FE-FC Holden Discussion Forum

Hi all, new to the forum and I've purchased an FC ute. We travelled from Gympie QLD to Gawler in SA and towed her home. The ute has bad rust in the rear floors and chassis rails. The doors aren't to bad and the front guards need a lot of work. Also the front floors and front floor cross member have bad rust and will need replacing.
So the plans are - 304 Holden V8 with 4 speed auto. Ford 9inch diff with 3.5 lsd. Also planning on an after market front end and triangulated 4 bar rear suspension.
So we'll see how close I can stick to the plan.

Can someone advise on the best way to add photos to my post.

Thanks

Mal

(https://i61.photobucket.com/albums/h41/cop111car/11a_zpsoq6j7po6.jpeg) ($2)

Hey Mal,

Welcome to the Forum. Looks like you figured out attaching pics!

Lots of friendly and helpful folks here, and lots of previous build histories to check out.

Good luck with your project.

cheers
RET

Hi Mal
Welcome to the forum lots of good people here and great help when needed.
Have you thought of using a VN,VP, VR LSD instead of the 9 inch, I've used them in my V6 FC sedan and my V6 EK Ute; I recently fitted a SBC 305 and a 9 inch to a friends FC sedan and have to say that I thought it was an overkill along with being quite a large diff of course we call it customizing and it is every-bodies own choice but just my 2 bobs worth.

If you are going to buy a donor car for the engine and gearbox etc may be worth also using the diff.

Good luck and I hope we see a lot of pictures of your progress.
Neil

 

Thanks guys, Neil I already have the 9inch fully rebuilt and the housing, the diff is a bit of overkill but I have a 9inch in my FB also and I just like using them.
I have bought a VT Calais as a donor car for the motor and box and any other bits I need and it has an independent rear end so I couldn't use that.

Just thought I show the cars I already have in my collection also-

My latest finished build is my 57 hardtop - took 8 years

(https://i61.photobucket.com/albums/h41/cop111car/IMG_1602_zpsvstkhluz.jpg) ($2)

Before that was my FB sedan that one was finished in 2008

(https://i61.photobucket.com/albums/h41/cop111car/vv%20142_zpsbmvbro0w.jpg) ($2)

Then before that was my trusty old 67 Mustang -  its been done now for about 19 years

(https://i61.photobucket.com/albums/h41/cop111car/4650584_zpsoma1m8rd.jpeg) ($2)

Hi Malcolm,
I remember following your build of the yellow FB.., and look forward to hearing about this one.
Cheers
Clay

Sent from my SM-G973F using Tapatalk

Hi Mal
No drama as I said just my 2 bobs worth and as Clay said I have read your build on the yellow FB that is a really nice car mate and well done, look forward to seeing the Ute
Neil

Just a couple of photos of when she first came home

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/11d_zpssvut2v9d.jpeg) ($2)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/11b_zps7k6av3bc.jpeg) ($2)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/11h_zps2rqaf1kp.jpeg) ($2)

Mal

Well the spare wheel door doesn’t look too bad....8)8)


Sent from my iPad using Tapatalk

Big job! Looking forward to watchinging you bring her back to life.

Welcome. Can't wait to see the progress pics

Sent from my G8342 using Tapatalk

Bit slow to get into things with the ute as I still have other projects that I'm trying to finish as the same time also.
Anyway - to start with the LH guard, I bought rust replacement panels for all the corners. The headlight panels were so far off fitting I ended up making my own for the top and used some of the aftermarket for the inside.
Original front headlight section

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_0292_zpsjwoqxmz3.jpeg)

New side panel made and fitted

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/5_zpsu2hc0nl2.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/8_zpshk8wyptd.jpeg)


Next side

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/15_zpswrggtdw8.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/16_zpsfnsjrqwf.jpeg)


Top, front and inner done

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/20_zpsaco77id4.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/19_zpsfyhrkoli.jpeg)


Next was the top rear section
Original

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/23_zpso5lovzdk.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/25_zpsgpygytra.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/29_zpsolf8exbm.jpeg)


And finally the lower section

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/32_zpsafzyhzly.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/34_zpsttebqmiv.jpeg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/37_zpsgspdyzb6.jpeg)


Thanks for looking
Mal

Genius at work.  Whose lower guard repair sections did you use?

You might need to transfer your attentions to the LHF wheel though . . .

Rob

Very nice work Mal wish I had half your metals skills
Neil

Wow off and running great work.. 

Your into it , I like your approach ,working the usual rust spots on the car ..going to love following this job ..Vern

Thanks guys, Rob all the panels I got were from Rare spares.

Mal that's swift progress by my standard and very tidy work on the headlight peak  no pull down on the butt welds. What's your secret?

Sent from my SM-G973F using Tapatalk

I'm a bit slow at getting the photos up on the site so it may look as thought I'm going ahead in leaps and bounds but its just catch up. Errol, no secrets just hammer and dolly.

Still trying to work out how to get the photos resized a bit smaller.

mal

Just a bit more from a few weeks back
My original tailgate

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/1_zpskikjqypc.jpeg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/4_zpsktoohyfb.jpeg)


My original tailgate was a bit worse for wear and I had planned on rebuilding it with a new skin for the inner ribbed section and I got a new skin for the outer.
As I found the outer skin is flat and looks like crap.
I ended up tracking down another tailgate that a bloke had sitting inside an old wreck for the past 20 years that didn’t have a rust hole in it, just covered in surface rust with a few dints in the outer skin but the inner looked as if it had been run over with a truck.
So I carefully removed the outer skin and straightened up the inner skin then cleaned off all the surface rust with hydrochloric acid.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/f_zpsgtvomylo.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/d_zpsxvmiaczr.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/i_zpsnfaiptsq.jpg)


I also took the hinge reinforcing plates off so I could clean behind them to and to make sure I got all the acid out of it.
I made and fitted a new reinforcing section to go across the centre also

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_1958_zpsiehdxuzu.jpeg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_1960_zps3q3oif1d.jpeg)


Then a trial fit

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_1961_zpsiiigpivz.jpeg)


Next on the tailgate is to weld up a few holes and straighten out a few dints and refit the skin

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/22_zpsuzrzi5rx.jpg)


Mal W

Hydrochloric acid? - Danger, Will Robinson.

Hydrochloric activates the metal surface and makes it rust before your eyes.  Even after you think you've cleaned the last traces of the acid off.  And the fumes get in everywhere and promote corrosion.

Phosphoric acid (aka Deoxidine) is a much better product to use.  It passivates bare metal surfaces.

Rob

I've used hydrochloric acid a lot on very rusty metals in the past and always after thoroughly cleaning it I treat it with deoxidine and never had a problem.

Mal

OK.  Your experience of HCl is better than mine, then . . .

Yes the flat tailgate repro skins. Put one on my FB Ute, the inner of which was pretty good. Foolishly I hoped that the skin would form a curve to match the inner. Perhaps if I had put some pie cuts in the upper lip but no. The new skin straightened out the inner of course. Still looks pretty good to the average punter like me. It's only an FB after all.

Sent from my SM-G973F using Tapatalk

 It's only an FB after all.
                    EK
CLAY
 Bite your tongue :P

Time to attack the RH front lower A pillar section – did the worst side first.

Cut most of the rust out just leaving enough to get the subframe bolt location.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_1990_zps7y70wjv1.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2099_zpsnzfj2fs3.jpg)


Stated making a section at a time. Each piece I made a pattern with cardboard so I could use it when I did the other side.

Started on the outside and worked my way in.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2102_zpsi6741xul.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2104_zps4jyzkv4e.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2106_zps26ih4k3q.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2108_zps7lweedvx.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2126_zps0iucnvm5.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2112_zpscvwdyizy.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2116_zpspo7zkp3t.jpg)


Now the inner section – new inner made. Don’t know if they originally had a crush tube in them but this one does now.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2124_zpsxfw4wsux.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2125_zpsykwizsv4.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2132_zpsjnkvlzci.jpg)


The old and the new

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2127_zpsxjdwxw8b.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2128_zps1v5wyidg.jpg)


Next the inner lower section

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2130_zpsrpryxuek.jpg)


And finally all welded together

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2135_zpsj5s5psgy.jpg)

Mal

All I can say is WOW  ;D ;D ;D

Regards
Neil

You are posting these photos in real time?
Because you appear to have done in a day what took me a couple of months . . .

