DeAgostini AE86 Build Journal 05 — Issues 46–58: Engine Bay, Dashboard & Interior

Issues 46–58 continue from the engine installation and electrical work covered in Build Journal 04.

The engine bay is becoming more crowded as the remaining auxiliary components, cooling system, wiring and piping are installed. The retractable headlights are also fitted, together with the first parts from AE86 Custom Part Set 1.

After Issue 51, the build moves away from the engine compartment and into the interior. The dashboard, steering wheel, floor carpets and centre console are assembled before the completed dashboard is fitted onto the floor plate.

There are some straightforward assemblies in this chapter, but also a few small details that need more care than expected. The wiring is becoming harder to access, and the interior carpets need to be positioned correctly before pressing them into place.

This article continues from the earlier chapters in the series:

• AE86 Build Journal — Project Introduction
• AE86 Build Journal 01 — Issues 1–13: Building the 4A-GEU Engine
• AE86 Build Journal 02 — Issues 14–22: Chassis and Suspension Work
• AE86 Build Journal 03 — Issues 23–33: Rear Axle, Exhaust & Fuel Tank
• AE86 Build Journal 04 — Issues 34–45: Engine Bay, Steering & Electrical System

In This Build Journal

• Milestone 1: Completing the Engine Bay — Issues 46–49
• Milestone 2: Retractable Headlights & Custom Part Set 1 — Issues 50–51
• Milestone 3: Dashboard and Custom Steering Wheel — Issues 52–54
• Milestone 4: Interior Carpets and Centre Console — Issues 55–58
• Overall Build Impressions
• From the Engine Bay to the Interior

Milestone 1: Completing the Engine Bay — Issues 46–49

Issues 46–49 continue adding the remaining components around the engine bay.

The battery, fuse box, ignition coil and windshield washer are installed first. The following issues then focus on the radiator, air-conditioning components and the remaining piping and wiring.

The main difficulty during this stage is no longer the individual parts themselves. It is finding enough space to work around everything that has already been installed.

Issue 46 — Engine-Bay Auxiliary Components

Issue 46 mainly assembles the battery, fuse box, ignition coil and windshield washer, then fits them onto the left side of the engine compartment.

I made a small change to the installation sequence for the battery ground cable.

Instead of connecting the ground cable to the battery terminal first, I passed the cable through the hole in the left front fender apron before connecting the other end to the battery terminal.

I found this easier because of the way the hole in the fender apron was formed. Following this sequence made routing the cable more straightforward for me.

Another small thing I noticed was the ignition coil.

The paint on the protrusion where the cable connects is quite thick. If the cable is difficult to fit, carefully removing a little paint from the protrusion should make the connection easier.

There is no need to force the cable into place.

Issues 47–49 — Radiator, Cooling System and Engine-Bay Wiring

These three issues mainly focus on the engine cooling system and the remaining engine-bay connections.

The radiator, air-conditioning condenser and receiver tank are assembled, followed by more piping and wiring around the engine compartment.

By the end of Issue 49, the radiator is installed in the engine bay, together with the air-conditioning connections, engine cooling pipes and fuel-system wiring.

This stage reminded me why I spent time labelling the wires and pipes during the earlier issues.

Most of them are black.

When the engine bay was still relatively empty, it was easy enough to identify where each wire or pipe came from. But now, with so many components installed, I could barely see the starting point of some of them.

Without the labels, identifying the correct connections would have been quite confusing.

I'm glad I did that preparation earlier.

The work also took longer because access to certain areas had become very limited. Sometimes the difficulty was simply getting my hands or tools into the right position without disturbing something already installed.

For anyone building this stage, I would recommend keeping the labels in place until the routing and connections are completed.

Milestone 2: Retractable Headlights & Custom Part Set 1 — Issues 50–51

Issues 50–51 continue the front-end assembly and introduce the first parts from the optional AE86 Custom Part Set 1.

I decided to start with the custom fog lights and retractable-headlight covers before continuing with the regular issues.

The custom steering wheel is also included in this set, but that will be fitted later during the dashboard assembly.

AE86 Custom Part Set 1 — Fog Lights and Headlight Covers

I started by assembling the fog lights supplied in Custom Part Set 1 and fitting them onto the front bumper.

I also replaced the original retractable-headlight covers with the custom versions.

These are optional parts, so builders who prefer the standard DeAgostini appearance can continue using the original components.

For my build, I had already decided to use the custom parts, so it made sense to prepare them while working on the front-end assemblies.

Issue 50 — Air Cleaner and Front-Bumper Brackets

Issue 50 mainly assembles the air cleaner and installs it into the engine bay.

There is also some additional wiring to complete around the engine compartment.

At this stage, the brackets used to connect the front bumper to the body are fitted onto the bumper.

The individual assemblies are not particularly difficult, but the engine bay is already quite crowded. As with Issues 47–49, I had to work carefully around the parts and wiring that were already in place.

Issue 51 — Retractable Headlights and LEDs

Issue 51 installs the retractable-headlight assemblies onto the front of the engine bay and fits the LEDs into the headlights.

There is one important thing to watch out for when securing the headlights.

Do not overtighten the mounting screws.

The headlight assemblies need to retain a little free movement. When touched, they should still be able to move slightly rather than being held completely rigid.

If the screws are tightened too much, the retractable-headlight mechanism may not operate properly.

I paid particular attention to this because the mechanism had already been assembled during the earlier issues. There is no point getting all the gears and moving parts fitted correctly if the headlights themselves cannot move freely.

Before moving on, make sure the assemblies are secured without restricting their intended movement.

