Author Topic: The Highlander crashes keep on coming -- Done!!  (Read 5557 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.

Online 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 »

Offline 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 »

Online 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

Offline 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.

When did the American Dream become an entitlement program?

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!
I'm just a guy in a garage with some tools...

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Re: The crashes keep on coming -- updated 4-27
« Reply #15 on: April 28, 2017, 05:27:54 PM »
Glad to hear she was OK.
At this rate the Jag will never get finished!

Not true, GF will have this one knocked out in a few weeks or so.  ;)
You boys better hold on cause i'm gonna have to stand on it!

NEED A 1/2" BONNEY STREAMLINE COMBINATION AND ANY OVER 13/16" TOO!



Andrew Jackson quote: But you must remember, my fellow-citizens, that eternal vigilance by the people is the price of liberty, and that you must pay the price if you wish to secure the blessing.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-27
« Reply #16 on: April 28, 2017, 05:44:35 PM »
Thanks guys -- peer support is always a good thing; especially from the GG. I was able to get a clean cut on that bumper support and rescue the bumper mount. I had to cut the support base that the core mounts on in order to separate the mangled bumper mount.



Then I made a cut on a good straight section of the boxed frame to get the crushed pieces free.



Here is the mount and the mangled mess. This mount took a good hit, but I was able to free the important mounting section and will use the new aluminum bumper reinforcing bar to align this mount with a new fabricated frame section.





This is what I was after -



The other pieces were not salvageable



 Tomorrow I will build a new outer and inner mount support structure. The OEM is high-strength steel, but if I can fabricate a double wall 16ga cold rolled sleeved mount with inner reinforcements, then I think I will be in the ballpark as far a OEM rigidity and strength are concerned.



Parts started showing up this afternoon -- aluminum bumper reinforcement bar and the new headlight assemblies.





What I really need is the core support to start measuring the frame standoff on the mounts. Hopefully it will show up early in the week.

Onward!
« Last Edit: April 28, 2017, 07:03:46 PM by goodfellow »

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Re: The crashes keep on coming -- updated 4-27
« Reply #17 on: April 29, 2017, 12:28:41 PM »
Yup better get your car junk out of Mrs. GF's nice clean living room Ray!  :POKIE:
You boys better hold on cause i'm gonna have to stand on it!

NEED A 1/2" BONNEY STREAMLINE COMBINATION AND ANY OVER 13/16" TOO!



Andrew Jackson quote: But you must remember, my fellow-citizens, that eternal vigilance by the people is the price of liberty, and that you must pay the price if you wish to secure the blessing.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-27
« Reply #18 on: April 29, 2017, 12:43:06 PM »
Yup better get your car junk out of Mrs. GF's nice clean living room Ray!  :POKIE:

I actually have permission -- because I really don't have any place else to store it. There are way too many packages arriving.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-27
« Reply #19 on: April 29, 2017, 04:18:42 PM »
I was a little time constrained today, but I did manage to get the inner frame section built out of 18ga steel. The inner section is boxed and braced with a triangulated section of 16ga intended to resist a crush on impact. It will be covered and welded to an outer 16ga shell that will act as the primary bumper support.





Trial fit looked good -



Top section welded in and ready for some clean-up





It's a good fit on the old mount





Things are coming together --



Tomorrow I'll need to fabricate the outer frame support shell out of 16ga, and make this thing a nicely welded support structure again.
Hopefully the core support will show up this week and I can start the reassembly and welding process.





Offline Heiny57

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Re: The crashes keep on coming -- updated 4-29
« Reply #20 on: April 29, 2017, 06:26:20 PM »
Glad your daughter was ok. Your traffic out there is scary.  panicx  I pulled my camper through D.C. And will never do that again.

But as usual you make this stuff look easy. You have worked on most everything in that vehicle. Impressive.  thumbsup2


 sharepopcorn
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If you can't fix it with a hammer, It must be electrical.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-29
« Reply #21 on: April 29, 2017, 08:08:25 PM »
Thanks Bob! Yes, I've been all over this car, but I'm willing to give it another chance hoping to get a few more years out of it. I love these old Highlanders, they are mechanically bullet proof.

Offline slip knot

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Re: The crashes keep on coming -- updated 4-27
« Reply #22 on: April 29, 2017, 11:24:24 PM »
Yup better get your car junk out of Mrs. GF's nice clean living room Ray!  :POKIE:

When it for the kids its OK. thumbsup2
Started with nothing and still have most of it left.

When did the American Dream become an entitlement program?

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Re: The crashes keep on coming -- updated 4-27
« Reply #23 on: April 30, 2017, 10:09:41 AM »
Yup better get your car junk out of Mrs. GF's nice clean living room Ray!  :POKIE:

When it for the kids its OK. thumbsup2

Oh, you are right, I forgot about that exclusion to the rule. In our house there is also an exclusion to the rules if her family members are involved!
You boys better hold on cause i'm gonna have to stand on it!

NEED A 1/2" BONNEY STREAMLINE COMBINATION AND ANY OVER 13/16" TOO!



Andrew Jackson quote: But you must remember, my fellow-citizens, that eternal vigilance by the people is the price of liberty, and that you must pay the price if you wish to secure the blessing.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-29
« Reply #24 on: April 30, 2017, 10:17:04 AM »
Yup better get your car junk out of Mrs. GF's nice clean living room Ray!  :POKIE:

When it for the kids its OK. thumbsup2

......... In our house there is also an exclusion to the rules if her family members are involved!

Absolutely!! -- interesting to see how those special "kin-folk" rules work at times.  frustratedx
« Last Edit: April 30, 2017, 10:20:54 AM by goodfellow »

Offline skfarmer

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Re: The crashes keep on coming -- updated 4-29
« Reply #25 on: April 30, 2017, 11:36:38 AM »
Nice work. I don't have the skill or patience to tackle that sort of project
from the ashes shall rise a phoenix

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Re: The crashes keep on coming -- updated 4-29
« Reply #26 on: April 30, 2017, 01:29:04 PM »
Yup better get your car junk out of Mrs. GF's nice clean living room Ray!  :POKIE:

When it for the kids its OK. thumbsup2

......... In our house there is also an exclusion to the rules if her family members are involved!

