Hey all... Here are some pics of the FC ute.. This was built as  tribute Ute to the neighbours FC Ute... They think I'm nuts but there is no suprises there....
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_1.JPG)
A bit worse for wear. Came with red motor (stuffed) and five speed (alloy case - did not use). HR front and rear ends... all there mostly but in poor condition . Purchase price $1200 from wreckers...
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_RAW_1.JPG)
Here you can see with the tailgate down it has had a very hard life... the tailgate was so bent it had some wood and packers to give a level (?) surface.. Had been used as a motor bike carrying Ute...
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_RAW_2.JPG)
With tailgate up it looks solid enough -but was very badly damaged and full of bog...
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_RAW_3.JPG)
The right side was no better than the left.....
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_RAW_4.JPG)
Lovely interior shot... came with no seats but plenty of rust. Note crappy trans tunnel...All what you see here was entirely scrapped.
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_RAW_5.JPG)
Beautiful engine bay... With out the engine and box... This ute had just been through a flood Engine was stuffed ....
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_RAW_6.JPG)
This tail gate was repaired as a bet that I couldnt.... Should not have risen to the bait....Took 472 heat shrinks and a whole three days to get right. I unpicked the frame work and repaired everything.... then welded it all back together. Here I am trail fitting it to make sure it all was straight and happy...
(http://www.fefcholden.org.au/forum/attachments/FC__UteTailgate_repair_1.JPG)
Here  you can see I had started to remove rust from the sill and the 1/4 panel... It got much  much worse than this. Also I started cutting a sedan door to suit (note frame removed). This door was not used in the end .. to much rust ...
(http://www.fefcholden.org.au/forum/attachments/FC_Ute_side_repairs_1.JPG)
Harold is peering through waiting for me to push it inside so he can steer it... Note the sill section I have cut out of a sedan wreck ...Nothing is wasted here...This was ultimately oxy welded in... Repairs to the rest of the inner sill have been effected already .
(http://www.fefcholden.org.au/forum/attachments/FC_Ute_side_repairs_2.JPG)
New tailgate skin fitted. Note door on left side even though its the same colour as the one in previous shots I went to Dalby and bought this one. It was burried 6" in the black soil and was not rusty! Amazing... .Also the sill in the back you can see was a repro one that was only good for small sections.... Tyre door was not used ...I ended up buyng a very good 'Glass one... I am glad I did as it is always full of water and crud now its on the road...
(http://www.fefcholden.org.au/forum/attachments/FC_Ute_side__and_tailgate_repairs_1.JPG)
Ready for sand blasters. Subframe and everything else removed except for diff... Jockey wheel made up to support the front...
(http://www.fefcholden.org.au/forum/attachments/FC_Ute_ready_for_blasters_1.JPG)
Another view ... Ute looked pretty solid at this stage.. I had done some repairs but decided it was too hard working around all the rust...
(http://www.fefcholden.org.au/forum/attachments/FC_Ute_ready_for_blasters_2.JPG)
Back from blasters.... Mounted on body pallet for ease of shifting...Drum of steel bits is for counter balance
(http://www.fefcholden.org.au/forum/attachments/Back_from_the_blasters_1.JPG)
Some repairs started again and holes in fire wall filled.
(http://www.fefcholden.org.au/forum/attachments/Back_from_the_blasters_2.JPG)
Another view...Although you can see the mig in the pic - I mostly use the oxy.....
(http://www.fefcholden.org.au/forum/attachments/Back_from_the_blasters_3.JPG)
Here you can see the WB Ute trans tunnel ready for trail fitting. This is oxy hammer welded into position . A nice sized tunnel and is the most common way I modify most cars using a HQ - WB trans tunnel. I sit it over the floor and mark out where to cut... This is a two person operation and most avoid me when they see I am about to do this....Wife normally helps with this one . I have her trained in this ... She gets under the car with a dolly and a bucket of water to cool the dolly down... Complains of burns but sticks with it any how.... She's great...