Rob

Rob I've been on this for about 2 months, on my days off.

Just got the forum worked out and now putting up photo's to get up to where I'm at, at the moment.

Only just finished the lower A pillar yesterday.

Mal

Mal,

Just imagine what might happen if you are forced to self-isolate inside the workshop for two, three, or four weeks.  As a public health and safety measure, you understand . . .

There are now so few people still at work that I'm hoping the powers that be will shut the doors, and then . . .
I can spend a couple of weeks uninterrupted on a project that's been languishing too long in the car port.

Rob

Rob, I'd be pretty happy with that....

I was recently looking at all the different new front suspensions that's available and one popped up on the for sale site.
So its now in my shed
Front end from Rod Shop complete with power steering, lowered stubs, wilwood brakes.
Also a full chassis strengthening kit, that I won't be using and a tilt stainless steering column with shaft and unis.
Also a large trans tunnel that I also needed.

Pretty happy with that. Its all new, never  been fitted to a car.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2145_zpsjjgrmpjq.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2146_zpsydo1whwm.jpg)

That is excellent Mal, passion mixed with skill ,keep it up ..Vern ..

 Mal
 What is the power steering out of and is it modified to suit

Not sure what the steering rack is originally out of as it is supplied standard with The Rod Shop front ends.

Fantastic work Mal, the photo of the old “A” pillar section shows what was left of the strengthening block that sits between the outer skin and the inner sill. When I did mine, I was lucky enough to have most of the blocks left so I cleaned them up and fitted a cut down a piece of 50x50mm square tube and welded it inside then put a new piece over the top. By the way, your looks a lot neater finished job that mine!!

Nice work man, love it

Sent from my SM-G960F using Tapatalk

Next the LH front corner panel
Inside wasn’t to bad as at some stage someone had put a new outer end of the floor brace and done a repair to the inner part of the front corner. Just a pity it was all a crap repair.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_1984_zpsz39asbcg.jpg)


The outer section was a total mess

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_1986_zpsn0z816nh.jpg)


Started by cutting all the crappy outer section out

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2259_zpstzhrrq8o.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2261_zpsriykybl0.jpg)


Now to start rebuilding the corner

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2277_zpsmo89d4rl.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2280_zpsyxc1vxu4.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2284_zpswut0g3qb.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2292_zps16tc0cvs.jpg)



With that done I went on to fit the new outer floor cross member panel

And moving right along
I did a bit of cutting and messing around to get the new transmission somewhere close to where it needed to be before starting on the hump section part of the floor cross member that goes over the top of the transmission


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2346_zpsbthqut2w.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2347_zps0plymlp6.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2350_zpspqystzvw.jpg)

Lovely work Malcolm. FB sold?


Sent from my iPad using Tapatalk

Geez Mal not a lot of floor left there mate :o but by the looks of the work you have already done it won't be a problem for you.
Loving the photos.
Neil

Thanks Neil, no not a lot left. Nothing like a challenge.
Errol, still got the FB. Haven't even had any genuine enquiries on it either. I've set my bottom dollar at 50k, If I can't get that for it, it can sit in the shed with the others.

Continuing on with the front floor support.
Making the transmission tunnel

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2352_zps8mrpagnc.jpg)


(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2353_zps2zlrtupb.jpg)


Finally both front and back sections cut to shape of the tunnel

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2461_zpsmd9fpcjw.jpg)


Then I used cardboard shaped into the tunnel and fitted the front and rear tunnel sections to get the shape of the top of the tunnel

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2462_zpswnhpmbyc.jpg)


With the pattern made I cut out the top of the tunnel section, shaped it and fitted it into the tunnel and retrimmed the front and back sections to fit then started welding

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2464_zpsbtjvamlm.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2465_zpsz4zpx0uu.jpg)


With the tunnel all welded up I took it out to clean up the welds

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2467_zps33ylara8.jpg)


Once that was done I refitted the tunnel and welded it all together

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2471_zpsnwhcjbny.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2472_zpsjjnhqlnq.jpg)


All done for now just needing the underside of the tunnel section to be made and fitted. I may leave this open just in case I need to trim it up a bit when I trial fit the engine and gearbox.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2494_zpsxqxc6rfl.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2495_zpskzhgxgh9.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2499_zpsxlu3o6wp.jpg)

Brilliant, Mal.  It looks like you have a clamp for every conceivable application . . .

Rob

Lovely job Mal. I hope the trans fits.
Cheers
Clay

Sent from my SM-G973F using Tapatalk

Great stuff mate ,she lives again ..stay well Vern .

Mal mate   I was just looking at yesterday ..  Now you done one could you maybe make another .. ;) ;D

Looks really nice well done

Nice Mal very nice.

Amazing metal craft. There is so much talent in this group. Its amazing. Thanks for posting the fabrication sequence.

Sent from my SM-G975F using Tapatalk

Just spent a few day messing around with the RHR wheel arch repair.

I ended up getting a wheel arch cut from another ute. Started by removing the inner wheel arch part from the cut and sandblasting the section I was going to use.

So this is the wheels arch in its unrepaired state

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2555_zps8fhvafkv.jpg)


Next I cut out the rusted section and exposed the also rusted out inner wheel arch section

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2566_zpsmqxdxyr5.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2565_zpsgrp6wqs4.jpg)


I started by repairing the rust to the inner section first

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2572_zpsbxxmg6oo.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2581_zpsjnqr2kt2.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2577_zpsyuqrpk3t.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2578_zpsnsbfukjx.jpg)


Then to trim the new section to fit

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2569_zpsareiv6yj.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2568_zpspnw5pox9.jpg)


Then all welded in doing a small section at a time trying to keep the warping to a minimum

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2584_zpsrmpmluw6.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2585_zpseqoqlwms.jpg)


And finally all ground up and done

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2587_zps8zminovb.jpg)

Very nice work mate.

. . . I'd say you succeeded in keeping warping to a minimum.

Rob

Great job Malc. Yes the panel above would have been very susceptible to distortion. I’ve got to do the same repair on my EK van when I get to it. You did well to get a nice solid cut as this is another of the tailor made rust traps that the General kindly endowed us with.


Sent from my iPad using Tapatalk

Update time,

I made some adjustable car stands to sit the car on while I replace the chassis rails

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2640_zps5nmyq6vj.jpg)


I took the body off the roll over jig and got it all squared up on the new stands

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2645_zpsrvi1pru4.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2644_zpsfoble6dm.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2649_zps3otislwf.jpg)


To start with I cut out the rear wheel arches

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2652_zpsha8jpy0k.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2656_zps1zqvhnbw.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2665_zps04sshvvb.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2663_zpsvezi3s7t.jpg)


Then started on straightening them up, never seen so many dints

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2670_zpsoqcj4bks.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2667_zpse6aoqoxe.jpg)


Now just waiting for the new ¾ chassis clip to turn up from McDonald Bros Racing. All set up with triangulated 4 bar and coil overs with a new 9 inch housing mounted in it, and a set of Wilwood brakes as well.

See you took care to preserve the original rails and outrighutriggers Mal and wondering why, as seems like they will be replaced. I guess you just wanted to use them to keep the quarters braced in position.

Sent from my SM-G973F using Tapatalk

Yep you got it Errol, the original rails are just there to keep everything square and straight until I get the new chassis clip. The new chassis is narrower by 100 mm and will actually fit inside the original rails.