Absolutely!! -- interesting to see how those special "kin-folk" rules work at times.  frustratedx

I do my best to avoid the "kin-folk" exemption as much as possible. It goes against my grain I will admit.
You boys better hold on cause i'm gonna have to stand on it!

NEED A 1/2" BONNEY STREAMLINE COMBINATION AND ANY OVER 13/16" TOO!



Andrew Jackson quote: But you must remember, my fellow-citizens, that eternal vigilance by the people is the price of liberty, and that you must pay the price if you wish to secure the blessing.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-29
« Reply #27 on: April 30, 2017, 03:49:43 PM »
Finished the outer frame section today. I can't say enough about these little forming bucks that some gent in England invented, and even though i have three sheet metal brakes, making complex bends sometimes limits the use of the brakes. I built this thing a few years ago very "quick and dirty" and it truly is one of my favorite forming tools.



This raised lip for example needed to mimic the original in the Toyota front bumper mount. It looks simple, but without special tooling it's difficult. With my little forming buck i was able to knock one out in less than 30 minutes.





I lightly tacked it up just to check the close fit and to take some measurement. Looks like this will work fine --





Tomorrow I'll weld in the inner support that i fabricated and then hopefully this outer frame section can get tacked in place for final bumper support fitment.



If this all lines up, then the core support should be easily aligned and fit into final position.

Onward

Offline Muddy

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Re: The crashes keep on coming -- updated 4-29
« Reply #28 on: April 30, 2017, 04:39:02 PM »
Nice work.

Think Goodfellow will ever let her drive the jag?

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Offline goodfellow

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Re: The crashes keep on coming -- updated 4-29
« Reply #29 on: April 30, 2017, 05:53:46 PM »
Nice work.

Think Goodfellow will ever let her drive the jag?

Sent from my XT1635-01 using Tapatalk


It'll be hers one day anyway -- might as well let her drive it when it's done and tested properly. Funny thing is she never liked it when I first bought it many years ago. Now that it's shiny, painted, and all new inside she likes it just fine. --- women!!

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-29
« Reply #30 on: May 01, 2017, 03:46:17 PM »
Everything tacked nicely in place and holding firm in order to get the final measurements double checked. The bumper is sitting level and has the correct offset from the body. All I need now is the darn radiator core support. It's been sitting in a UPS truck since late last Friday - and the UPS tracking site says that it will get delivered today. -- Fingers crossed.





Without that core support I can't weld everything up solid because the support must fit exactly between the two bumper mounts -- so I still may have to tweak my fabbed mount a bit.



Most importantly, everything is square and true again -



I've been working this job a couple of hours each night -- hopefully next week when I'm on vacation I can get a good solid week in on this thing.

Offline OldnSlo

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Re: The crashes keep on coming -- updated 4-29
« Reply #31 on: May 01, 2017, 08:08:12 PM »
Very nice.....well thought out too!

Offline Heiny57

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Re: The crashes keep on coming -- updated 4-29
« Reply #32 on: May 01, 2017, 08:58:09 PM »
Goodfellow insurance is better than State Farm.  And cheaper too.....

I'm sure you raised a gal who appreciates your efforts and that is what drives you to do this.  My hats off to you sir.


And,,,,,,,  sharepopcorn
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If you can't fix it with a hammer, It must be electrical.

Offline goodfellow

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Re: The crashes keep on coming -- updated 4-29
« Reply #33 on: May 02, 2017, 07:14:23 PM »
I finally made some good progress -- the core support showed up and I trimmed and drilled it for the plug weld holes.





I clamped everything in place and double/triple checked the measurements using the strut towers as my baseline.

The core support needed a small tweak on the driver's side to make it fit.



Next I fitted the fenders to get the top of the core to the proper offset so that the hood and latch can line up properly



I cut the last of the old support base when all the measurements were the same from the left and right sides.



The newly fabbed frame support was permanently welded in place, and the right fender was attached.





Notice the door gap? It was a bit too wide, so it needed a few tweaks to make the gaps even. I eventually got it right.



I finally fit the headlight assembly supports and they were spot on -- on both sides.





Everything looked good, so I lightly tacked the entire support in place to keep it from moving around.





Finally I fit the bumper support and tacked the support bracket to my fabbed frame section.





The core support is lightly tacked in place because tomorrow I want to fit the hood. The hood will be the  "proof of the pudding" so to speak. If the hood installs with good gaps and the latch has a good purchase on the hood, then I know for certain that all my measurement are alright and then I can weld everything up permanently.

Onward!





« Last Edit: May 02, 2017, 07:57:26 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-2
« Reply #34 on: May 02, 2017, 08:27:01 PM »
 sharepopcorn

Can't wait for the next update!  Thanks for posting.
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Offline brslk

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Re: The crashes keep on coming -- updated 5-2
« Reply #35 on: May 02, 2017, 08:44:15 PM »
Excellent work as always Ray.
I'm just a guy in a garage with some tools...

Bruce.

Offline goodfellow

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Re: The crashes keep on coming -- updated 5-2
« Reply #36 on: May 02, 2017, 10:13:27 PM »
Thanks guys --  I have to go out of town for a day, so this thing will have to wait a bit. Good thing is that the new hood arrived this afternoon and I can fit it up to do the final adjustments before final welding.

Offline Heiny57

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Re: The crashes keep on coming -- updated 5-2
« Reply #37 on: May 02, 2017, 10:51:19 PM »
Ray where did you get frame measurements from?
Wake Up America

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Re: The crashes keep on coming -- updated 5-2
« Reply #38 on: May 02, 2017, 11:13:53 PM »
Ray where did you get frame measurements from?

I used the centerlines of the shocktowers as my left and right baseline Bob. All my measurements were taken from those two points.

Offline goodfellow

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Re: The crashes keep on coming -- updated 5-2
« Reply #39 on: May 05, 2017, 04:36:55 PM »
The hood arrived, but I it was a bit of a disappointment. The rear edges were bent due to transport, the center had a ding in it, and the right edge was bent  -- also due to transport problems.