(http://www.fefcholden.org.au/forum/attachments/Trans_tunnel_trail_fit_1.JPG)
This is where it gets really scary... That is the entire rear of the floor removed... note self draining ability in these old utes....
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_floor_1.JPG)
Here you can see the rust repairs I have done to the door pillar and sill on the front . floor is ready to be dropped out
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_floor_2.JPG)
Here is the view from within ...rust as far as the eye can see...
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_floor_3.JPG)
Here is the new and the old. I have cut out a floor from an FEsedan wreck I was given . ( I was doing this on that famous sept 11 ) . This floor need repairs too and was an easier operation to do this out of the car . You can see where I have been here . Floor braces under neath had to be replaced too with good ones. A very lenghty repair here....All is sand blasted and etch primed with wattyl black etch....B4 welding braces back in etc...
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_floor_4.JPG)
Entire inner and outer sill was rusted... This was removed completely.. At this stage I considered seriously scrapping the entire project.... I was fast running out of Ute! Perserverence was running mighty thin... Th ewhole thing was getting very floppy and there was no wher to add bracing to that would not get in my way. I flipped the ute on its side to stop it from waving in the breeze...
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_sill_1.JPG)
I cut another rusty sill/pillar corner from a doner car and painstakingly over 22 hrs commenced a operation involving removing a small section hand fabricating a new peice, oxy welding it into place and removing the next rusty peice... this is made up of dozens of peices ... all hand made and metal finished .... very time consuming and very finnicky. Here you can see the old and the new... the old is about to be cut out using a reciprocating hacksaw...
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_sill_and_pillar_cnr_1.JPG)
A close up of the pillar cnr. This shows the inside of the item . all internal bits have been faithfully reproduced as well .... Note where the subframe bolts on... When all was said and done it fitted perfectly...
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_sill_and_pillar_cnr_2.JPG)
the entire sill is fitted inner and outer from doner vehicle ( EK actually). Even though its not seen I also replaced the bracket bits that tie it all together. most would not bother but I want it right... am obsessed with perfection at this point and am not nice to be around ...madness continues...
(http://www.fefcholden.org.au/forum/attachments/Rust_repairs_to_sill_2.JPG)
Excellent Photo-Journalism Streetneat,
Question: I'm going to re-spray my Wagon in 2 pac.
If I discover any sections needing fill, do u recommend etch priming the bare metal first? then filling, then priming then paint.
Is Wattyl black etch the one to use?
Thanks for your input to the site
Matt F
The subframe has been powdercoated( Very poorly! >:() and the engine has been built. Trail fitting taking place here
(http://www.fefcholden.org.au/forum/attachments/Subframe_and_eng_trail_fit_1.JPG)
Trail fitting continues .....Notice no powder coating under outrigger !... I was mightily pissed of at this and I wont mention the name of the LOCAL powder coaters that pissed me around , I just post pics of their poor quality control... I dont recommend them and I tell others of their poor work . They never wanted to remedy the work and it was too late once it was fitted into the car.... I just painted that area. The price went up as well to add insult to injury!... and they lied to me about the powder priming they reckoned they did  as well. You can plainly see that  there is bare steel there ...no priming. Also the subframe had powder coating over grease .... Crappy job that I had to re -do myself with two pack satin  Black.... Moral: use the people you have always used . dont fall into the trap of convenience... ???
(http://www.fefcholden.org.au/forum/attachments/Subframe_and_eng_trail_fit_2.JPG)
Doodle ( Graham the kiwi painter that works with me) gets caught in the frame... Handsome bloke he will tell you ... let you be the judge of that!....