Ok, don’t want to spoil the plot but it’s pretty obvious, seeing you’re straightening the original tubs, that you are going to make it look factory at least above the cargo floor by re-using. I must say I like the idea. While it is desirable to be able to fit big rubber and still get nice and low, I’m not so keen on the sheet metal fabricated  wheel tub look in the back of a ute. Great stuff.


Sent from my iPad using Tapatalk

Yes I don't like the look of the fabricated tubs either, I'm going to put about 60 mm in each side and refit them so it has the original appearance. Not that any of the mechanical s will be original but the body will mostly be.

Lovely work mate.

Looking forward to more pics.

Great progress Mal.
sure is looking good.

Cheers Stewy   8)

Thanks guys.

Today I got the firewall finished.
Just a matter of a couple of modifications and filling a few holes.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2701_zpsugbgopmv.jpg)


Seems as how I’m not using the original wipers I decided to get rid of the hump in the centre of the firewall that it mounts to, and smooth it off so to speak.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2703_zps4ohmehuu.jpg)


To get rid of that I just cut across the edge of the hump and a couple of vertical cuts and then folded it back in.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2704_zpsudzoe51v.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2707_zpsv93z1jkw.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2709_zpsrl4z7wwd.jpg)


Middle section done

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2711_zpswoyt4eg4.jpg)


Then I removed the seem that runs across from one side to the other
And while doing that I recessed the left side of the firewall about an inch to give the motor a bit more clearence on that side.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2714_zpsm2ydp5cu.jpg)


Next I welded in the steering column plate and smoothed that off

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2715_zpsstozttid.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2718_zps4mdbvwvd.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2724_zpsyyspapkc.jpg)


Lastly a trial fit of the steering column

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2734_zpshnq8xw4z.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2731_zpsssqumeem.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2730_zpsnkstejn3.jpg)

That would be a WEEKS work for me  :o :o :o

WOW ! WOW! WOW ! ..I put the Winged bird and HOLDEN letters on the bonnet yesterday , mind you I was blinded by the glare off the 2pack super smooth , gleaming ,you could kiss it , spray job ….Vern ..

Hi, is the complete steering column from Mc Donald Bro’s ??   AL.

wow you are flying along looks great

What size tyres are you looking at putting under there. I may be able to help with what you are doing.

http://i5.photobucket.com/albums/y184/Fevanv6/story%20to%20tell/IMG_0201.jpg

http://s5.photobucket.com/user/Fevanv6/media/story%20to%20tell/10F35F39-3F86-469E-ADE9-CC19EDEA0BD4_zpsaprguulq.jpg.html

Thanks guys,

Al,
The front end, power steering rack, steering shaft and steering column is all from the Rod Shop.

Still haven't got the wheels yet, but was looking at 10x15 rear and 5x15 on front. Rear tyres I wanted was 285/40/15 but they seem to be no longer available so I guess it may have to be 295/50/15 if I still go with the 15 inch.

From memory I went 75 mm strip down the tubs and get 285’s in ok. So you may want to get the tyres on the rims to make sure of the tub size needed.
Cheers

Great job Mal she’s looking great.  AL.

JB, I like what you did with your spare wheel door.

Mal

Hey Mal, great to see you well and back at it. Your FB and Chev build threads were an inspiration.
Cheers, John


Sent from my iPad using Tapatalk

Update rounding up from the weeks work,

I got the brake pedal and under dash brake booster bracket mounted.
Brackets made, a bit of messing around but not to bad.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2728_zpsia7l4hqa.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2729_zps9vc07uvj.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2737_zpscxi9uhdz.jpg)


And, with the bracket in place. Will be able to fit a small booster in there no problems.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2741_zpsy3nwna7o.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2743_zpsh8h3jtme.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2739_zpsirx4vadp.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2740_zpspani52r8.jpg)


Then a couple of bits I wasn’t quite happy with on the firewall. Having filled in the holes in the firewall I wanted one side to mirror the other side so it looked all even so to speak.

The bits I wasn’t happy with are in the next photo where the red arrows are. The ID plate area and the lower horizontal rib that goes to the edge on one side but not the other

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/firewall_zpseuonp5h1.jpg)


Reshaped the RH side to look like the LH side

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2745_zpswcctjel4.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2746_zpsiygprugx.jpg)


Then the lower rib section

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2749_zpssnrxluih.jpg)


Now that looks better

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2750_zpsrgax3xxz.jpg)


But wait, there’s more

To finish off the last half of my Saturday I gave the donor engine a pressure clean and relieved it of its outer shell. :D

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2752_zpshfqkeerz.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2753_zpsbabg3e0r.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2768_zpsae27vllg.jpg)


And tomorrows another day.

great work Mal ..great progress ..hope to see the car one day ..Vern

Mal,

It looks like the ute's previous owner did the famous "Old Holden Waltz" a few times, judging on the the inscription on the passenger's side cowl.

And the firewall interests me.  From the inside it looks like a textbook allergic reaction (think hives), but I gather they're hot shrinks.

The brake booster runs east-west under the dash?  So the pedal box will have a bellcrank or similar arrangement inside?

Rob

Hey Rob, yes the hot spots on the firewall are heat shrinks. The booster runs sideways as you said and works with a vertical shaft and rose joints. Its an engineered unit I bought over the counter. The last one I did I used a setup out of a Hiace van and that was a lot more messing around but still works well.

Cheers
Mal

Well my holidays are over and its back to work on Tuesday. Pretty happy with what I got done over the past few weeks

I ended up spending a few days on the front subframes welding holes, removing seams and repairing rust

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2851_zpskz6e0xeg.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2852_zpsuzuuabsb.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2854_zpsvlek0eos.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2855_zpsetbuwqoc.jpg)


Then with fingers crossed I attempted to refit the subframes to the body. 

Can’t believe how easily this went back on. So glad nothing moved that I had braced while I was rebuilding the front floor cross member

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2866_zpsxxn9btee.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2869_zpsijm1qxuh.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2872_zpsyjw9fegh.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2878_zpspgwurkxa.jpg)


So happy with how that went back on I couldn’t resist trying the front end to. Still have to get the new bushes for the front end as well.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2881_zpsoyfqeawa.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2882_zpsb0oy5x2n.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2885_zps3sqevxcv.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2886_zpsmezhc53l.jpg)

Happy days Malcolm 👍👍


Sent from my iPad using Tapatalk

Well my timing was perfect, I went back to work on Tuesday after 5 weeks leave and my rear chassis clip turned up Wednesday.
Pretty happy with how it turned out to. Fully adjustable top and bottom control arms and new diff housing. Also got the Wilwood rear disc brake kit to match the front to go with it.
Now just have to find the time to get started on fitting it.

A few pictures

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2895_zpsxa9es5xw.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2896_zpspwb4vxfh.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2897_zpsbhaz5lqt.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2899_zpshzd3lij9.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2901_zpsuvm1sz9f.jpg)

Looks awesome mal

Sent from my SM-G973F using Tapatalk

Where did you get the rear clip from? I’m interested in who can bend the 100x50 to make a chassis

JB the chassis clip is from McDonald Bros Racing and its 75 x 50 x 3 box.

Mal

Let the fun begin, fitting the new chassis clip.

Now to get the old rails out. There wasn’t much left to cut out due to having already cut out the entire floor and inner wheel arches.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2661_zpsao3ehhgo.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2662_zpszfp0wal8.jpg)


Before removing the original rails, I had to work out how to relocate the new diff into the original location once I'd cut everything out. As I didn’t have a chassis bench to attach the car to , this is my method. I welded 2 - 25x25 box sections across the top of the rear section, side to side and then welded another 2 pieces on each side going down to create a V section under the original diff housing. Once I removed the original diff the V sections would stay there for the new diff housing to sit in to get a location, while I fitted the chassis clip in where it should be. This would get it pretty close to where it should be and with the new top and bottom control arms being adjustable, getting it spot on would be easy with a wheel alignment.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2865_zps6cwyfywc.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2864_zpstis91fx8.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2863_zpshzcy8lvo.jpg)


Not a lot of work getting the old rails out, only 3 spots where I had to cut to get each rail out.

