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Oldstinky
Oldstinky New Reader
4/26/24 10:24 a.m.

So this is the beginning of actualization. Long-time lurker, I've been planning a million builds in my head but this winter , with some planning , it's been started. Not my dream donor or fantasy body, but an affordable design exercise, if you please. A study in practical functionality.

1997 Avalon, gold trim pearl white old man car. He loved it, kept it serviced decently, bone stock with 230,xxx on the odometer. Fall of 2022 received a $1700 tune-up and new Toyos.  Then winter came and with it snow. Too much, too heavy, cheesy old Sears and Roebuck's carport caved in, totalled the car. In exchange for helping the old guy out, he gave me the car after surrendering the title and taking the $2400 from his homeowners insurance. 

So here's my donor.. what to do with it? Never owned an Avalon, started the interwebs up and began learning. Dimensions, performance (of course!!), known issues, common parts with other fine Toyota vehicles for future wrecking yard crawls. A year goes by, tax refund is designated as the budget limits ($4000ish), so my partner and I started earnestly creeping through Marketplace and CL.

Search parameters were 1960 to 1975 ( because draconian emissions restrictions in CA) and needed to have current reg and all glass to keep things simple. No brand loyalty allowed, all body configurations considered. I'll spare everyone... because we looked at alot. I began disassembly on the Toyota to help be pick some dimensions to work with and that helped. Google is awesome for quick dimensions, photos to check visually how something might look, certainly helped eliminate many cool possibilities.

Karin found the car we ended up purchasing. 3 hour drive got us a running ( sort of) and registered 1961 Lancer 170. Base 4-door, 170 had been "upgraded" to an '80's 225 , newer clutch, starter, alternator.. no floor. Coastal Oregon life had turned the firewall and floor into air. Wiring was a mess, but it ran well enough to drive on the trailer and off again.

All glass, no missing trim, mouse eaten stock interior and a terrible rattlecan black over the original red. $2300 and we drove him. Current registration was in hand, no need to buy glass. Wheelbase is within an inch of the Avalon, body width... Close, but a tad narrow.

DeadSkunk  (Warren)
DeadSkunk (Warren) MegaDork
4/26/24 10:31 a.m.

You can't start a build thread like this. Geez man, where's the picture of the Lancer ? We like pictures!

I do like the concept of a Toyota Lancer cruiser though !

Colin Wood
Colin Wood Associate Editor
4/26/24 10:41 a.m.

I'm in. Can't wait to see more of this build.

(And good luck!)

Recon1342
Recon1342 SuperDork
4/26/24 10:47 a.m.

In reply to Oldstinky :

You'll fit right in around here...

wyndscreen
wyndscreen New Reader
4/26/24 11:34 a.m.

This is gonna be good!

Oldstinky
Oldstinky New Reader
4/26/24 4:14 p.m.

This is the best side of the Lancer. Anyone not familiar, Lancer and Valiant (Plymouth) were direct competitor with Falcon and Corvair, basic transportation. IMHO the Lancer is somewhat prettier, the peaked grill and front bumper are especially nice. Despite the rust, all specific trim and glass are useable and that saves money and headache. Two year only body means parts are simply unavailable.

Avalon was cut down to the rollerskate, wiring maintained intact and I drove it around the business park to verify function.. no CEL - calling it a win for a guy who despises wiring and related electrical complexity.

Lancer immediately got stripped and I have to confess I felt a little bad. I've rescued many older vehicles over the decades.. I love old tech and readily identify as a Luddite.. forced to use tech. But I had to be ruthless and stay the mission. Modern drivetrain and as much of the tech a 1997 Toyota luxury sedan offers. Some poor bugger had installed new fuel pump alternator, clutch kit, rebuilt the drum brakes and single pot MC. All had to go.

I'm going to pause and underscore something for the casual observer... Do not skimp on your budget for consumables!!! My current estimate for blades and cutoff discs, flapper discs, paint stripping discs, flux core welding wire and various paints and sealants and adhesives... at least $600. I was a little surprised. Also.. protect your radiator during mock-up and tear down. I started this with a nearly new radiator.. replacing it upon start-up was another $250😠.

Didn't weigh the shell, but I'm a moderately strong 55 year old.. it was not a problem. OSHA- approved hoist mechanism included six (!!) 2x6s and one Harbor Freight 1ton come-a-long. I'll share more tonight. 

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
4/26/24 5:49 p.m.

i don't think i've ever seen a Lancer before.  very cool.

Oldstinky
Oldstinky New Reader
4/27/24 12:22 a.m.

so here's a couple shots of the two day process.. body up, body back down. Identify the tight spots, pull it off and trim.  A brief word about the Plan.