(http://www.fefcholden.org.au/forum/attachments/Subframe_and_eng_trail_fit_3.JPG)
A door and a guard in bare steel The door was made from a sedan door on this side... I sandblasted them and run the 3m clean and strip disc over the areas that were starting to rust again . These then get EPOXY PRIMED witha high quality very exspensive two part ( not two pack ) EPOXY PRIMER ( glasurit) You CANNOT put this stuff over acrylic etch . The inside surfaces with wattyl black etch is covered with a normal two pack primer (glasurit again in this case)
(http://www.fefcholden.org.au/forum/attachments/some_panels_in_bare_metal_1.JPG)
A second FC mud guard was obtained that was in better nick than the one I started with .. so I repaired it as well. A panel shop snapped up the first one for $350 for an insurance job....I get asked for these all the time and they are not getting any cheaper.. I get annoyed at guys that offer me less for panel beaten guards and other good quality parts ... so be warned! I would like to see them get it done better and cheaper... ::)
(http://www.fefcholden.org.au/forum/attachments/some_panels_in_bare_metal_2.JPG)
Its all coming together here . I have ommitted a lot of boring rust cuting stuff Note the tyre door fitted and tailights squared up...All that black etch has to come off. Its the way it comes back from the blasters- so I cant do much about it... its full of grit as well, so I would not want them putting my epoxy primers on!
(http://www.fefcholden.org.au/forum/attachments/Trail_fitting_of_panels_3.JPG)
This is a process known as oxy hammerwelding. I am fitting a new fabricated bottom section to the lower of a FC guard... this one did not end up on the ute... but shows how I repair panels...
(http://www.fefcholden.org.au/forum/attachments/Andrew_welding_1.JPG)
Starting to take shape FE grill is used for holding the front together only. Brakes and front end have been rebuilt and most mechanicals finished..
(http://www.fefcholden.org.au/forum/attachments/Trail_fitting_of_panels_4.JPG)
OK..... Keen observers will note that the right guard is an FE - Until I could find a FC guard ... which eventually I did ... none of this front was actually used... There was nothing wrong with it ... just found really mint panels on another car I bought later in the projects life.... Bugger...
(http://www.fefcholden.org.au/forum/attachments/Trail_fitting_of_panels_5.JPG)
my good mate Marty Dean Making the 2/12" Mandrel Stainless exhuast... Boy this thing is Loud! :o
(http://www.fefcholden.org.au/forum/attachments/MARTY_exhaust_building_1.JPG)
Tig welding is an exacting process... Marty makes this look easy .. I am often asked what the machine is in the background ... its a guillotine....
(http://www.fefcholden.org.au/forum/attachments/MARTY_exhaust_building_2.JPG)
Maybe you should use the Guillotine on the Powder-coater!! ;)
just a question here strretneat
if all this work had been contracted out to a panelbeater
cause we were panel beating skill challenged what would the approximate cost have been ???????
cheerrs kiwi -panel beating skill challenged bird
The ute is assembled and panels gapped. All surfaces are coated in epoxy primer... Bog work where necesary is done OVER the epoxy primer... This acts as an adhesion promotor and is far superior to Bogging over bare steel where it can sweat and delaminate. As a mater of interest I dont use much bog... I panel beat then after epoxy priming I will use a final glazing putty for the minor imperfections. All rust repairs are first primed and then given a thin smear of fibre glass bog to ensure that any moisture cannot get through to the bog work through tiny pinholes in the welding process.. Bog is hydroscopic so this is a very important step to take...
(http://www.fefcholden.org.au/forum/attachments/assembled_ute_2.JPG)
Another view of the Ute no bog work done as yet here.... Notice the weld on the lower front of the 1/4 panel near the door....
(http://www.fefcholden.org.au/forum/attachments/assembled_ute_1.JPG)
The floors and tunnel have been done the dash is a FE item I hate the plastic crap on FC dash's... Steering wheel is restored as is the colum which is shaved of its shifter... Note how the tunnel fits the floor... I later re did the welds on the floor to dress them up a bit better ... I metal finshed BOTH sides of the floor as well as fabricate a member to run under the floor to continue the sub frame bracing... To answer KIWIS Question this whole project consumed 16 months and $80 000 0f shop time...@ $50/hr Net material cost was $15 000 approx for all the parts put into the project... now you might know why I wont sell my cars.....
