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Old 01-02-2020, 10:37   #1
Rampant
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Cusco strut brace refurb

My Mrs is a legend.

Earlier this month I had a real surprise present for my birthday. She had remembered that I mentioned wanting a decent set of strut braces for the Evo many, many months ago.

So she decided to get the Evo a set of front and rear. The rear one is a 3-point brace, off ebay I would think, and presumably a copy of an original JDM design. It's nice and it's light, so the bars must be hollow extruded items.

The front one, however, she got a (very) used original Cusco from one of the used import parts dealers. She guessed I could improve it...

Here's how it arrived:








Pretty grotty in places, I think you'll agree, and lots of surface corrosion on both the alloy arm and lots on the brakets.


First thing I did was dismantle and take the brackets to a local powder-coaters. That's the easy part to get them sorted.

But the arm itself I really had no idea how to tackle it.

First attempt was with a DA polisher (DAS-6 Pro+) and small cutting pad with Meguairs metal polish. It kinda worked OK, but it was taking too long to remove the corrosion on the alloy and really caked up the pad. It did start to make a real shine on the alloy, though - so this gave me confidence of getting a decent end result. I also tried a bodywork cutting compound as an experiment, which also worked, but not as well as the metal polish.

The next idea was to get a bit more aggressive and so decided to break out the wet and dry paper and tackle the underside of the bar, so that if it didn't work or I really fogged it up, it wouldn't normally be seen.

Using 1200 grit, wetted with de-ionised water, started to work really well and knocked down the corrosion on the bar really quite successfully. Then a tentative pass with the metal polish using DA polisher took out all the light fogging and brought up a really nice shine.

Here's the end results:










It isn't a "perfect" finish, but neither was I aiming at one. What I didn't really want was for the fitted item to look far too far out of place. The car is far from a minter in terms of cosmetic condition, so a perfect item would look far too incongruous.

This will look just right on the car, I think. The alloy still has remnants of pitting from the corroded areas, but that will fit just fine in the engine bay...


One last thing, though. There was corrosion on the surface alloy right up to the very edges of the Cusco Sticker. So I decided to remove it to get at the entire area. It came off in one piece, which is when I discovered that corrosion had previously gotten right underneath one end, and that a previous owner had used some kind of adhesive to re-attach the sticker.

The sticker itself cleaned up quite well with Sticky Stuff Remover and flatted out quite nice by running it over a metal edge a few times.




Question now is whether I reattach the original sticker?

What product would be best to adhere it to the alloy?

It could be flatted down really well using some compression over the top of it to get it to bond flat, using a heap of tie-wraps for example, to get a high pressure onto a flat flexible cover that presses the sticker flat to the metal, but have no clue what adhesive would be suited to the task?

Alternatives would be to just leave the logo off, or get a new custom Cusco logo cut from vinyl?


I'd appreciate any suggestions on the sticker/logo.
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Old 01-02-2020, 10:49   #2
McGoo60
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Cracking job!, could you use some very thin double sided tape cut to size, it would stiffen up the sticker a bit and should stick well?
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Old 01-02-2020, 11:40   #3
gordonm
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Nice job!

Here is an option for you with regards to the sticker
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Old 01-02-2020, 11:57   #4
Rampant
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Quote:
Originally Posted by gordonm View Post
Nice job!

Here is an option for you with regards to the sticker
That's a great option...

Like it, thanks for the link

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Je cherche l'orgasme d'auto
J'ai trouve l'orgasme d'auto
C'est une evo VI bleu par le Rountree

***Go soothingly on the grease mud, as there lurks the skid demon***
//// Do as you OUGHT, not as you WANT ////
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Old 01-02-2020, 12:15   #5
gordonm
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Quote:
Originally Posted by Rampant View Post
That's a great option...

Like it, thanks for the link

No problem! I did the same when I had my Cusco front Brace powder coated.

Not identical to what you had but at least it's a genuine Cusco sticker
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Old 01-02-2020, 12:50   #6
Lee-C
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Ive been looking for cusco stickers since i refurbed my 4 cusco braces, thanks for the link.
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Old 04-02-2020, 09:05   #7
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I know Dave Cee replicates oem stickers on parts he 're furbs. You'd struggle to tell the difference once they are fitted. Might be worth a pm?
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Old 04-02-2020, 11:09   #8
Dave-Cee
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I only have a monochrome laser printer so can only do the silver stickers with black or black on single colour vinyl.

Not something I do a lot of as its time consuming doing the artwork in Illustrator etc.
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