Author Topic: The Highlander crashes keep on coming -- Done!!  (Read 5563 times)

Offline goodfellow

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The Highlander crashes keep on coming -- Done!!
« on: April 26, 2017, 11:29:42 PM »
If it wasn't so seriously banged up, it'd be funny. Monday was a miserable day in southern Virginia -- torrential rains, fog, and lots of accidents on I95. Unfortunately my daughter was in a huge car pileup on I95 south during a torrential flood. She was heading back to school from DC after a job interview and was caught up in it big-time. Thankfully she's OK  -- just a little bruised and shaken from the airbag deployment.

The car on the other hand is in far worse shape. It's 12 years old and we stopped carrying collision on that car after it turned 10 years and only carry liability. I was tempted to scrap it out, but I really like this model year and decided to tow the damn thing back home and start the rebuild process. What the heck -- I have tools, welding equipment, and and some time over the next month, so I will rebuild it.

This is how it arrived off the flatbed this morning -- the entire front sheetmetal and fenders were off.









I started to strip it -- and pretty much the entire core support and ancillary pieces (radiator, condenser, lights, bumper supports), were trash.





Only thing that was intact was the "iddy-biddy" horn --  :))



Stripping a tangled mess  -- what joy!!





Headlights are toast --



The biggest issue is the reinforced frame bumper mount -- it's totally crushed. I'll have to cut this out and replace it with a new fabricated frame mount.



Radiator is toast, but surprisingly the fans are in good shape and can be reused.



Even the plastic washer bottle was spared. Which is also a surprise since it sits way in front, and right behind the bumper mount.



The core support need to have the spotwelds cut and be totally removed. My job for tomorrow is to cut all those spotwelds and remove the crushed support



Finally, at the end of the afternoon I got around to placing an order for about $1000 in new parts. I plan of replacing the parts and giving this old Highlander a complete paint job. Including this little fiasco, over the past seven years I've pretty much touched every body panel on this car with some sort of bodywork. Might as well give at final "hurrah" with a new paint job.

Onward!!







« Last Edit: May 27, 2017, 02:48:45 PM by goodfellow »

Offline chopper1

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Re: The crashes keep on coming --
« Reply #1 on: April 26, 2017, 11:36:28 PM »
Thankfully your daughter is okay.  thumbsup2   Vehicles can be repaired.
mike

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Offline strik9

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Re: The crashes keep on coming --
« Reply #2 on: April 27, 2017, 01:07:27 AM »
You got off light for what guys here want us to fix.
    And we don't get new panels, we usually fix the bent junk.

  We have two bent rad supports and two hoods in the scrap pile after five years.  Only because they were totally crushed to destroyed.

Offline fatfillup

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Re: The crashes keep on coming --
« Reply #3 on: April 27, 2017, 07:45:40 AM »
Glad Lil' GF is fine thumbsup2

How bad was the other car?

That scalloped box end is one of the few BB features that doesn't make Elroy puke

Offline goodfellow

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Re: The crashes keep on coming --
« Reply #4 on: April 27, 2017, 09:20:35 AM »
Glad Lil' GF is fine thumbsup2

How bad was the other car?



Crushed the rear left side of a delivery van --

Offline tool hunter

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Re: The crashes keep on coming --
« Reply #5 on: April 27, 2017, 09:59:17 AM »
That will keep you out of trouble for a little while. Glad to hear she's ok

Offline lauver

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Re: The crashes keep on coming --
« Reply #6 on: April 27, 2017, 10:17:24 AM »
GF,

Glad to hear that nobody was hurt & the damage to the vehicle is fixable/doable.

I feel for you and the project you undertaken.

My kids are now driving my wife's old 2003 Highlander (same color as yours) and keep me busy replacing and/or patching the front bumper fascia. 

Hell the last time the girls were home, I had to Duck Tape the fascia on temporarily until I can get to it  fishslap fishslap
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Offline Rewind

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Re: The crashes keep on coming --
« Reply #7 on: April 27, 2017, 11:16:15 AM »
Looks like you've got your work cut out for you!! Glad your daughter is ok.

Offline goodfellow

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Re: The crashes keep on coming --
« Reply #8 on: April 27, 2017, 11:20:04 AM »
Wow -- talk about service!! I ordered my parts last night at 5PM, and this morning my new Denso AC condenser was sitting on my front porch -- Amazing!!

Company is called NEWPARTS, and has an ebay store -- definitely a name to remember. They were 25% cheaper than the next best seller.

Offline goodfellow

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Re: The crashes keep on coming --
« Reply #9 on: April 27, 2017, 05:39:49 PM »
It was a hard day - spent most of it cutting spotwelds to get the crashed core support out, and to straighten some associated mounting points. The good news is that the headlight mounts are in great shape -- a little tweak here and there and they were straight.



The big job was removing all the tangled core support pieces. There were spot welds everywhere --







I also had to keep track of the wiring loom and associated control module mounts -- there are a lot of them.









I started with the top left mounts and worked my way down and across to the other side -- centerpunching, spot drilling, and then finally weld drilling.





Tedious, but I got good results --



The bottom support was fairly easy because it was flat and easy to access -



Lots of dropped fasteners and hardware in that cavity -- when I finally open it up, there must have been a dozen screws and bolts trapped in there. I know they didn't come from me, so I assume that was done at the factory.







Finally I made my way back up the right side and called it a day



Completely removed core support and after I straightened a few flanges, I feel pretty good about it.





Tomorrow will be the critical day though because I will have to cut off the passenger side bumper mount in order to straighten it. That thing is crushed like and accordion. Time for some plasma cutting work --



Onward --


« Last Edit: April 27, 2017, 06:57:40 PM by goodfellow »

Online john k

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Re: The crashes keep on coming -- updated 4-27
« Reply #10 on: April 27, 2017, 10:25:50 PM »
An awful lot of work done so far.   Any evidence of the wiring loom pinched?  Chased electrical problems in a T bird for weeks, due to a similar crash.  Even for a couple of grand,  can't begin to touch another vehicle for that. 
« Last Edit: April 28, 2017, 06:47:43 AM by john k »

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-27
« Reply #11 on: April 27, 2017, 10:35:44 PM »
An awful lot of work done so far.   Any evidence of the siring loom pinched?  Chased electrical problems in a T bird for weeks, due to a similar crash.  Even for a couple of grand,  can't begin to touch another vehicle for that. 

The electricals are in tact -- in fact the car was driveable. My daughter drove it for a few hundred yards after the crash into the road median to get it out of harms way. It was leaking coolant, but drove like a champ.
« Last Edit: April 28, 2017, 10:28:44 AM by goodfellow »

Offline fatfillup

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Re: The crashes keep on coming -- updated 4-27
« Reply #12 on: April 28, 2017, 09:39:04 AM »
Getting after it fast.  Hope Lil'GF realizes how blessed she is
That scalloped box end is one of the few BB features that doesn't make Elroy puke

Online slip knot

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Re: The crashes keep on coming -- updated 4-27
« Reply #13 on: April 28, 2017, 05:13:04 PM »
damn, you make that work look easy.  thumbsup2  glad the daughter is OK.
Started with nothing and still have most of it left.

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Offline brslk

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Re: The crashes keep on coming -- updated 4-27
« Reply #14 on: April 28, 2017, 05:14:07 PM »
Glad to hear she was OK.
At this rate the Jag will never get finished!
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Re: The crashes keep on coming -- updated 4-27
« Reply #14 on: April 28, 2017, 05:14:07 PM »

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