Aygo Sport Tte Project Thread - Complete Respray & Light Mods

[aygo_rory]

hey all,

just registered today as im the proud owner of an aygo sport with all the tte goodies :)

Anyway I bought the car direct from the insurance company with light damage for £495 which i think is a steal, as I saw a basic aygo with a heck of a lot more damage go through on eBay for over £1100 the other day :)

I own and run my own bodyshop business so ive got the car in the bay in my workshop ready for repairs and a respray and a few little extra touches!

plans so far is to add a full alarm system with all the bells and whistles, full sound system with screens, tinted windows, del -locked doors, bonnet vent and a full repair and complete repaint so it is totally mint!

I will update this thread every day or two with progress pictures as soon as the new parts ive ordered arrive!

Heres some pictures of the car at the side of the road minutes after its little hick up - hope you all enjoy!

[kevin65]

Welcome to forum. Looking forward to seeing the progress

[aygo_rory]

well the aygo has been started,

so far i have installed the alarm completly , all the remote starter etc is all wioirking and programmed. ii also tesa taped the complete car loom so you cant find the alarm wires now to make it more secure :)

II have also removed all the damaged front panel and crosmember . i have also rested the new front panel in place and it fits in and lines up perfect :)

I have removed the damaged rear tail light and used the pin puller on the quarter panel and given it a nice light skim of filler.

the drivers door has also been de-locked, i welded a plate in there and ground it back ! there unfiortunatly was damage all down the leading edge of the drivers door so had to straighten that and give that section of the door a skim to get it arrow straight!

anyway heres some progress pics,

ill update pics as it progresses

[Uncle Bob]

Look at that ....now the alternator is piece of cake to replace :) look forward to your project with lots of photos :)

[Raistlin]

Coming together nicely

[aygo_rory]

well another update,

all the new parts arrived the other day, front bumper,reinforcer, headlights, and grill and a new absorber

the next stage was to trial fit it all up to check gaps and measurements etc.

i also finished de-locking the car and doing the other small repairs. i also put some 2k primer on it the other day :)

[Raistlin]

Brilliant work mate ...

[Uncle Bob]

As you have the rear lights out now, you will see what a rubbish seal they have on them, this also goes for the high level brake light, good time to break out the black sealer gun as you reassemble :)

[Uncle Bob]

You've gone quiet on us hope project is all going to plan .

[Valvematic]

Love body filler looking good.

[aygo_rory]

hey guys sorry for the long quiet period!

Basically without going into too much detail, me and the missus went through a horrible breakup and unfortunately the aygo was pushed to the back of the bodyshop and left for a few months while i sorted her mess out,

anyway back to the car, its all painted now, only painted it on saturday actually but it has come out really nice indeed! i painted the front panel and the front impact bar etc today and the front end is all rebuilt now bar the front bumper :)

upon further inspection a while ago i noticed that the bonnet had actually moved and the inner flitch panel on the o/s had actually moved outwards by 4mm , this wasnt a problem as ive got a blackhawk jig setup, it was just a ball ache as it meant more time. I put the car on the jig and gave it the necessary repairs and reassembled the front end and everything clicked in exactly where it should, all screws and bolts lined up perfect and the gaps are amazing!

anyway enough of me rambling heres some pictures of my progress to date , ill put a few more up of the front panel and impact bar etc all painted and fitted up!, it looks like a new car and its almost done externally now :)

this was just after the car had been fully jigged and all welding repairs had been done and the front panel fully inline and again welded, the car looks really sorry for itself at this point!

check the gaps now after the jig work :)

in primer and masked all ready for the repaint!

all masked up ready for colour

[aygo_rory]

and heres the pictures of it in basecoat :

and now ready for the drop coat :)

and now for clear coat my choise was sikkens autoclear lv superior! amazing clear coat used to love it when i painted in an insurance only bodyshop!

[Unklian]

Having done a few cars myself......
Nice Job!

......Just wondering......Can't make it out on the pictures......

Why mask half-way up the sills?

Have you some kind of bodykit / covers on them?

Not a criticism, just wondering.

Ian.

EDIT: ...... zoomed in on originals......I can see 'em now.

Edited May 30, 2014 by Unklian

[Raistlin]

Well done , it's looking great

[aygo_rory]

Cheers guys :)

the front panel is all painted and the headlights etc are all in, the alarms fully working now too so another couple of days its ready to be booked in for its vic test and mot!

Just got to do a couple of small mechanical jobs and shes on her way :)

[aygo_rory]

heres some pictures of what i did on it yesterday,

bumpers are painted and mouldings too, all fitted up, only a couple of small things to do now, fit new front numberplate, and new badges front and rear.

next week ill put it up in the air on the ramp and ill swap the steering rack out, the arm is bent but its cheaper to wack another rack in than just change the arm.

I've got another set of wheels that im going to fully refurb and jobs a gooden!

all front panel painted and being rebuilt

bumpers, mouldings and handles painted :)

front all fitted up (just need to set the bonnet up properly - hence gap on right hand side, bonnet is too high that side)

rear end cleaned ready for refit,

[Raistlin]

Not long now...

[kevin65]

looking good!

[G6-R]

Nice job enjoy the Car

[V3nom]

Loving the de-locking the drivers door. I'm seriously considering this little mod!!

[Devon Aygo]

Just noticed your second to last picture, your rear panel vent seals are shot, a prime source of water ingress to the boot. Part # 62930-0H012 x 2 will get you the latest leak free panel vent.

[aygo_rory]

Well guys, sorry for the quiet period again! it's been hectic, my bodyshop is packed with cars atm so havent had any free time!

Anyway the cars finished, passed its mot first time, no advisories, it also went straight through the vic test and it's been on the road now for 2 weeks and im loving it :)

[aygo_rory]

a nice pioneer double din installed :)

Heko wind deflectors :)

Rear spoiler all fitted :)

Now that the cars all road legal and driving straight I'm going to take the car back in to my bodyshop so I can paint the inside of the doors and the skirts as the rest of the car is pristine without a single mark and it lets it down a bit

[G6-R]

Top Job

Maybe some MK2 rearlights