I intended all along to mate the Avalon floorpan pinchweld face to the Dodge pinchweld flange, the rocker. Width was close, ended up reforming the Toyota in about an inch each side and bending up a new mating surface. All good so far except the Dodge leans in at the cowl. Bottom of the door pillar is 54"ish.. top width just below the windshield... 51". So began a long process (horrifying from a structural integrity standpoint) of eventually cutting off the entire top of the Avalon firewall, door pillars and multiple layers of sturdiness. Scary.  

 

Everything eventually dropped down where I needed it to be. But by then the entire Avalon dash was out, pad and some structure, all that remained was the innermost layer with all the wiring and electronics attached. Quick mock-up of the front fender allowed me to compromise the wheel location in the Dodge body and begin knitting it all together.

Oldstinky
Oldstinky New Reader
4/27/24 2:12 p.m.

So this is where the knitting started on the lower part of the A pillar. For reference, the windshield base moved 12" closer to the rear and the imaginary line vertically through the door hinge pins moved back about 4". A mix of 1/8" & 1/16" steel was used to knit the Toyota cowl to the Dodge. Pinch welds top and bottom mated fully from front to rear for the rockers.

 

View shows how much wider at the cowl the Avalon is, the slight narrowing of the Lancer cowl really accentuates it. All that excess width and structure had to go.

Passenger side starts to come together. Couple of progress notes. I wanted to maintain a fully stock exterior appearance, so the stock wipers had to get adapted to the Toyota motor. Not a perfect outcome honestly, range of motion isn't quite as complete as I'd like, but 3speed with delay working off the stock Toyota switch and motor is a win. The hood hinges were a concern as well. The pocket and mounting location required time and care, some modification was required, but in the end they work and stock springs still hold the hood up without a prop... Win.

The cowl vent/louvers remain, however I just epoxied a shallow pan with a drain fitting and 1/2" poly line because the Dodge vent sits directly atop the Toyota heat/AC unit and wiring. 

 

TurnerX19
TurnerX19 UberDork
4/27/24 10:49 p.m.

Oh man, I'm following this one. I loved the look of the Lancer when it was new. It aged out quickly, as did all of Virgil Exner's work. To see a running one today will be grand. The aged out part is emphasized by Angry's lack of familiarity!

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
4/27/24 11:19 p.m.
TurnerX19 said:

The aged out part is emphasized by Angry's lack of familiarity!

And im almost as old as the Lancer!

I do remember the valiant, of course.

TurnerX19
TurnerX19 UberDork
4/27/24 11:26 p.m.

In reply to AngryCorvair (Forum Supporter) :

In fairness to your observation capacity, the Valiant outsold the Lancer near me 4/1, and I expect the same elsewhere, it got no promotion on the dealer level. Too bad, as the front styling is much more cohesive than the Valiant.

Oldstinky
Oldstinky New Reader
4/28/24 10:12 p.m.

This gap got filled with 1/8" spot welded and seamsealed. Down the pinchwelds I went with selftap screws, hammered things as tight as I could and used lots of vicegrips, drilled a 3/16 hole between every screw and filled it with the welder. Then pulled the screws, drilled the whole out a little and welded those up. So a throughweld every 2".

Teaser with the backseat popped in.. motivation. 

Once the sills were done I figured it was rigid enough to go on jackstands and begin trimming the front end down

.

More motivation! Mocking up the front end was huge hurdle and that 2 weeks went pretty quick.

 

 

​​​​This is where the battery used to live, the swept -to- center line along the hood and fenders made it necessary to relocate the battery to the right of the trunk and the power steering reservoir lives where the Toyota wiper started. THAT now occupies the space where the (deleted) passenger airbag was. Also built an adjustable strut tower brace to hold everything stable while I reconstructed a narrower front end. Lots of "lucky" moments like the inner edge of the fenders barely cleared the strut tops. Phew!!

 

MadScientistMatt
MadScientistMatt UltimaDork
4/29/24 12:32 p.m.

See if you can keep the front wheels where they are. I've seen a similar build that pulled the front wheels too far back and ruined the proportions.

golfduke
golfduke Dork
4/29/24 1:00 p.m.

I have long thought about a modern-drivetrain'ed valiant rat rod, so this tickles all of my fancy.  Please carry on and post as much as you can, this is awesome! 

 

Robbie (Forum Supporter)
Robbie (Forum Supporter) MegaDork
4/29/24 2:07 p.m.

totally thought this thread was going to be about an avalanche or an evo. Couldnt be happier to be so wrong on BOTH counts!!

