my passenger door, showing signs of the old dreaded rust.

Further update:

The C-One sills were part of the full C-One bodykit I acquired from the Muddy's ex Toyota Sprint Series ST205. The GRP is lightweight and thus quite thin so it was a bit of a challenge to remove from his Sprint shell without damaging it. Fortunately the only damage was a small split which could be easily repaired. I did this before prepping with 320 grade wet and dry and delivering to shell prep.













There was quite a bit of stone chip damage to the underside of the sills. Spray filler was used to eliminate these stone chips and any pin holes in the GRP. I will use paint protection film on the underside to prevent stone chip damage.





DP40 surface primer was applied after spray filler on GRP

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

RT Performance - Carbon Tailgate

Like all RT Performance parts the quality of the tailgate was pretty good however, there were a few gaps and pinholes that needed attention. I had already decided to paint it in Toyota Super White 2 so it was easy to fix up these imperfections as part of the prep.

The hinges and brackets were donated from the OEM steel hatch but I have kept the frame as a spare. I now have two steel and one GRP spare hatches....plus the glass which is the rare blue tint now no longer available.

The rear window wiper hole has been filled as this is no longer required.

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Man after my own heart, I always thought that even if I did buy carbon fibre parts I would paint them the same colour as the car....its one thing to stick on carbon parts....IMO its a class above to paint it. Not a fan of cars with odd coloured bonnets or boot lid just because its carbon fibre, makes the car look like a Taxi.

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ST205

Now starting to bolt shiny bits onto the painted shell

Fuel system installation.....

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Underfloor cooler?

Hate to say it at this stage but I never noticed the filler position before. Seems like it might be vulnerable to a Norris attack located low on the rear quarter

Do you have a particular reason for side feeding/filling the tank Don?

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René - Carlos Sainz 2433•5000
Turbocelica.nl | ST185 CS restoration and full rebuild

If it ain't broken.. it soon will be

Moving the fuel filler to the side reduced the length of the filler pipe and also makes it less of a fire hazard inside the car.

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Very nice looking.

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ST205

Further progress update. The rear subframe, diff, driveshafts, hubs, suspension assembled andd fitted to the freshly painted shell:




































Next step will be to fit the front suspension:

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Don
GT4DC Chairman
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
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Looks really good.

I know you've kept the standard pickup points for the rear subframe - did Jon mention anything about the alignment of it?

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GT4DC Events Co-ordinator
1996 ST205 UK