I'm not going to send it back. I have to paint it anyway, so I'm going to fix it and just roll with it. Truth be told, I've never received a body panel that didn't have some sort of ding or scrape.

I did a trial fit before welding the core support, and it seemed to line up pretty well. I had to widen the fender bolt holes a bit to get them to slide inward a little more and close the gap. But after a few tweaks I was able to align everything to a point where the core support could be permanently fixed in place.







Getting the bumper support straight and tight was a big job, but in the end it was a great fit.







Finally, the hood and fenders were attached and the gaps were checked -- a little bit off on the right front, but the left was right on.





Adjusting the fender a tad  inward solved the gap issue.

This is how far I got -- unfortunately I didn't get all the driver's side core support plugwelds done because I ran out of .023 Mig wire. I NEVER run out of that gauge wire, but sure-nuff I didn't have another spool. I had a spool of .030, but it doesn't run too well on my machine for making plugwelds and welding light gauge steel. I order two new 10lb spools, but to finish this off tomorrow I had to order a 2lb spool from my local Home Depot -- and I paid through the nose for it. 

$12 for a 2lb spool at HD, vs $36.55 for TWO 11lb spools from my online supplier.

Anyway -- I'll be done welding core tomorrow. Most of it is already burned in solid, just a few moire plugwelds to go.





Onward!

« Last Edit: May 05, 2017, 05:14:12 PM by goodfellow »

Offline goodfellow

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Re: The crashes keep on coming -- updated 5-4
« Reply #40 on: May 06, 2017, 04:47:43 PM »
Finished the last few plugwelds today and then dressed the welds a bit to make them flush. I'm not too concerned about cosmetics with this thing, but a little neatness never hurts. I then took a red scuffing pad and and scuffed the entire radiator core surface to get it ready for paint.



I had some paint left over from a previous repair and put the first coat down.





Three coats did the trick



The paint did a good job brightening this front end back up





Now to get the fenders hung permanently and get ready to install the new parts.



Onward
« Last Edit: May 06, 2017, 04:50:50 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-6
« Reply #41 on: May 06, 2017, 09:47:03 PM »
I just seen this thread. Wow. It's an ambitious project for sure and you got so much done in a few days. Nice work and I'm glad she's ok too.
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Offline goodfellow

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Re: The crashes keep on coming -- updated 5-6
« Reply #42 on: May 06, 2017, 10:25:05 PM »
I just seen this thread. Wow. It's an ambitious project for sure and you got so much done in a few days. Nice work and I'm glad she's ok too.

Thanks Mike! --  beerdude

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Re: The crashes keep on coming -- updated 5-6
« Reply #43 on: May 07, 2017, 10:29:59 AM »
I just seen this thread. Wow. It's an ambitious project for sure and you got so much done in a few days. Nice work and I'm glad she's ok too.

Thanks Mike! --  beerdude

Do you paint the back side of the fenders and underside of the hood prior to hanging them Ray? Then paint the exposed surfaces once the panels are mounted?
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-6
« Reply #44 on: May 07, 2017, 11:54:18 AM »
On post #39, I didn't quite follow this. Was new metal sectioned in (below where your c-clamp was positioned) and behind the bumper mount, as a result of needing to push the bumper a bit more forward?

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Re: The crashes keep on coming -- updated 5-6
« Reply #45 on: May 07, 2017, 06:24:26 PM »
I just seen this thread. Wow. It's an ambitious project for sure and you got so much done in a few days. Nice work and I'm glad she's ok too.

Thanks Mike! --  beerdude

Do you paint the back side of the fenders and underside of the hood prior to hanging them Ray? Then paint the exposed surfaces once the panels are mounted?

The hood is there temporarily to align the fenders Herb. Given all the shipping damage, it will need some extensive bodywork -- mostly lead work where the rear corners had collapsed. You can't do the corners with filler -- not strong enough. Once the lead work is done, I will prime the top and paint the underside of the hood before proceeding on with final finishing the top side.

As far as the fenders are concerned, yes, I did shoot a light coat of paint on the flanges just to protect them against rust. They are the original fenders, and only the right one was very lightly damaged.

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Re: The crashes keep on coming -- updated 5-6
« Reply #46 on: May 07, 2017, 06:28:35 PM »
On post #39, I didn't quite follow this. Was new metal sectioned in (below where your c-clamp was positioned) and behind the bumper mount, as a result of needing to push the bumper a bit more forward?

Yes, I fabricated inner (18ga) and outer (16ga) sections that replaced the collapsed front section where the bumper mount was attached. The 18ga section basically slid into what was left of the exiting mount (once I had cut the crushed piece off), and acted as a reinforcement crush sleeve for the heavier 16ga outer section. Once installed they were plug welded to each other to make a strong joint. This new section is a lot stronger than it really needs to be.
« Last Edit: May 07, 2017, 06:34:07 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-6
« Reply #47 on: May 07, 2017, 08:44:22 PM »
I just seen this thread. Wow. It's an ambitious project for sure and you got so much done in a few days. Nice work and I'm glad she's ok too.

Thanks Mike! --  beerdude

Do you paint the back side of the fenders and underside of the hood prior to hanging them Ray? Then paint the exposed surfaces once the panels are mounted?

The hood is there temporarily to align the fenders Herb. Given all the shipping damage, it will need some extensive bodywork -- mostly lead work where the rear corners had collapsed. You can't do the corners with filler -- not strong enough. Once the lead work is done, I will prime the top and paint the underside of the hood before proceeding on with final finishing the top side.

As far as the fenders are concerned, yes, I did shoot a light coat of paint on the flanges just to protect them against rust. They are the original fenders, and only the right one was very lightly damaged.

I missed the fact that you were re-using the fenders. I thought they were new as well.
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Re: The crashes keep on coming -- updated 5-6
« Reply #48 on: May 08, 2017, 07:37:59 PM »
Well, today I was able to actually install some new parts -- new radiator, new condenser, new lights, and new bumper reinforcement beam. I reused the old washer bottle and associated clips and fasteners.





I reused the old fenders since there was minimal damage -- they will be easy to paint. The lights needed to be installed to the fender cutouts to match the seams for proper sealing and fit





The condenser and center support were installed with minimal effort. I was worried about this part because if the radiator core support would have been installed off-center or crooked, then these parts would not fit very easily (or not at all).