(http://www.fefcholden.org.au/forum/attachments/Iside_of_Ute_-_dash_and_tunnel_1.JPG)
Not the clearest of photos but shows the dash restored and painted ( parts of it anyhow)
(http://www.fefcholden.org.au/forum/attachments/FC_Dash_-_painted_1.JPG)
The green primer is the Glasurit epoxy primer the grey is PPG epoxy primer... I normally dont mix brands but as I know the products are compatable this is not a problem... ;)
(http://www.fefcholden.org.au/forum/attachments/Ute_in_primer_1.JPG)
another angle - ute can be started but not driven
(http://www.fefcholden.org.au/forum/attachments/Ute_in_primer_2.JPG)
Front floors being tackled... I took a break from these repairs and did other things to the ute... It had to be done eventually.. All was oxy hammerwelded with the wifes assistance...
(http://www.fefcholden.org.au/forum/attachments/Front_floor_repairs_1.JPG)
The ute has now been fully dissasembled  and loaded back onto the body pallet. It has been Spray polyestered (spray bogged) to find any irregularities and then epoxy primed one last time. That was then covered with this tinted blue primer and is ready for final rubdown.... :P
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_1.JPG)
Rear view... the floor has been made and this will be covered with Aqua fleck along with the rest of the load area... All the load area had to have rust removed as well... This is getting to the more interesting stage now... The black paint you see is a guide coat for rubbing down. This allows us to make final repairs and adjustments to the utes surfaces...
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_2.JPG)
Graham is checking for minor details after it has been wet rubbed... Note ute is now on axle stands for stability and ease of access to all surfaces to be painted.
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_3.JPG)
All is now carefully masked off. This is to ensure that any dust is kept out of the paint from the inside....
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_4.JPG)
Base coat colour being applied by GRAHAM... 8)
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_5.JPG)
Painters DO bend their backs .... Sometimes... Graham is careful to get plenty of coverage....
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_6.JPG)
Its important to have the vehicle at a comfortable working height. Note the protective gear for two pack painting. At this stage this is only the base coat and the clear is the two pack part. This is why two pack cannot be sprayed at home . Very carcenogenic with free organic isocynates. Is only a hazard in spray form. Not a problem when its dry nor is the dust ... the dust can cause irritations and other problems ... so best left to the professionals...
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_8.JPG)
All is now painted and dried .... 8)
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_9.JPG)
Another view....note guards in back ground outside -they have been stippled on the inner surfaces.....
(http://www.fefcholden.org.au/forum/attachments/Painting_of_ute_10.JPG)
This is worth getting X-cited over... The rebuilt 186s with celica five speed....
(http://www.fefcholden.org.au/forum/attachments/eng_ready_for_fitting_1.JPG)
Well this is how I put em together.... I fit the engine and box to the fully assembled front...not unlike Holden did.... This is moved around on the engine crane...
(http://www.fefcholden.org.au/forum/attachments/eng_ready_for_fitting_2.JPG)
At this point I have a video I made of this final assembly If any one wants a copy I will be getting some done. Its a bit amateurish but effective. Cost is $25 plus postage (no gst) goes for an hour or so... shows full assembly to turn key. Subframe going on here... ( after I repainted the jolly thing >:(!) I will give more details elswhere of this video and time of availability expressions of interest welcomed at this stage....
(http://www.fefcholden.org.au/forum/attachments/Final_assembly_1.JPG)
Andrew
What a great thread a full diary of work in progress. I will save any questions that may arise untill you have completed your resto.
Believe me I will have plenty of questions especially in relation to rust repairs and welding.
This is how Holden did it ... Steering is installed and the whole lot lowered onto the driveline/suspension....
(http://www.fefcholden.org.au/forum/attachments/Final_assembly_2.JPG)
Another view... this whole processs took less than twenty minutes... Holden would probably sack me for taking so long........ ??? B4 any of this took place I sprayed the under side in stipple finish black.... as well as seam sealing all joins and rustproofing any thing that stood still long enough....