Front

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2957_zpsaae08lfz.jpg)

Middle

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2956_zpsw7ecwkaw.jpg)

And rear where the chassis meets the body

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2954_zpsk1wxbrx2.jpg)


Then to do the same to the other side, after that just a matter of cleaning up where they were spot welded to the body. I have been tending to grind the spot welds off rather then drilling. It may take a little longer but at least you don’t have a ton of holes to tend with.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2965_zps2lcvowjj.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2963_zpsfkk793fh.jpg)


All out and no turning back now

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2971_zpslgzpka29.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2973_zpsmgnsbpuw.jpg)


Then I lifted the new clip up close to where its going and with a bit of trimming it looks like its going to fit in quite nicely.

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2979_zpsvt02zwlg.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2982_zpsg0z7buzh.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2985_zpspwey6w3x.jpg)

(https://i61.photobucket.com/albums/h41/cop111car/FC%20UTE%20PROJECT/IMG_2987_zpshhpypfc0.jpg)

Mal

wow alot of work done in a short period of time. That rear is looking good

Love it

Sent from my G8342 using Tapatalk

Continuing on with fitting of the rear suspension clip.
With everything old cut out there was really no where to secure the rear of the rails to so I ended up cutting a bit more of the rear tail panel out and made a frame to secure the chassis rail ends to.

To start with I had to do some rust repairs to the panels beside the spare wheel door.

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3005.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3007.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3004.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3011.JPG?width=1920&height=1080&fit=bounds)


With that done I stated on the frame. As I’m no longer going to have a spare wheel door this area would be all filled in by making a new outer panel to blank off the opening.
First the frame, this is made out of 30x30x3mm box section

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3021.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3025.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3026.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3032.JPG?width=1920&height=1080&fit=bounds)



Now to make the new outer panel. The old spare wheel door was pretty rusty along the bottom and would take as much work to fix that to use as it would just make a new one.
I made the new panel out of 1.2 sheet.

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3031.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3034.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3038.JPG?width=1920&height=1080&fit=bounds)



With the general shape there I used 8mm rod to strengthen the top and side edges, also something with a bit of thickness to weld to.
 
(https://hosting.photobucket.com/images/h41/cop111car/IMG_3041.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3043.JPG?width=1920&height=1080&fit=bounds)



With the round section in place I used 30mm round tube cut in half to give the curve to the edges.

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3048.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3049.JPG?width=1920&height=1080&fit=bounds)



With all that welded together it just was a matter of cleaning it up before welding into place.

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3053.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3054.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3055.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3059.JPG?width=1920&height=1080&fit=bounds)



Now to start welding it in.

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3061.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3063.JPG?width=1920&height=1080&fit=bounds)



And all done

(https://hosting.photobucket.com/images/h41/cop111car/IMG_3070.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3072.JPG?width=1920&height=1080&fit=bounds)


(https://hosting.photobucket.com/images/h41/cop111car/IMG_3075.JPG?width=1920&height=1080&fit=bounds)


 Next to fit the inner frame panel to secure the chassis to.

Outstanding work. Most people would have left it flat or welded in a donor section. I’ve retained the door in my ute but it is one I picked up that had been bogged and painted. I have a couple of others, I’m doing an EK van as well, but they need a lot of work. But you’ve practically made a door from scratch. Well done.


Sent from my iPad using Tapatalk

awesome stuff

Thanks guys. Was a lot of work but worth the effort I thought. I’ve since got the rear clip all welded in now and will post up some photos soon. Am currently having problems with photobucket not working properly.

Great work Mal, if you use the Tapatalk app it’s easy to post a photo, just use your phone!


Sent from my iPhone using Tapatalk

So I got the rear clip all welded in and looking pretty solid

(https://uploads.tapatalk-cdn.com/20200708/fb0c5be0bc2a09a83042a37c33567250.jpg)

(https://uploads.tapatalk-cdn.com/20200708/b9649154fa5f52a2bb40d42199f585d1.jpg)

(https://uploads.tapatalk-cdn.com/20200708/4d82004c8b21d9115724e2c05fbce003.jpg)

Now I started on removing some rust from the floor pan .....

(https://uploads.tapatalk-cdn.com/20200708/b8491a187a33a2cb0f8fd4b2a864ae18.jpg)

(https://uploads.tapatalk-cdn.com/20200708/d21ef430a3ca2e9165d76e4448fb99e2.jpg)

(https://uploads.tapatalk-cdn.com/20200708/4156166ed2d072f480b4b9b038f30580.jpg)


Sent from my iPhone using Tapatalk

That’s a lot of rust


Sent from my iPad using Tapatalk

Looks great Mal fantastic work I'm loving this build mate.
Neil

Brilliant mate ,just great work ,if Holden starts again you will be CEO ,,,and what a car would be produced if all the blokes on this forum were on production team ..Vern

Where are you thinking of running the exhaust?

Thanks guys, JB not sure on the exhaust as yet, just making it up as I go... ;D

Got the connecting rails in this arvo, will have to do a few modifications to the Tailshafts loop(https://uploads.tapatalk-cdn.com/20200709/c15fee8b779d6d42ca6e31ed05dff267.jpg)

(https://uploads.tapatalk-cdn.com/20200709/52249ecb704a65563e1c470bbb9aec1a.jpg)
(https://uploads.tapatalk-cdn.com/20200709/eda29e3599f4f4e7ea41807bc4325e6b.jpg)


Sent from my iPhone using Tapatalk

Just lower it six inches mal.


Sent from my iPad using Tapatalk

Yep lower the top and and add a bit into the bottom

I was being flippant, meaning just lower the whole car, not serious.


Sent from my iPad using Tapatalk

A bit of Tailshafts loop surgery today

(https://uploads.tapatalk-cdn.com/20200713/0247169bcf13e8e758c8cce33664873e.jpg)

(https://uploads.tapatalk-cdn.com/20200713/ba9cc8156c4cc44c9d0f8db67beb6655.jpg)

(https://uploads.tapatalk-cdn.com/20200713/e3c9f1e4a3b7816f452c4f91352f63e0.jpg)

(https://uploads.tapatalk-cdn.com/20200713/0befea0c30c8b9f729948fd99ec1934a.jpg)

(https://uploads.tapatalk-cdn.com/20200713/2f1ddfbe1e3de82430ccf5efbfa8a5eb.jpg)

(https://uploads.tapatalk-cdn.com/20200713/15cfec54a5061ec9d8b10740aaf0eb0b.jpg)

(https://uploads.tapatalk-cdn.com/20200713/e70f866fbd3639c4158d526dd9259ecc.jpg)


Sent from my iPhone using Tapatalk

Very very beautiful work mate.

A master at work ,master class ,and great images also ...Vern

Talk about ground up rebuild, this is AMAZING!

Today I made and fitted the subframe connectors. My version is welded into V of the subframe legs and bolted to the floor cross member

(https://uploads.tapatalk-cdn.com/20200714/2121f60c4ab8fe795445c05f8532cf04.jpg)

(https://uploads.tapatalk-cdn.com/20200714/9c3b6b4a8f1064d9b18e2937f8dd2512.jpg)

A fair bit of messing around went into these

(https://uploads.tapatalk-cdn.com/20200714/84f972f0f97f67f0de1a2ef109003c10.jpg)

(https://uploads.tapatalk-cdn.com/20200714/60ac610f9a87fff54c9cc7b736e64ec4.jpg)

(https://uploads.tapatalk-cdn.com/20200714/dac9dca3f7d7f858ecd7518fe61920b2.jpg)

(https://uploads.tapatalk-cdn.com/20200714/3c19521380043f527c716a0abf06fe9d.jpg)

Just have to add the crush tubes for the bolts and finish dressing up the welds when I take the subframe off


Sent from my iPhone using Tapatalk

Thought today I’d try the front rims of my FB on the Ute to see how I would go for clearance. These are very similar style and size that I was hoping to fit on the old girl(https://uploads.tapatalk-cdn.com/20200718/7a3f730f234c751f9646ecc0903635bb.jpg)

(https://uploads.tapatalk-cdn.com/20200718/fdeabbdffae91d8557baa48dcd72c76b.jpg)

(https://uploads.tapatalk-cdn.com/20200718/7b252adf0d814586e7bc98a74aada4ba.jpg)

(https://uploads.tapatalk-cdn.com/20200718/b85226efba27deb3dff5c3094a7bce0c.jpg)


Sent from my iPhone using Tapatalk

Well they look the horn to paraphrase Pete and dud. But can you get any lock without the tyre ripping the guard lip out?