The light assemblies fit very well -- good to go.





Door gaps are pretty even as well





Done for today -- everything seems to fit well. The wiring harness and the connectors were double checked, and finally the battery and hold-down bracket was reinstalled. Tomorrow, I'll fill it with fluids, evacuate the AC system to see if it will hold vacuum, and then hopefully start her up to see if the fans and cooling system work.



If all checks out, I maybe able to get to the bodywork stage at the end of the week.

Onward!
« Last Edit: May 08, 2017, 07:42:45 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-8
« Reply #49 on: May 10, 2017, 08:02:58 PM »
Something happened with my camera this morning. I took some pics this morning, but when I went to download them to my computer this evening they were gone. Lord knows how that happened. It's a new camera, so it's probably operator error, but still disturbing because I don't know how it happened.

I started this morning with leading the collapsed edges of the hood. They were damaged during shipping and needed to be reinforced at the corner with something much stronger than fiberglass or plastic filler. I did use some plastic filler to fill in several small shipping dents, and then prepped the entire top surface for primer/filler.





By late afternoon I was ready to spray three coats of primer/filler and a guide coat for finish sanding. I let the primer cure in the hot sun all afternoon and it's pretty well hard.



The hardest part of this day was tracking down an electrical problem. I put a vacuum on the AC system for over an hour to get any possible moisture out and then let is sit for two hours under vacuum to see if there were any leaks. Luckily the system was tight. I then tried to charge the system with the recommend 24oz of 134a refrigerant, but that's where the problems started. When the AC system is energized, one of the two radiator fans should kick on and stay on for as long as the AC system is running. Unfortunately the fan never came on; making it impossible to charge the system in a proper manner. I had checked the fans before installation and they were good to go; so something was not right with the electrical system.

I jumped the pressure switch plug and the fan did't respond, hence it's either a broken or shorted wire due to the crash, or a relay, or fuse -- or both.



I checked continuity on all the fan wires and on my final test checked the relays and fuses. Sure enough I found a diagram on line that identified the 30A fuse marked CDS as the primary circuit to the AC fan. While a corresponding 30A RDI fuse was in the primary circuit to the radiator fan. The CDS fuse had probably blown when the fan blades were pinched against the collapsed radiator; which made the current draw spike. That little bit of diagnostic work took way over an hour.





Hopefully I can get the front bumper cover prepped for paint tomorrow, and paint these panels over the weekend.


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Re: The crashes keep on coming -- updated 5-8
« Reply #50 on: May 10, 2017, 09:06:41 PM »
It's amazing how those little things can eat up so much time and drive you nuts while doing it!

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Re: The crashes keep on coming -- updated 5-8
« Reply #51 on: May 10, 2017, 09:21:24 PM »
It's amazing how those little things can eat up so much time and drive you nuts while doing it!

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LOL -- darn right Tim, and the older I get the lower my patience level with this kind of stuff.  angryguyx  frustratedx

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Re: The crashes keep on coming -- updated 5-8
« Reply #52 on: May 14, 2017, 05:31:36 PM »
The last three days have been wet and rainy, so no work on the paint. Yesterday the skies cleared and I was able to pull the old hardware from the damaged panels. A lot of hardware was lost so I opted for a complete Toyota hardware kit on ebay -- it comes with the most common body fasteners.



I pulled the old foglights and after installing new bulbs I will reuse them in the new bumper cover



The bumper cover was scuffed with a gray scuffing pad, while hood was scuffed on the bottom side and sanded with 220 and 320 grit on the top -- everything nice and smooth.









I partially sprayed the underside of the hood because most of the surface will be covered by heat/sound shield pad.



The leaded corners came out nice --





This morning I setup a small paintbooth using 7-mil plastic and used my fresh air system to spray three coats of color and two coats of clear on the hood, the bumper cover and the inner grill.







Everything came out OK -- a few dust spots, but tomorrow I'll color sand and buff the panels, and they should look very good.







Hopefully I can try to assemble everything tomorrow afternoon or Tuesday

Onward





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Re: The crashes keep on coming -- updated 5-14
« Reply #53 on: May 14, 2017, 06:23:59 PM »
That's going to look new.   sharepopcorn
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If you can't fix it with a hammer, It must be electrical.

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Re: The crashes keep on coming -- updated 5-14
« Reply #54 on: May 15, 2017, 10:28:04 AM »
I need some help on this one. I know that the airbag control module sets a hard code once the vehicle is hit, and it can't be erased. To fix this problem I need to find the airbag control module  and send it out to a specialist to get the memory erased.

Does anyone on the GG know where the airbag control module is located in a 2005 Highlander? or direct me to a source where this info might be available?

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Re: The crashes keep on coming -- updated 5-14
« Reply #55 on: May 15, 2017, 10:29:36 AM »
I need some help on this one. I know that the airbag control module sets a hard code once the vehicle is hit, and it can't be erased. To fix this problem I need to find the airbag control module  and send it out to a specialist to get the memory erased.

Does anyone on the GG know where the airbag control module is located in a 2005 Highlander? or direct me to a source where this info might be available?

Would a dealer be of any help Ray? If not them what about a friendly local body shop guy?
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-14
« Reply #56 on: May 15, 2017, 10:48:57 AM »
I need some help on this one. I know that the airbag control module sets a hard code once the vehicle is hit, and it can't be erased. To fix this problem I need to find the airbag control module  and send it out to a specialist to get the memory erased.

Does anyone on the GG know where the airbag control module is located in a 2005 Highlander? or direct me to a source where this info might be available?

Would a dealer be of any help Ray? If not them what about a friendly local body shop guy?

Dealers are worthless around here Herb. I called the dealer about replacing the airbag module and all they said was that the entire airbag control system needed to be replaced -- $3200

They provide no info -- ostensibly for insurance reasons. It's a gouging game. I can send my module and seatbelt restraint to a company in Georgia and they will refurbish to OEM specs. To do that I have to get the seatbelt restraint out today and find that control module to send off for service. The car won't pass a June inspection with that idiot light on.

