I get order of one off all aluminum Toyota 2000GT

I want show up this big project to you.                   I removed body from frame and checked all dimention.

My idea was make just out side panels by aluminum but original steel body was very poor and I decided make full body!(I'm stupid).

Long time I made aluminum bodys for show or concept but those were just shell and had no inner panels.

This project will be make like production model.

Removed  body from frame.

Start making floor panel.

Try put on frame,just fit!

This is driver side floor panel.

Full floor panels done and waiting weld together.

Weld together,it beautiful?

Start making side sills.

I making body frame by aluminum square tube. Also make wheel arch.

Door skins

Door and other outer panels.

I made 3 pieces roof panels and weld together but Idid not like because two roof frames leave under roof panel.

Fainally I remade single piece roof panel and cut off roof frames.

This is most difficult shape of Toyota 2000GT. 

I made  Rear panel by just wooden hammer. It was hard job with out wood bug.

This is high light of this project!

Tilt hood,I made additional frame for supported radiator,oil cooler and tilt hood.

Tilt hood hinge has two different shape arms. 

These are rear panel and rear fender.

I made tail gate by 0.050 but remade by 0.065.

This is new tail gate by 0.065.

This moment tail gate panel is over size than openning and I will cut off to just fit on openning.

Also I made hinge made by aluminum.

Now I weld quater panels.

This is inner panel.

I made both side engine bay walls and inner wheel archs.

This clum shell hood use for my next projectcar KAI 3000 Spyder too.

Start paneling on hood frame.

Radiator mount on sub frame.

I'm making door panel,this is inner panel.

This is outside,outer skin weld on here. 

I made access holes on panel.

I put extra structure and mounts of window rail and regulator system.

Side bar is not impact bar,this is hold outer panel

I made pockets on door and body for set door latch.

Doors are perfect fit on body.

It was so hard to lock system or crank window system put in narrow door but I made it.

Door outer panel on it!

Tom cutting edge for perfect fit! 

I made front fenders and grill,I welded small lip on end of fenders for fit headlight lens.

How about fitting?

I made Toyota 2000GT's identity T bar in grill by aluminum and wider than original.

I made headlight bowl.

These are roof liners.

Front wheel arch inner panel.

Finished side sill.

Almost finish detail work.

New design front winker.

Also I made rear reflectors with same design too.

I made hood latchs and hot air outlet louvers on coner of hood. 

I found rear taillight bezel are little different right and left! and I reform rear panel.

Also front wind shield has not same curve right and left too,and changed A pillar angle and shape.                                                                  It was not easy job but almost finished detail work

How about body work?

I made mount of wiper motor and set up wiper.

I set up fuel cap on rear left fender.

I made polished aluminum trim for windshields.    (Original were chrome trim)

I set battery tray on new position.

Removed body from frame for weld under body and done complete welding.