Milestone 3: Dashboard and Custom Steering Wheel — Issues 52–54

After spending so much time around the engine compartment, Issues 52–54 move the build into the interior.

These three issues assemble the AE86 dashboard, including the instrument panel, switches, centre controls and steering wheel.

The dashboard is built as a separate assembly at this stage, before being fitted onto the interior floor plate later.

Issue 52 — Upper Dashboard and Instrument Panel

Issue 52 focuses on the upper section of the dashboard.

The combination meter, windshield-wiper switch and light-control switch are fitted into the instrument panel.

This is also where the gauge-illumination feature is incorporated into the dashboard assembly.

After working with the larger engine-bay components, the dashboard brings the focus back to smaller interior details.

Issue 53 — Lower Dashboard and Centre Controls

Issue 53 continues with the lower dashboard.

The speaker panels, centre cluster, ashtray and cigarette lighter are assembled and fitted into place.

Once these parts are installed, the upper and lower dashboard sections are joined together.

At this point, the separate dashboard components finally become one complete assembly.

Issue 54 — Custom Steering Wheel Installation

Issue 54 completes the steering assembly and fits it onto the dashboard.

Instead of using the original DeAgostini steering wheel, I installed the custom steering wheel from AE86 Custom Part Set 1.

The assembly itself was quite straightforward.

There is only one thing I would pay particular attention to: make sure the steering wheel can still turn freely after it is fitted onto the steering shaft.

The wheel should not become stiff or restricted after the installation.

With the steering wheel fitted, the dashboard assembly is now ready for installation into the interior.

Milestone 4: Interior Carpets and Centre Console — Issues 55–58

Issues 55–58 move the build onto the interior floor plate.

The main work is fitting the carpets and floor mats, followed by the centre console and dashboard.

There is nothing particularly complicated about the carpet installation, but this stage requires patience and careful alignment.

Unlike a plastic part that can usually be removed and refitted, the carpets are much less forgiving once they have been pressed firmly into place.

Issues 55–57 — Interior Carpets and Floor Mats

Issue 55 installs the front and rear carpets onto the floor plate.

Issue 56 adds the driver's and passenger's floor mats, followed by the rear-seat floor mats in Issue 57.

The most important part of this process is getting the alignment right before pressing the carpets down.

Once the carpet is firmly stuck onto the floor plate, adjusting its position becomes very difficult.

Trying to peel it off again can tear or damage the carpet material.

So I took more time checking the position before applying pressure.

This is one of those stages where slowing down at the beginning can save a lot of trouble later.

My advice is to check the edges and alignment carefully, and only press the carpet firmly into place once you are satisfied with its position.

Issue 58 — Centre Console and Dashboard Installation

Issue 58 assembles the centre console and fits it onto the interior floor plate.

There are two small mechanical details worth mentioning.

The shift lever is fixed and does not move, but the handbrake lever can be moved up and down.

After the centre console is fitted, the completed dashboard from Issues 52–54 is installed onto the floor plate.

This brings together the carpeted floor, centre console and dashboard into one interior assembly.

After working on these parts separately, it was good to finally see the dashboard sitting in its proper position with the interior floor.

Overall Build Impressions — Issues 46–58

Issues 46–58 cover two quite different parts of the AE86 build.

The first half continues the mechanical and electrical work around the engine compartment. By this stage, the engine bay is becoming crowded enough that even simple connections can take more time than expected.

The second half moves into the interior, where the dashboard and carpets require a different kind of attention.

The main things I learned from this stage are:

• Installation sequence matters. Routing the battery ground cable through the fender apron before connecting it to the terminal made the job easier for me.
• Small fitting problems should not be forced. Thick paint on the ignition-coil connection may need to be carefully removed before the cable can fit properly.
• Labelling wires and pipes saves time later. Once the engine bay becomes crowded, tracing the original connections can be difficult.
• Moving assemblies need some freedom. Overtightening the retractable-headlight screws can interfere with the mechanism.
• Check the custom steering wheel after fitting. Make sure it still turns freely once installed on the steering shaft.
• Carpet alignment needs patience. Once firmly pressed onto the floor plate, the carpet is difficult to reposition without risking damage.

None of these are major modifications to the build.

They are mostly small decisions about installation order, fitting, alignment and handling. But these are also the things that can make a straightforward step take much longer than expected.

From the Engine Bay to the Interior

By the end of Issue 58, the engine bay has most of its auxiliary components and cooling system installed, the retractable headlights are fitted, and the dashboard and interior floor have come together.

The AE86 is now taking shape in two major areas: the mechanical assemblies around the chassis and the interior where the driver and passengers will sit.

There is still quite a lot of work ahead, particularly around the remaining interior assemblies and bodywork.

But with the dashboard finally fitted onto the carpeted floor plate, another major section of the car is starting to come together.

Continue the AE86 Build

This article covers Issues 46–58 of the DeAgostini 1/8 Toyota Sprinter Trueno AE86.

For the earlier stages of the build:

• Project Introduction — DeAgostini 1/8 Toyota Sprinter Trueno AE86 Build Project
• Build Journal 01 — Issues 1–13: 4A-GEU Engine
• Build Journal 02 — Issues 14–22: Chassis and Suspension Work
• Build Journal 03 — Issues 23–33: Rear Axle, Exhaust & Fuel Tank
• Build Journal 04 — Issues 34–45: Engine Bay, Steering & Electrical System

You can also visit the DeAgostini AE86 Build Project to explore the completed model, other Build Journals, Custom Part Sets and Full Build Service.