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Re: The crashes keep on coming -- updated 5-14
« Reply #57 on: May 15, 2017, 11:39:23 AM »
I need some help on this one. I know that the airbag control module sets a hard code once the vehicle is hit, and it can't be erased. To fix this problem I need to find the airbag control module  and send it out to a specialist to get the memory erased.

Does anyone on the GG know where the airbag control module is located in a 2005 Highlander? or direct me to a source where this info might be available?

Would a dealer be of any help Ray? If not them what about a friendly local body shop guy?

Dealers are worthless around here Herb. I called the dealer about replacing the airbag module and all they said was that the entire airbag control system needed to be replaced -- $3200

They provide no info -- ostensibly for insurance reasons. It's a gouging game. I can send my module and seatbelt restraint to a company in Georgia and they will refurbish to OEM specs. To do that I have to get the seatbelt restraint out today and find that control module to send off for service. The car won't pass a June inspection with that idiot light on.

So remove the bulb that makes it light up to pass the inspection then reinstall it and figure out your issue on your time frame Ray. I do not usually feel bad cheating government sniffers on something like that. Ya, I know it makes me a bad guy........ fishslap
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-14
« Reply #58 on: May 15, 2017, 11:46:10 AM »
I need some help on this one. I know that the airbag control module sets a hard code once the vehicle is hit, and it can't be erased. To fix this problem I need to find the airbag control module  and send it out to a specialist to get the memory erased.

Does anyone on the GG know where the airbag control module is located in a 2005 Highlander? or direct me to a source where this info might be available?

I put a call in to a good friend that owns body shop and has been in the business for decades with dealers and the like before going out on his own about 20 years ago. I know he does a lot of insurance work and as such is likely real familiar with the issue Ray. When I called he was laying down some paint so I left a message that hopefully he will return and be able to answer your question. Things are a lot different in KS (even Topeka) than they are where you are so this might be a bit easier to get an answer.
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-14
« Reply #59 on: May 15, 2017, 12:10:03 PM »
I need some help on this one. I know that the airbag control module sets a hard code once the vehicle is hit, and it can't be erased. To fix this problem I need to find the airbag control module  and send it out to a specialist to get the memory erased.

Does anyone on the GG know where the airbag control module is located in a 2005 Highlander? or direct me to a source where this info might be available?

I put a call in to a good friend that owns body shop and has been in the business for decades with dealers and the like before going out on his own about 20 years ago. I know he does a lot of insurance work and as such is likely real familiar with the issue Ray. When I called he was laying down some paint so I left a message that hopefully he will return and be able to answer your question. Things are a lot different in KS (even Topeka) than they are where you are so this might be a bit easier to get an answer.

Thanks Herb -- much appreciated. Independent repair centers are definitely a bit more forthcoming with info. I'll visit a local independent garage later today that I know very well and see what they have to say on the matter. They do mostly mechanical and HVAC work -- not too much electrical diagnosis on Asian cars, but it's worth a shot. 

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Re: The crashes keep on coming -- updated 5-14
« Reply #60 on: May 15, 2017, 10:13:47 PM »
Most of the vehicles I worked on the module was under passenger seat or under console
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Re: The crashes keep on coming -- updated 5-14
« Reply #61 on: May 15, 2017, 10:59:25 PM »
Most of the vehicles I worked on the module was under passenger seat or under console
I'm not positive but i think on yours GF its under the rear of the console.

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Re: The crashes keep on coming -- updated 5-14
« Reply #62 on: May 16, 2017, 02:29:13 PM »
Thank you gents! -- I really appreciate all the input.

I did pull the entire console and "sure-nuff" the module is located right under the transmission selector assembly. I'll have to pull it after work this evening.

On other matters, the seatbelt assembly wasn't that hard to remove either. I will package these things up and send them out for rebuilding and reflashing.

I'll post some pics this evening in case anyone has to pull the console.

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Re: The crashes keep on coming -- updated 5-14
« Reply #63 on: May 16, 2017, 07:57:07 PM »
The console is pretty straight forward to remove

Remove the shift console binnacle -- it simply pries up and is only secured by four snap-in clips

The console itself has two bolts in the rear bottom compartment, one side bolt (each side) by the seat rails, and three Phillips screws once you remove the console binnacle 



The airbag module is located directly underneath the shift lever assembly and is held in place by three 12mm bolts. -- one in front and two in the rear.



The best way to get at it is to clear as much carpet as possible to make room for extracting the entire module



This is what the module looks like -- the single rear bolt is easy to remove, but the two bolts on the side are tough. Best way to tackle that problem is to disconnect the rear air ducts from the blower unit. There are two air ducts -- one duct on each side of the module -- effectively blocking access to the module side bolts. I simply pushed down hard on the ducts where they connect to the blower and they sprang loose and I was able to push them out of my way to make room for a 12mm swivel socket on a 12" extension. That solved the access problem.





Here is a two pics of the empty space where the module resides





The other issue was the driver's side seatbelt.

I removed the plastic front and rear door sill covers -- the simply push/slide forward (toward the front of the car) and then you pull up to release the sill covers  (I had to pull the door seals out of the way a bit, but that is a trivial matter.







The inner "B" pillar plastic cover can now be removed by simply pulling on it -- it releases 5 clips in the pillar. Then the top seatbelt mounting clip on the "B" pillar is simply split open (like a clamshell) to reveal the mounting bolt -- it's fairly tight and I had to use a long handle 3/8" drive ratchet to get it off. Then the lower "B" pillar mounting bolt is removed.



The seatbelt module sits in the bottom of the "B" pillar and is held in by two bolts. The electrical connection is a lock type. Pull/pry up the lock tab with a small screwdriver and the connector comes loose.