Sent from my iPad using Tapatalk

Gets full lock both ways without rubbing but will still fold the guard lip up

When the weight is on the frontend, everything will change.
Regards
Alex

The issue I’ve had is only where the inside wheel rides up over a bump on lock, but rolling the guard helps of course. Then it only rubs and doesn’t rip the lip outward. Sometimes a modicum of driveability gets sacrificed for a vast improvement in appearance.


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I'm going to roll the guard lip with a 8mm rod welded into the lip. I did this on my FB so even if the tyres do hit the guard its like you say, it only rubs and doesn't tear. And it make the edge nice and rigid.

Another couple of big days on the old girl.
Finished the floor frame.

(https://uploads.tapatalk-cdn.com/20200723/ed3265373735987d8fe6a38fd1020970.jpg)

(https://uploads.tapatalk-cdn.com/20200723/519bd5ce7c6d6cf8421727fd008de755.jpg)

(https://uploads.tapatalk-cdn.com/20200723/bd6eb20ff7140d6880a4eecc909861fa.jpg)

Then fitted the motor and gearbox, a bit of messing around making the front engine mounts, but it all slotted in quite nicely.
Now just have to make the rear gearbox mount

(https://uploads.tapatalk-cdn.com/20200723/1f21025b59076302bd31cdcd5bd9e1be.jpg)

(https://uploads.tapatalk-cdn.com/20200723/739dde0366c688e87a34f582a34dd5e1.jpg)

(https://uploads.tapatalk-cdn.com/20200723/bb49fbc0d34c9f0a3dd6ea106d5f122a.jpg)

(https://uploads.tapatalk-cdn.com/20200723/5c83052f2f28677e07a877b9e7bc6b1c.jpg)

(https://uploads.tapatalk-cdn.com/20200723/de82009628771d538f332d7b2250068a.jpg)

(https://uploads.tapatalk-cdn.com/20200723/c76c31dbc7752e3bebd4ab3209b2eb61.jpg)

(https://uploads.tapatalk-cdn.com/20200723/fc925d9d4e11b1c03560841cb82ab5ec.jpg)

All in a days work🤣🤣


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Got the rear gearbox mount made and fitted . Simple and strong, made out of 75 x 8 mm plate

(https://uploads.tapatalk-cdn.com/20200728/a207e8931cc3aa53b6a1b2ae9fbf6ed4.jpg)

(https://uploads.tapatalk-cdn.com/20200728/4672cbf6e92e53b1db6dfe71bc636c3a.jpg)


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That's nothing to fail in a hurry. Tidy work as ever.

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My new fuel tank turned up today
Mustang tank set up for EFI

(https://uploads.tapatalk-cdn.com/20200730/44220b5e68f1d60b15792dcc02cca594.jpg)

(https://uploads.tapatalk-cdn.com/20200730/6faa3ef53813ddfc68e186e646107718.jpg)

(https://uploads.tapatalk-cdn.com/20200730/ec2ddf455152a95fa159d535847bc281.jpg)


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Mal,
Great build your up to there!
Curious about the Mustang tank, obviously it's deeper, but any idea how close it is to the original hole in the floor, (assuming you had a floor left)
Cheers, Gary

Hey Gary,
All my floor is cut out and gone but it will definitely fit between standard rails with some trimming, as my new chassis is about 100mm narrower than standard and this tank fits perfectly between my new rails.
I put a XB falcon tank in my FB which also fitted between the standard rails but of course had to be trimmed.
Mal

Thanks for the info Mal, its getting hard to find original tanks, looks like a good alternative.

Well done Mal looking good.
Gary, a few others have used the Mustang tanks, they will take up most of the boot so you would loose the spare wheel well in the sedan.
They come in 3 sizes,
18 US gallons —-14.98 imp
20   “     “           16.6    “
22    “     “          18.3    “

Making extractor time. What a prick of a job
Started with a box of bends and finally ended up with extractors
Bought a pair is flange plates and started from there
(https://uploads.tapatalk-cdn.com/20200820/ab4b3ba4441ae0d3d51bde0922000d92.jpg)

My ruff but workable angle finder
(https://uploads.tapatalk-cdn.com/20200820/9cf2d1bdfcc6f2d1bccddfb5e6d6ad6e.jpg)

(https://uploads.tapatalk-cdn.com/20200820/1dd1a4454a9a0cbe12319927a9894924.jpg)

(https://uploads.tapatalk-cdn.com/20200820/5ce60054c10bc8eb8c39358df50b7865.jpg)

(https://uploads.tapatalk-cdn.com/20200820/01f9456f32443d29d8c76591bf1fc021.jpg)

(https://uploads.tapatalk-cdn.com/20200820/199548b1ca6f07c798148cee1ceac863.jpg)

(https://uploads.tapatalk-cdn.com/20200820/bc1c559a353bc1a31d544443a0965337.jpg)

(https://uploads.tapatalk-cdn.com/20200820/7655993df604e36bd267a735a598770d.jpg)

Not much room to work with on the driver side
(https://uploads.tapatalk-cdn.com/20200820/b710374f25550e888ba043687f33bfbe.jpg)

(https://uploads.tapatalk-cdn.com/20200820/b0cf61a2013c7c8df55dcac531ee9f3a.jpg)

The passenger was quite a bit easier
(https://uploads.tapatalk-cdn.com/20200820/1683649d7852a04c1870615ba8d2770f.jpg)

(https://uploads.tapatalk-cdn.com/20200820/8b3320841ac7f81b338f4d8d6d7bb2b0.jpg)


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beautiful job on pipes... awesome build, the only thing i would change in this build is i would have fitted a 350 alloy headed TPI out of a corvette.. but nevertheless, magnificent
i for one salute you

What a test of patience! Good on you for sticking with it & producing such a result.

Great work, that does look like one prick of a job to do..

Yep. Very clever work. I detest the guard dump headers. Bloody tight where the steering goes through. One guy on the fb ek site managed to mix and match cast headers and get them to fit but this was a 253 and a real factory look. Your ute will be very different. Thanks for posting and keep the updates coming Malcolm. Very inspiring.


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Thanks guys, there was no way I was going to put the pipes through the inner guards as I’m no a fan of that either.


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Picked up the new wheels today. Couldn’t be happier with the choice and fit(https://uploads.tapatalk-cdn.com/20200821/2df11fac8cff3a311ab56a2c98e8c7d9.jpg)

(https://uploads.tapatalk-cdn.com/20200821/9164431623592361a02e64cab14d2563.jpg)

(https://uploads.tapatalk-cdn.com/20200821/0d3a498fca3d491b2359e6000528a01f.jpg)

(https://uploads.tapatalk-cdn.com/20200821/76b14fdc64371ce3865ecb18572b3d9b.jpg)

If the frond discs were 3 mm bigger they wouldn’t have fitted.

(https://uploads.tapatalk-cdn.com/20200821/361fcdce20d37b5ef16a82c0901a8046.jpg)

(https://uploads.tapatalk-cdn.com/20200821/6bf67a789f95b2869807deeac019dcd5.jpg)

(https://uploads.tapatalk-cdn.com/20200821/a045d13b7e07414907398fad424d6c37.jpg)

(https://uploads.tapatalk-cdn.com/20200821/ed892411869971004e995f59972e54b5.jpg)

15 x 6 on front and 15 x 10 on the back


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Cool as Mal, please keep the photos coming as I'm really enjoying this build of yours.
Neil

Smokin  Love the look the rims, especially the rear with the deep dish, Nice work.