(http://www.fefcholden.org.au/forum/attachments/Final_assembly_3.JPG)
A big leap foward here.... ute is nearly finished and is going to trimmers... this is the only time it leaves the place other than for rego... All assembly is covered in video... Only time it sees a trailer as well....Brakes are not hooked up and wiring not completed... Was a bugger pushing it aroud at the other end ... :-/
(http://www.fefcholden.org.au/forum/attachments/Finnished_ute_going_to_trimmers1.JPG)
Finished eng bay ....Note use of recessed radiator alows for fan and even a fan boss... This makes the red motor installation look factory.
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_ENG_bay_1.jpg)
A look inside... FB seat with cut out 4 shifter... Navy blue retractable seat belts custom ordered ... Cd player in glove box plays its tunes through the single 6x9 speaker in original housing ... modern speakers are a perfect fit here...
(http://www.fefcholden.org.au/forum/attachments/FC_UTE_INSIDE_1.jpg)
The finished article and the ute that inspired it in background ... It ( the old ute) still rusts in peace today across the road... I used the interior light lens from it and some other bits were used on the FC Coupe....
(http://www.fefcholden.org.au/forum/attachments/Tribute_ute_and_its_inspiration_1.jpg)
A significant moment ... here are the freindly neighbours that belong to the Old ute I took inspiration from The last time Mrs Zcolsay sat behind the wheel of a car was over thirty years prior ... she sat in behind the wheel of the old ute hoping to learn how to drive... she quickly abondoned this idea and the Ute soon ground to a halt where it sits today... Ironic I thought as I took this picture . here she sits beaming her enjoyment at trying out my Ute for size ... Her son Peter was also very impressed... Both think I 'm quite mad to do this tribute ute but childhood memories drove me to it... This moment made it all very worthwhile...
(http://www.fefcholden.org.au/forum/attachments/A_signifificant_moment....1.JPG)
Im sure they think I am presenting them with the Ute as a gift... had to wrestle it back from them
(http://www.fefcholden.org.au/forum/attachments/A_signifificant_moment....2.JPG)
Same utes .... Different lives....
(http://www.fefcholden.org.au/forum/attachments/A_signifificant_moment....3.JPG)
If these two could talk I imagine there could be some tales swapped.I used the old ute for a template for the tonneau cover for the correct number and place ment of studs....
(http://www.fefcholden.org.au/forum/attachments/A_signifificant_moment....4.JPG)
mate thats one very nice machine,i would love to have the patience and money to go this same way but budget and impatient person that i am,i will be just fixing whats needed to make roadworthy,
that engine bay looks really sweet
Streatneat
I thought I had seen your ute b4. I think it was at Banyo and most definantly at knights soccer club swap. I did admire your car that day. It looks even better in the flesh.
Great stuff,from what ive seen,I reckon you could fix that other ute in the photo with yours.Count me in for a video.
Cheers Geoff
id like a copy of the video too please and prehaps bout 3 weeks of your time next time ya missus and ewe come HOME ;D ;D
Hi streetneat,
What can I say but UNREAL, Its a credit to you. :o :o 8)
Regards,
Steve.
Hi Streatneat,love your ute, and what a great story. Tony :)
Hey Streetneat,
Having completed your story, I think u have answered all the questions I have.
Excellent reading!! Good technical info in a very fun to read form.
I wish I had school teachers with your skills when I was much younger.
Keep up the posts!
Matt F
Hey Ret does he make guru in one day! Brilliant.
emu i agree
havin streetneat on the forum is a real asset to us all
was a bit suprised ewe went to school but emu
The video is something I need to work on a bit. I have to edit out the gaps and pauses as well as include some other footage... I will be approaching a professional video editor and this we expect will set me back some $... I will advise on a release date... Most would be happy with it in its pesent format but there is a whole range of media packages I will be working on..(Books .videos/dvds etc...) and I need to make it look a bit more professional...Cheers streetneat ... thanks for all the response...