« Last Edit: May 16, 2017, 08:14:01 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-16
« Reply #64 on: May 17, 2017, 12:03:13 PM »
For the folks that wanted to know where I sent my airbag module and seatbelt unit for refurbishment --

myairbags.com in Duluth GA =

$49 for the airbag module reflash, and $77 for the seatbelt module rebuild. The shipping back to me is free for the airbag module, but since the refurbished seatbelt unit will contain a hazardous material package, there is $38 HAZMAT shipping fee assessed.
« Last Edit: May 28, 2017, 11:28:29 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-16
« Reply #65 on: May 17, 2017, 12:21:26 PM »
For the folks that wanted to know where I sent my airbag module and seatbelt unit for refurbishment --

airbags.com in Duluth GA =

$49 for the airbag module reflash, and $77 for the seatbelt module rebuild. The shipping back to me is free for the airbag module, but since the refurbished seatbelt unit will contain a hazardous material package, there is $38 HAZMAT shipping fee assessed.

Some of the underlying costs not often considered by customers that are all part of the cost of putting a vehicle back right after a collision.

Ray, at the risk of sounding ignorant I understand having to do something special with an airbag after a collision. Honestly though, generally I would think in terms of loading the airbag bundle or it's replacement back were it belongs in the vehicle. Re-flashing I would know nothing about. And as for having to have something special done with the seatbelt I have zero knowledge of why you would need to have anything done with the seatbelt either. Mind you, I am not questioning having either done, (I am sure they had to be done) I am simply looking for some schooling to bring me up to speed about how you determine when either one needs doing, and what are the tells indicating needed attention? Perhaps I might run into something like this someday and it would be great to know these answers!
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-16
« Reply #66 on: May 17, 2017, 03:59:33 PM »
For the folks that wanted to know where I sent my airbag module and seatbelt unit for refurbishment --

myairbags.com in Duluth GA =

$49 for the airbag module reflash, and $77 for the seatbelt module rebuild. The shipping back to me is free for the airbag module, but since the refurbished seatbelt unit will contain a hazardous material package, there is $38 HAZMAT shipping fee assessed.

Some of the underlying costs not often considered by customers that are all part of the cost of putting a vehicle back right after a collision.

Ray, at the risk of sounding ignorant I understand having to do something special with an airbag after a collision. Honestly though, generally I would think in terms of loading the airbag bundle or it's replacement back were it belongs in the vehicle. Re-flashing I would know nothing about. And as for having to have something special done with the seatbelt I have zero knowledge of why you would need to have anything done with the seatbelt either. Mind you, I am not questioning having either done, (I am sure they had to be done) I am simply looking for some schooling to bring me up to speed about how you determine when either one needs doing, and what are the tells indicating needed attention? Perhaps I might run into something like this someday and it would be great to know these answers!

Herb -- the airbag system is controlled by a computer that constantly gets input from an array of sensors (impact sensors) -- once an impact occurs, the module commands both the airbag to deploy (a controlled explosion) and the seatbelt pre-tensioner to take up any slack in the belt and make it very tight. The pre-tensioner is activated by another controlled explosion which pushes on a piston and tightens the belt. That's why the belt needs to be refurbished -- another pre-tensioner charge needs to be reinstalled and the seatbelt rewound on the ratcheting mechanism. That is also why there is a $38 HAZMAT charge for shipping -- because there is a potentially explosive charge in the refurbished seatbelt module.

The control module itself registers an impact and will keep that data stored in memory unless it is erased -- a standard OBDII scanning tool can't erase that log. It needs to be sent to a specialist, or an expensive new module needs to be purchased and reflashed to match the VIN of the car.

Unless that module is reflashed, the airbag idiot light on the dash will stay lit and (depending on some car models) the new airbag may not function at all.
« Last Edit: May 28, 2017, 11:29:04 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-16
« Reply #67 on: May 17, 2017, 04:09:24 PM »
For the folks that wanted to know where I sent my airbag module and seatbelt unit for refurbishment --

airbags.com in Duluth GA =

$49 for the airbag module reflash, and $77 for the seatbelt module rebuild. The shipping back to me is free for the airbag module, but since the refurbished seatbelt unit will contain a hazardous material package, there is $38 HAZMAT shipping fee assessed.

Some of the underlying costs not often considered by customers that are all part of the cost of putting a vehicle back right after a collision.

Ray, at the risk of sounding ignorant I understand having to do something special with an airbag after a collision. Honestly though, generally I would think in terms of loading the airbag bundle or it's replacement back were it belongs in the vehicle. Re-flashing I would know nothing about. And as for having to have something special done with the seatbelt I have zero knowledge of why you would need to have anything done with the seatbelt either. Mind you, I am not questioning having either done, (I am sure they had to be done) I am simply looking for some schooling to bring me up to speed about how you determine when either one needs doing, and what are the tells indicating needed attention? Perhaps I might run into something like this someday and it would be great to know these answers!

Herb -- the airbag system is controlled by a computer that constantly gets input from an array of sensors (impact sensors) -- once an impact occurs, the module commands both the airbag to deploy (a controlled explosion) and the seatbelt pre-tensioner to take up any slack in the belt and make it very tight. The pre-tensioner is activated by another controlled explosion which pushes on a piston and tightens the belt. That's why the belt needs to be refurbished -- another pre-tensioner charge needs to be reinstalled and the seatbelt rewound on the ratcheting mechanism. That is also why there is a $38 HAZMAT charge for shipping -- because there is a potentially explosive charge in the refurbished seatbelt module.

The control module itself registers an impact and will keep that data stored in memory unless it is erased -- a standard ODBII scanning tool can't erase that log. It needs to be sent to a specialist, or an expensive new module needs to be purchased and reflashed to match the VIN of the car.

Unless that module is reflashed, the airbag idiot light on the dash will stay lit and (depending on some car models) the new airbag may not function at all.

WOW, I had no clue. So then any late model (post mid 1990"s) OBDII equipped car would be like this then regardless the brand I would assume?
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-16
« Reply #68 on: May 17, 2017, 04:20:56 PM »
For the folks that wanted to know where I sent my airbag module and seatbelt unit for refurbishment --

myairbags.com in Duluth GA =

$49 for the airbag module reflash, and $77 for the seatbelt module rebuild. The shipping back to me is free for the airbag module, but since the refurbished seatbelt unit will contain a hazardous material package, there is $38 HAZMAT shipping fee assessed.

Some of the underlying costs not often considered by customers that are all part of the cost of putting a vehicle back right after a collision.