Next I started on the fitting of the radiator. Was planning on using the original VT Commodore radiator but it just turned out to be to tall for where I wanted to fi it. So I’ve ordered one from the USA that will fit with a little less cutting up.
Same as this but complete with fans and shroud

(https://uploads.tapatalk-cdn.com/20200903/8621f941356c743d5c933ab52cba943a.jpg)

So while I’m waiting on the radiator to turn up I started on putting some of the floor back in

(https://uploads.tapatalk-cdn.com/20200903/dbc1cdad90cda80a408395e50a685f70.jpg)

Started with boxing in the front main cross member.

(https://uploads.tapatalk-cdn.com/20200903/9926cdee7269f25d7e2f2231898794fb.jpg)


Then I fitted the front section of both floor pans

(https://uploads.tapatalk-cdn.com/20200903/5a5c570e46b7a2b1f07cd94a0fc902e5.jpg)

(https://uploads.tapatalk-cdn.com/20200903/bd972e1bbb45a6e3c98f9db3a0e5d4e0.jpg)

Next I got the transmission tunnel cut ready to fit

(https://uploads.tapatalk-cdn.com/20200903/28d549f63ce603e4135b5d42e2728476.jpg)

(https://uploads.tapatalk-cdn.com/20200903/7e13e754d3929613e8dec03be2635fcd.jpg)

(https://uploads.tapatalk-cdn.com/20200903/d4fb4757dd24ece80a166458ae21b453.jpg)

Currently getting the Tailshafts tunnel rolled up.


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I like your methodology malcolm👍


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wish I had those skills to custom fabricate stuff ...Vern ...

Still jumping from job to job.
Started on the sills, cut off both sills and cleaned up the inner sills
(https://uploads.tapatalk-cdn.com/20200913/70b397d78a23d008d3cebc0f15d977b8.jpg)

(https://uploads.tapatalk-cdn.com/20200913/e14e369f30c399a95055668ff87f5319.jpg)

Had to do a repair on the back of the drivers sill

(https://uploads.tapatalk-cdn.com/20200913/fa9de7f9008fc7c45e5f90f1dbe0431f.jpg)

(https://uploads.tapatalk-cdn.com/20200913/9a914adcf820f8117dc66a3e4eb8b0e5.jpg)

With the sills I’m doing the same as the FB EK utes with putting an intermediate support panel in between the inner and outer sill for extra strength

(https://uploads.tapatalk-cdn.com/20200913/9dd8d8b01d92ce396d54acf683516087.jpg)

(https://uploads.tapatalk-cdn.com/20200913/2d2251acf44188e0a0912f2d58454fa0.jpg)

(https://uploads.tapatalk-cdn.com/20200913/b198acb58ad273242032c36b0b78bc2e.jpg)

(https://uploads.tapatalk-cdn.com/20200913/0bbc2345072660cff2014f520aaaa6fb.jpg)

(https://uploads.tapatalk-cdn.com/20200913/75e900e1c7a64fda83282727e7114c41.jpg)

(https://uploads.tapatalk-cdn.com/20200913/b1c6956dd592990d4807c01cda1b895d.jpg)

(https://uploads.tapatalk-cdn.com/20200913/7f26fc20f2c430c71d95055c89974de7.jpg)


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Mal,

Not bloody bad at all.  Tell me - when putting the outer sill on, did you overhead-weld all the plug welds?  Because it looks like you can't tip the body shell over.

Rob

Hey Rob, yes and I really hate welding upside down....

Don't know how many times I've set myself on fire.

Hey Mal
Fantastic work as always mate, looks like the Ute was in pretty good shape even though you had to take the whole floor out; the bottom of the 'A' pillars and the inner sills all look really good.
I like the fact that you kept the seam between the 'B' pillar and the wheel arch and the outer sill, you can always tell when this area has been repaired as most just weld up and lose the seam.
I did the same with my EK Ute and made sure the seam stayed.
The 'D' bar for your steering seems pretty close to the head mate are you going to have enough clearnace for engine rock under acceleration I wonder??
As I said before great work and this is going to be a great looking Ute Mal.

Just a quick update, have finished the both sills now.
Same as the other side, I’ve fitted an intermediate strengthening panel inside the sills


(https://uploads.tapatalk-cdn.com/20201004/d711bca78045a49c38be0f90ca98313e.jpg)

(https://uploads.tapatalk-cdn.com/20201004/80c854b21eb9478dead03c9126e5bd81.jpg)

(https://uploads.tapatalk-cdn.com/20201004/71ba2a23cdecc9ff1bc51771336b38ae.jpg)

(https://uploads.tapatalk-cdn.com/20201004/b00a5401455807d81716c0c35e569c02.jpg)

Bit of rust to repair on the rear quarter panel also

(https://uploads.tapatalk-cdn.com/20201004/ee36b023ade303a3962f7e73280b51e8.jpg)

Just have to put a new panel into the lower rear quarter panel to sill area.

Next ive cut and trial fitted the trans tunnel and tailshaft tunnel

(https://uploads.tapatalk-cdn.com/20201004/11e64c4a0fd02a2a36105e42c8fc0447.jpg)

(https://uploads.tapatalk-cdn.com/20201004/6434b3201ff2a458aea06d6d89dfeaf4.jpg)

(https://uploads.tapatalk-cdn.com/20201004/1adcc62bc291fd6278ac96c82b4e5e78.jpg)

(https://uploads.tapatalk-cdn.com/20201004/b562e125572536d4a24bf316571238be.jpg)

Not going to weld it in yet until I get the shifter and handbrake as they both fit onto the gearbox and they will be easier to fit to start with, without the trans tunnel in.

Tomorrow I’ll start on cutting in the floor pans.


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Ended up making new engine mounts, the standard ones were just way to much messing around to change
(https://uploads.tapatalk-cdn.com/20201020/b47e2669e22aa2e10cdde9b0e15f5e42.jpg)
(https://uploads.tapatalk-cdn.com/20201020/32031f9ff68c211a8801ea1f89e7ecae.jpg)

(https://uploads.tapatalk-cdn.com/20201020/4082585d2a15b27ed24857406f2e208b.jpg)


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My version of tough mounts


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Hi, excellent work on your project. The radiator you have ordered, is that a standard size they sell?. Do you have a part number?. Thanks Scott

Thanks for the update Malcolm. Magnificent work!
Cheers
Clay


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Scott the radiator is a standard size. Part number GRI-CU-56271-xs

Mal

My gear shifter and handbrake finall turned up. Si I fitted those up, very happy with my choice

(https://uploads.tapatalk-cdn.com/20201023/6eaa2448141e6941091b4218de487cb7.jpg)

(https://uploads.tapatalk-cdn.com/20201023/474bcdaed0e885db7a4a88c6d10420ae.jpg)

(https://uploads.tapatalk-cdn.com/20201023/dd8c01ed02fd779b93e3344ba2d8d3ed.jpg)

Next was trial fitting up the brake booster and master cylinder, and of corse nothing is straight forward
The bolts on the booster were way to far apart for the master cylinder to just bolt straight on

(https://uploads.tapatalk-cdn.com/20201023/0c43ce4c48b95925f67b5bfa4c1e8de9.jpg)

(https://uploads.tapatalk-cdn.com/20201023/465d3261e8ce0c0b875425ff51c48ef2.jpg)

So I had to knock up an adapter plate to suit

(https://uploads.tapatalk-cdn.com/20201023/9c058a22016c7733dfadf4e910ea5f7c.jpg)

Pretty easy job

(https://uploads.tapatalk-cdn.com/20201023/8d4c5ec25a465eb253e4ef6cdfb49288.jpg)

(https://uploads.tapatalk-cdn.com/20201023/bf8b29aea8464ff600eff0a1ee39213a.jpg)