Colin Wood
Colin Wood Associate Editor
4/29/24 2:34 p.m.
Robbie (Forum Supporter) said:

totally thought this thread was going to be about an avalanche or an evo. Couldnt be happier to be so wrong on BOTH counts!!

Glad I wasn't the only one.

Oldstinky
Oldstinky New Reader
4/29/24 4:22 p.m.

In reply to MadScientistMatt :

Spoiler alert.. approaching 1000 legal/registered/ insured miles on this abomination. Couple of freeway trips too. 60 days from purchase to registration day. Silly fun.

Oldstinky
Oldstinky New Reader
4/29/24 7:29 p.m.

In reply to MadScientistMatt :

Spoiler alert.. approaching 1000 legal/registered/ insured miles on this abomination. Couple of freeway trips too. 60 days from purchase to registration day. Silly fun.

John Welsh
John Welsh Mod Squad
4/29/24 8:37 p.m.

In reply to Oldstinky :

Great success!

Oldstinky
Oldstinky New Reader
4/30/24 7:16 a.m.

Radiator and condenser moved 6" approximately. Re-used the lower crossmember for mounting, Nissan pusher fan is center mounted in front, fits snug behind the peaked grille and bumper. 1/4" between radiator and alternator, no interference so far, engine hasn't gotten over about a 1/4 indicated on the temp guage.

Grandson comes to inspect, he is interested in knowing when I'm going to put the wheels back on. So am I.

Another example of "lucky".. earlier I mentioned my reluctant and childish relationship with electrical things. A little elaboration and ultimately, success for this proof-of-concept construction is in order.

My previous experiences with Toyota/Lexus products is good. Huge fan. But I have found that their philosophy regarding robust yet heavily integrated electrical is a little intimidating, to keep it simple I have left the entire harness unmolested with the exception of lengthening a couple harnesses to accommodate the relocated wiper motor and such. All 4 of the door jamb switches were installed and functional, dome light and safety circuits are happy and complete. Battery relocation got a pair of 8-0 ( because cheap/free jumper cables..) for the extended positve cable, two 4-0 ground straps go to the "frame" in the trunk area, a second 4-0 ground strap up front doubled the grounding from engine block near the starter to the left frame rail. Bigger (850CCA) battery in rear has provided constant perfect starts so far no electrical issues beyond the occasional security system going off. No fob came with the vehicle and I did some googling the first time it tripped and set the alarm, lights and ignition shutoff going.

By temporarily mounting the front door power lock tumblers in the Dodge doors, I can use the plain in keys I have to reset the security system and everything is happy for now.

 

TurnerX19
TurnerX19 UberDork
4/30/24 8:24 a.m.

By temporarily mounting the front door power lock tumblers in the Dodge doors, I can use the plain in keys I have to reset the security system and everything is happy for now.

This sounds like a permanent solution to me.smiley

Oldstinky
Oldstinky New Reader
4/30/24 12:53 p.m.

In reply to TurnerX19 :

Eventually. For now they are ziptied to the inside of the doors.. provisions for proper locking/ security are lagging. I live in a small relatively safe town, leaving the key in the ignition most of the time is perfectly fine. My short "fabrication season" is over, my regular gig is about to begin.. traveling to exotic locations around North California building bridges. For now the Dodge is together enough to jump in and drive wherever with comfort and a certain panache.

Piguin
Piguin Reader
4/30/24 9:45 p.m.

In reply to Oldstinky :

Driving impressions? How does the suspension deal with the (guessing) lighter weight? 

Oldstinky
Oldstinky New Reader
5/1/24 6:40 a.m.
Piguin said:

In reply to Oldstinky :

Driving impressions? How does the suspension deal with the (guessing) lighter weight? 

I had high hopes.. for wicked 0-60 performance and constant smoke shows.. initial research shows Avalon at 3400lbs stock and the Dodge was under 3000 originally. One of my first stops when I started driving it was like county dump.. you know, scales to drive on!! I'm 200, in the vehicle we weighed 3450.  

Having driven a couple of stock Avalons and several Camrii.. I swear it feels different.  Maybe the slight weight loss, battery relocated and 6" less mass on the fore end and the trunk being 6" longer... Pretty damn nimble on stock Toyos. PO had recently paid for front struts, rears are a little saggy.  But so far, it's extremely quiet, very adequate acceleration, braking is quite good, with cruise control set about 80, two separate freeway runs of about 150 miles each showed 25 and 26 mpg on a 230,000 mile drivetrain. Calling it a win.

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