Ray, at the risk of sounding ignorant I understand having to do something special with an airbag after a collision. Honestly though, generally I would think in terms of loading the airbag bundle or it's replacement back were it belongs in the vehicle. Re-flashing I would know nothing about. And as for having to have something special done with the seatbelt I have zero knowledge of why you would need to have anything done with the seatbelt either. Mind you, I am not questioning having either done, (I am sure they had to be done) I am simply looking for some schooling to bring me up to speed about how you determine when either one needs doing, and what are the tells indicating needed attention? Perhaps I might run into something like this someday and it would be great to know these answers!

Herb -- the airbag system is controlled by a computer that constantly gets input from an array of sensors (impact sensors) -- once an impact occurs, the module commands both the airbag to deploy (a controlled explosion) and the seatbelt pre-tensioner to take up any slack in the belt and make it very tight. The pre-tensioner is activated by another controlled explosion which pushes on a piston and tightens the belt. That's why the belt needs to be refurbished -- another pre-tensioner charge needs to be reinstalled and the seatbelt rewound on the ratcheting mechanism. That is also why there is a $38 HAZMAT charge for shipping -- because there is a potentially explosive charge in the refurbished seatbelt module.

The control module itself registers an impact and will keep that data stored in memory unless it is erased -- a standard ODBII scanning tool can't erase that log. It needs to be sent to a specialist, or an expensive new module needs to be purchased and reflashed to match the VIN of the car.

Unless that module is reflashed, the airbag idiot light on the dash will stay lit and (depending on some car models) the new airbag may not function at all.

WOW, I had no clue. So then any late model (post mid 1990"s) OBDII equipped car would be like this then regardless the brand I would assume?

I'm not certain when these technologies became the de-facto standard in modern cars, but certainly by the early 2000's these systems were increasingly standardized into every make, model, and price range of cars.
« Last Edit: May 28, 2017, 11:29:23 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-16
« Reply #69 on: May 19, 2017, 03:01:31 PM »
Well, the body and paint work on this thing is essentially done. I hung all the panels, and with very few exceptions the panels went on as expected -- I guess my measurements and fabrications were within the spec for fitting up parts.

The only real problem I found was with the aftermarket hood. I couldn't check the original hood's front crown lines and compare them with the aftermarket hood because the original piece was so crushed and crumpled that a comparison would have been impossible. Turns out that the new hood crown lines are stamped inward a bit too far to match up nicely with the grill on the corners. It is what it is, and I should have remembered to check it, but I forgot and just went with it -- my bad!





Overall the car looks tight and the color looks OEM. I painted the hood, the bumper cover, and the grill, and there are a few dust particles in the clear coat, but after this paint job has a chance to harden for a few weeks in the summer heat, I will sand it with 2000 grit and give it a nice buff and polish. It should look factory.

I was going top paint the entire car, but my daughter needs the car in two weeks for summer work; hence she only gets the Earl Scheib treatment. We'll see about painting the entire car in the fall.



All that's left is to install the plastic inner fender liners, the new seatbelt module, and the reflashed airbag control unit. I also have to charge the AC. Hopefully all will be done before Memorial day.

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Re: The crashes keep on coming -- updated 5-19
« Reply #70 on: May 19, 2017, 03:44:39 PM »
So what job did daughter get?
That scalloped box end is one of the few BB features that doesn't make Elroy puke

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Re: The crashes keep on coming -- updated 5-19
« Reply #71 on: May 19, 2017, 03:50:59 PM »
Looks great Ray. The only person that's ever gonna notice the hood is you and whoever you point it out to.
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Re: The crashes keep on coming -- updated 5-19
« Reply #72 on: May 19, 2017, 03:51:39 PM »
You are going to notice deficiencies more than about 98% of the rest of anyone whose eyes would ever land on it Ray. Takes either a very discerning eye, or that of an actual paint/body man to even notice what you are speaking of. Personally, I think it came out smashing, just as I expected! I knew you would knock it out in a couple of weeks too and you did not disappoint!  thumbsup2
You boys better hold on cause i'm gonna have to stand on it!

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Re: The crashes keep on coming -- updated 5-19
« Reply #73 on: May 19, 2017, 04:23:41 PM »
So what job did daughter get?

Phil -- she got an internship at a non-profit social welfare group in Alexandria.


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Re: The crashes keep on coming -- updated 5-19
« Reply #74 on: May 19, 2017, 04:30:43 PM »
Looks great Ray. The only person that's ever gonna notice the hood is you and whoever you point it out to.

You are going to notice deficiencies more than about 98% of the rest of anyone whose eyes would ever land on it Ray. Takes either a very discerning eye, or that of an actual paint/body man to even notice what you are speaking of. Personally, I think it came out smashing, just as I expected! I knew you would knock it out in a couple of weeks too and you did not disappoint!  thumbsup2

Thanks guys! These little issues are not uncommon, but it's just irritating because it doesn't quite match the OEM look. That said, many of these aftermarket parts are much lower quality in terms of fit and finish than original Toyota parts. I debated about getting an OEM hood from the local car recycler, but it was just way easier to get on ebay and have the stuff shipped to my house. Overall I saved about $1300 by going for aftermarket Taiwanese parts over OEM Japanese production parts. For a 12 year old car, this was a reasonable compromise.

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Re: The crashes keep on coming -- updated 5-19
« Reply #75 on: May 22, 2017, 02:20:46 PM »
i am in awe of the work you turn out in such a short time, not to mention the quality. i would not have the patience or skill to tackle it.
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Re: The crashes keep on coming -- updated 5-19
« Reply #76 on: May 22, 2017, 04:37:02 PM »
i am in awe of the work you turn out in such a short time, not to mention the quality. i would not have the patience or skill to tackle it.

Thanks SK --

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Re: The crashes keep on coming -- updated 5-19
« Reply #77 on: May 23, 2017, 06:48:12 AM »
i am in awe of the work you turn out in such a short time, not to mention the quality. i would not have the patience or skill to tackle it.
+1
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Re: The crashes keep on coming -- updated 5-19
« Reply #78 on: May 23, 2017, 09:06:57 AM »
GF possesses a wide and deep set of skills not to mention knowledge.  Oh,,,,,,,,,,,,and a whole lot of patience and stick to itness. 