Only had to cut a small piece from the return part under the dash to get the 8 inch booster fo fit

(https://uploads.tapatalk-cdn.com/20201023/1f2d3f33a7dceaa9dc054d372304f6af.jpg)

(https://uploads.tapatalk-cdn.com/20201023/69c24e5c376807aceeb56627ea83acec.jpg)

(https://uploads.tapatalk-cdn.com/20201023/25d85230256dfa15956e23f88bee907c.jpg)

I’m planning on mounting the reservoirs under the ash tray lid in top of the dash. That’s today’s job.
Mal


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Update also on the floor pans
Transmission tunnel welded together

(https://uploads.tapatalk-cdn.com/20201023/5d28faab69d1d97dca0d45c950b94e62.jpg)

Then started making the floor pans

(https://uploads.tapatalk-cdn.com/20201023/bcb32b98919fd4428a009e2bea6e30d2.jpg)

(https://uploads.tapatalk-cdn.com/20201023/db5bb9aff43387b9ca34c2e0e5c713f9.jpg)

(https://uploads.tapatalk-cdn.com/20201023/d34de8d33c244f1f7a5ab5bd1f18106b.jpg)

(https://uploads.tapatalk-cdn.com/20201023/b3d02400c5149e2195007fa4e69b8c12.jpg)

Also added some gussets into kick up on the rear rails

(https://uploads.tapatalk-cdn.com/20201023/08a2d1832533f11b4bd88036febbb7cf.jpg)

(https://uploads.tapatalk-cdn.com/20201023/413c91451e3ccc0658e885e8b1f76805.jpg)

(https://uploads.tapatalk-cdn.com/20201023/d35e4562fadaa890e8515b3709a3059a.jpg)

Both sides cut to fit

(https://uploads.tapatalk-cdn.com/20201023/d335520d2c4dfa94814939b5804e5fb7.jpg)

(https://uploads.tapatalk-cdn.com/20201023/95a1c938c620132d310e98ecd7599f5c.jpg)

(https://uploads.tapatalk-cdn.com/20201023/b7e953121fce8721bfc9de0c146a6b6c.jpg)


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Thank you Mal

just awesome Mal , no doubt about you , and the other guys on here into serious resto's ..loving following ...Vern ..

Just started making the exhaust system
This is going to be a long tedious job

(https://uploads.tapatalk-cdn.com/20201125/65458864601d5cc3b1252081634bc7bf.jpg)

Some of the bits I started with

(https://uploads.tapatalk-cdn.com/20201125/96a3d07f3cf876b9f46039895c88b072.jpg)

(https://uploads.tapatalk-cdn.com/20201125/86cd43e2700fb7b7e78f3781176f4536.jpg)

(https://uploads.tapatalk-cdn.com/20201125/cb37a6235dab43fb37654f90c5b546ce.jpg)

Lots of grinding involved

 (https://uploads.tapatalk-cdn.com/20201125/37b00b4365fcb02995f0d9e427cda27c.jpg)


Both front pipe sections done
Now to go into the x pipe


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(https://uploads.tapatalk-cdn.com/20201125/2aeaf302e25eab9ce3aff5b637f3eb63.jpg)


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awesome ,just awesome ,class all the way ,it looked like electro polished before welding and after ,how did you do that ?

Thanks
The system is going to be full 2 1/2 inch stainless
Its all stainless steel and most parts are polished when I buy them.
I use stainless wire in the mig to weld everything together
The most tedious part is the grinding, being careful to only grind the weld.
When I have the weld ground close, I use a flap wheel in the grinder, then 120 sanding disc, then 320 sanding disc, then polish the section on the pedestal polisher.

 This is an amazing project to witness as it progresses. Worthy of a TV Doco. It more than compares to the  American Custom shows. The standout for me is that it is a "one man band" & not a workshop Team effort.  Will this get to the HILL in 2022? Top stuff Mal.   Cheers Kevin.

That polishing would take 10 times at least the welding time ,do you use a buffing bar like Josco on the fabric buffing wheel ?

Yep thats exactly what I use

Only had a few hours in the shed today as it was so hot I started to melt, so not a lot done

(https://uploads.tapatalk-cdn.com/20201129/38514557c80d7beed7f4afb9c3a8e80f.jpg)


(https://uploads.tapatalk-cdn.com/20201129/005710927834068e19b879bf990d9d94.jpg)


(https://uploads.tapatalk-cdn.com/20201129/3ba72fb2b2f47521a9be3c9171a3d153.jpg)


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Exhaust all finished (https://uploads.tapatalk-cdn.com/20210207/cfbc846ef361837002cddad3d4fb36bc.jpg)
(https://uploads.tapatalk-cdn.com/20210207/8f15dbfb4a74be20935286731a4f7475.jpg)

(https://uploads.tapatalk-cdn.com/20210207/e3c72723ea906d1bf8347aa365391e54.jpg)

(https://uploads.tapatalk-cdn.com/20210207/4fb431f29af0bd7abf18d58bad3ee617.jpg)

(https://uploads.tapatalk-cdn.com/20210207/3e12269aef83547be5cbd0454be780ea.jpg)

(https://uploads.tapatalk-cdn.com/20210207/32d07a875096925a99b28aa5fa70beea.jpg)

(https://uploads.tapatalk-cdn.com/20210207/acaa790ef2d8ff6e9eebac01f7b9d056.jpg)


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you have had a brake in your postings ,I can see why ,that is awesome ,Vern

Yeh its been a while Vern, have got lots of updates to come.

Good to see you back Mal was wondering what had happened please keep the updates coming.
Neil

Next, radiator all fitted up
Radiator is a Griffin that I got from the States
Made up saddles for it to sit in and these are welded on with the top being held by made up brackets that are welded to the top radiator support brace

(https://uploads.tapatalk-cdn.com/20210208/e131363cf737beb3ba492a2979cd8738.jpg)

(https://uploads.tapatalk-cdn.com/20210208/74d4f4ee1144bc56c638c00361a601a2.jpg)

(https://uploads.tapatalk-cdn.com/20210208/46142312fdafee66a4e826bde77177b9.jpg)
(https://uploads.tapatalk-cdn.com/20210208/ce98536fca1f4a72c0eabd08dbe56f01.jpg)

(https://uploads.tapatalk-cdn.com/20210208/d324d8e8ea3605e3fa774a9e0f33484f.jpg)
(https://uploads.tapatalk-cdn.com/20210208/ff0d6538d66ad5349da890dda2c0ebd7.jpg)
(https://uploads.tapatalk-cdn.com/20210208/830cee62026ebba461e2e4e9f960fac0.jpg)
(https://uploads.tapatalk-cdn.com/20210208/f15eb607be4d5fa429e6e319d41d95ff.jpg)

Not a lot of room in there


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Moving on to the top cover panel and modified bonnet catch

(https://uploads.tapatalk-cdn.com/20210208/ab5ab63adc629bdea5be129b196f5710.jpg)

(https://uploads.tapatalk-cdn.com/20210208/9d2c82a1a30be6f6c496b28808a82340.jpg)

I made up a section to go around the radiator cap and welded it into place

(https://uploads.tapatalk-cdn.com/20210208/32f342c93951e779b2d056a54564b16d.jpg)

(https://uploads.tapatalk-cdn.com/20210208/9742c384e65c6fde7d88e92f07812f73.jpg)

(https://uploads.tapatalk-cdn.com/20210208/8d9155fe05e183f0cb0d05226986cb7e.jpg)

(https://uploads.tapatalk-cdn.com/20210208/c6a1667ad4ab523cf9296823b54a2b43.jpg)

(https://uploads.tapatalk-cdn.com/20210208/94bbb558d19331b417e1374465ddec09.jpg)

(https://uploads.tapatalk-cdn.com/20210208/0f5f1190eb4c39ef01fa54ee2434e6aa.jpg)

(https://uploads.tapatalk-cdn.com/20210208/1f8fa45476aedc19ebbb430a1e39f4cf.jpg)