Looking quite good Ray!!

Now I think some remedial driving lessons are in order for young daughter lolx
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Re: The crashes keep on coming -- updated 5-19
« Reply #79 on: May 23, 2017, 10:59:50 AM »
GF possesses a wide and deep set of skills not to mention knowledge.  Oh,,,,,,,,,,,,and a whole lot of patience and stick to itness. 

Looking quite good Ray!!

Now I think some remedial driving lessons are in order for young daughter lolx

Thanks Phil -- and yes, we will probably have to get a review of remedial driving skills -- LOL  frustratedx

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Re: The crashes keep on coming -- updated 5-19
« Reply #80 on: May 23, 2017, 12:35:25 PM »
GF possesses a wide and deep set of skills not to mention knowledge.  Oh,,,,,,,,,,,,and a whole lot of patience and stick to itness. 

Looking quite good Ray!!

Now I think some remedial driving lessons are in order for young daughter lolx
I agree.

I always thought girls/women were better/more cautious drivers than boys/men. But, not true with my son and daughter at least.
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Re: The crashes keep on coming -- updated 5-19
« Reply #81 on: May 24, 2017, 06:42:34 PM »
Today I received my airbag module and seatbelt back from the rebuilder. It was a quick turnaround, and they provided very good service -- I highly recommend myairbags.com in Duluth GA





First thing after work was to get the airbag control module back in the floor plate, and the center console hooked back up.







Once you've removed that darn console, it's pretty easy to get it back into place. The hardest part was aligning the bottom console bolts





The electrical connections are all one-way fitted plugs and you can't make a mistake -- they only fit their unique sockets.





These cheap $15 Toyota plastic clip kits from ebay make the job a snap because many of the old clips just break when you try to remove them. Easier to just replace --



The front kickpanels were cleaned and reinstalled with new clips as well.



The seatbelt module came next. It was bolted in place and the belt reattached to the "B" pillar.





Finally the "B" pillar cover and the plastic trim and weather stripping were reinstalled -



Lastly I tackled the airbag. When I removed the old airbag, the electrical lead plugs were damaged. The plugs have a locking tab on them that must be pushed up with a screwdriver or pick in order to release the plug. Easier said than done, because in my case the locking taps were glued in place. The glue was transferred from a wiring bundle retainer which was sitting right underneath the plugs and over time had leached/melted into the locking tabs. Breaking these things is apparently a common problem since the plugs are sold in bulk all over the Internet. I purchased a new plug set for $2.50 on ebay.





All soldered up and ready for the airbag





Unfortunately I ordered the wrong airbag -- my fault. The airbag I ordered/received is for a Highlander with left/right steering wheel mounted control pods. Mine doesn't have those. So I will have to wait a few days and exchange it for the proper airbag. The plugs are the same, but my current airbag is too small for my steering wheel center due to the lack of those control pods. 



« Last Edit: May 24, 2017, 06:56:24 PM by goodfellow »

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Re: The crashes keep on coming -- updated 5-24
« Reply #82 on: May 26, 2017, 06:55:37 PM »
Finally got to install the inner fender liners -- glad I had ordered those cheap ebay clip kits, because without them those liners would have been a real pain.





While I was installing the liners, my "supervisor" who was visiting for the Memorial Day weekend, mentioned that I better check the brakes because "they didn't look right". Sure enough the pads had worn down to a point where they needed to be replaced. So after a trip to the parts store we have new brakes on this jalopy.





Last two things to do on this job is to install the new airbag (which according to the USPS tracking system should arrive early next week), and to recharge the AC system. It has been holding a vacuum for over a week, and should be OK once the airbag is installed and the car is roadworthy again.

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Re: The crashes keep on coming -- updated 5-26
« Reply #83 on: May 27, 2017, 02:31:44 PM »
I guess we'll call this one done. The airbag arrived today, and after installation I hooked up the battery and hoped for the best. The seatbelt and airbag codes were gone and no more idiot light. Everything checked out fine. I took the car for a drive around the neighborhood and then on the freeway -- no problems. It tracked well and no funny noises anywhere. The thing drives nice!! That's one of the reasons I decided to keep it.



I did hook up a trickle charger to charge the battery since it hasn't been used in over a month. A night of trickle charging should bring it back to a premium state. The front end and the core support look stock and you can't tell it was ever hit.





Overall it came out nice -- and she'll last another few years. At least until my daughter graduates college next year.

Done!!!





Now it'll take me three days to clean up the garage -- it's a total mess -- LOL



« Last Edit: May 27, 2017, 02:45:43 PM by goodfellow »

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Re: The Highlander crashes keep on coming -- Done!!
« Reply #84 on: May 27, 2017, 04:28:37 PM »
nicely done. thumbsup2
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Re: The Highlander crashes keep on coming -- Done!!
« Reply #85 on: May 27, 2017, 10:58:33 PM »
Great work. Hopefully she'll not be bringing it back to 'Ray's auto body' anytime soon!
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Re: The Highlander crashes keep on coming -- Done!!
« Reply #86 on: May 27, 2017, 11:44:10 PM »
Good one,,,,

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Re: The Highlander crashes keep on coming -- Done!!
« Reply #87 on: May 28, 2017, 08:45:57 AM »
Outstanding,,,  beerdude
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Re: The Highlander crashes keep on coming -- Done!!
« Reply #88 on: May 28, 2017, 11:37:07 PM »
Thanks for the support guys!


Great work. Hopefully she'll not be bringing it back to 'Ray's auto body' anytime soon!

LOL -- yes Bruce; after this one I think I'll be closing down for a few months. I need to get back on my own projects and finish up this damn Jag.


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Re: The Highlander crashes keep on coming -- Done!!
« Reply #89 on: May 29, 2017, 07:03:55 AM »
Goodfellow Garage ships another job well done!

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Re: The Highlander crashes keep on coming -- Done!!
« Reply #90 on: May 31, 2017, 03:34:33 PM »
 Clean them wheels, I could tell it needed brakes from here.
 angryguyx


Came out great! thumbsup2
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Re: The Highlander crashes keep on coming -- Done!!
« Reply #90 on: May 31, 2017, 03:34:33 PM »

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