(https://uploads.tapatalk-cdn.com/20210208/69c6a4a96aec87c1ffd6a6e0df250384.jpg)

(https://uploads.tapatalk-cdn.com/20210208/c7dfd5350edb254eac6943fabecc5661.jpg)

(https://uploads.tapatalk-cdn.com/20210208/f481ba3d5eb4b151aba6c6412da2b027.jpg)

The next problem was the radiator cap hitting the inside of the bonnet support

Nothing a bit of cutting couldn’t fix

(https://uploads.tapatalk-cdn.com/20210208/3a178b32213659bd8216466a0ed13d09.jpg)

(https://uploads.tapatalk-cdn.com/20210208/9e1f5acae89eb1e2b7db26cf74afa233.jpg)


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Bonnet catch modification
I didn’t like the look of the cable so a bit of welding and messing around and now the cable is out of sight

(https://uploads.tapatalk-cdn.com/20210208/3562e8764edeb5b60678fd1bffb242a8.jpg)

(https://uploads.tapatalk-cdn.com/20210208/7cf49b6cbc00c56da1e3f607296a67a5.jpg)

(https://uploads.tapatalk-cdn.com/20210208/998051b2fe26871ffc187d9a188f0421.jpg)

(https://uploads.tapatalk-cdn.com/20210208/e001f8084d65a37adb4ca332dad4549a.jpg)


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Bonnet repairs

The inside of the bonnet had a fair bit of surface rust and a couple of holes on the front so I removed the front and rear inner bracing and acid cleaned the bonnet skin inside and out and sandblasted the 2 bracing sections.
The bonnet has now been sent away to get louvred

(https://uploads.tapatalk-cdn.com/20210208/825b2e28fb171b70ed48c98f4b3b8afa.jpg)

(https://uploads.tapatalk-cdn.com/20210208/25707bcf7861f54942bc5ac1e2b4b1e9.jpg)

(https://uploads.tapatalk-cdn.com/20210208/aee05ecc27e41425e7cfa9dbe213d2b0.jpg)


Sent from my iPhone using Tapatalk

Next the alternator
I ended up getting a new 140 amp alternator and wanted to do a low mount bracket with the Gilmer belt set up.

I couldn’t but one that was just going to be a bolt on so I had to make it myself. The low mount didn’t give me much room to play with either

(https://uploads.tapatalk-cdn.com/20210208/baf2634ad76d452102260fd964e4351a.jpg)

(https://uploads.tapatalk-cdn.com/20210208/e163be3fb38f2a1799f8a5cf43409407.jpg)

(https://uploads.tapatalk-cdn.com/20210208/1d4a486eb118c1e5dbd83173a7421165.jpg)

(https://uploads.tapatalk-cdn.com/20210208/47c736c36322bd6fa3babd50214ab768.jpg)

Was sweeting bullets with the length of the belt, but it ended up fitting perfectly with plenty of adjustment


Sent from my iPhone using Tapatalk

I finally got the tyres fitted to the rims so I could cut the diff to length and get that area all finished off.

I ended up using 265/50/15 on the back and 185/65/15 on the front.
The rear tyres are a nice snug fit.

(https://uploads.tapatalk-cdn.com/20210208/1155fbf2bce8e3d83bf0ba65e640004e.jpg)

(https://uploads.tapatalk-cdn.com/20210208/a97e0a0052b70c83de69b9f50b3cc6a6.jpg)

(https://uploads.tapatalk-cdn.com/20210208/ba4e0430c638b64fff6676953d4a3dfe.jpg)

(https://uploads.tapatalk-cdn.com/20210208/56f90dc1d1126efdb3912bf9277772ca.jpg)

(https://uploads.tapatalk-cdn.com/20210208/20ac5b6fb58a1dba79d80c15f12ddf03.jpg)

(https://uploads.tapatalk-cdn.com/20210208/7d5d1cd374f1543bfc9510ba9d1ccb62.jpg)

The front tyres I’m hoping will be ok for clearance to the guards

(https://uploads.tapatalk-cdn.com/20210208/062cd368f574a3ab643002e959a5d8a5.jpg)

(https://uploads.tapatalk-cdn.com/20210208/7ab18413522c141e58a2582030f4fc30.jpg)


Sent from my iPhone using Tapatalk

Bit of an update
Modified the wall behind the seat to move it back 50mm

(https://uploads.tapatalk-cdn.com/20210329/6765d3c1bc97484ca262afb8644c3344.jpg)

(https://uploads.tapatalk-cdn.com/20210329/eb2478fbe0c12c516201359b38dc0789.jpg)

(https://uploads.tapatalk-cdn.com/20210329/2696c2c5ab6e9bb2350d301e94da7e5f.jpg)

(https://uploads.tapatalk-cdn.com/20210329/37e36deb190cb7d1768707e94111127d.jpg)

(https://uploads.tapatalk-cdn.com/20210329/2f5bc1494e02f9d275969be904e509b7.jpg)

(https://uploads.tapatalk-cdn.com/20210329/f65702d07ed162c4d123a3195577d301.jpg)


Sent from my iPhone using Tapatalk

Wow. A lot of work. I’m glad I’m only 6ft nothing. Got my seat back against the rear wall in my ute and there are two holes left on the runners.


Sent from my iPad using Tapatalk

Now started on rebuilding the rear tray floor
Firstly starting with the wheel arches, making them 50mm wider

(https://uploads.tapatalk-cdn.com/20210329/bb6ee0138258fb607d4cebba94fa8a70.jpg)

(https://uploads.tapatalk-cdn.com/20210329/2ea8917aabc4daa9a1da837fd31eeac3.jpg)

(https://uploads.tapatalk-cdn.com/20210329/af2699e33d4d1454ab1bade0b6f9975d.jpg)

(https://uploads.tapatalk-cdn.com/20210329/6c28205f78134e4012e5eaf791903351.jpg)

(https://uploads.tapatalk-cdn.com/20210329/9f19ce7e901a0785e62b5f5857b134f3.jpg)

(https://uploads.tapatalk-cdn.com/20210329/f6d4d3a8dfef54a08a244829c3015b0c.jpg)

(https://uploads.tapatalk-cdn.com/20210329/d2094d4829e39e56bd758e0eeb1566f7.jpg)

(https://uploads.tapatalk-cdn.com/20210329/4c1bc33e0ed9e87efc9c1aa80f21ffbc.jpg)

(https://uploads.tapatalk-cdn.com/20210329/f79385d9414bdd7c2cedb2ab518a8bab.jpg)

Now for the next side


Sent from my iPhone using Tapatalk

Looks good, well done

Was wondering where you got to Mal  ;D
Love the work you are doing on this Ute it is going to turn out spectacular mate.
Neil

Yesterday I got a bit more done on the LH rear wheel arch up to where I decided to do a bit of fuel filler surgery while that area was still accessible.

Been struggling with the fuel filler option in my head for a while and bought a flush mount filler door that I was going to put in place of the original recessed one.

(https://uploads.tapatalk-cdn.com/20210330/5a6aeee0b2fb45303903c8c34cb48870.jpg)

(https://uploads.tapatalk-cdn.com/20210330/fb8b91ef96f21452767c9bedb9bf3067.jpg)

(https://uploads.tapatalk-cdn.com/20210330/02bf1742f8647b0e9e6da88ad6257243.jpg)

(https://uploads.tapatalk-cdn.com/20210330/693482cf45f5baa49758041f5358ddd1.jpg)


This change came about as I was going to have to change the routing of the filler tube, due to the inlet on the Mustang tank being in the middle at the back

(https://uploads.tapatalk-cdn.com/20210330/53e5061f676e571385cd022d07ccf93f.jpg)

(https://uploads.tapatalk-cdn.com/20210330/90ec3244a41194699f625a858d954889.jpg)

So ended up not using the new filler door at all and cut out the original recessed one and filled it in all together

(https://uploads.tapatalk-cdn.com/20210330/4b1b22b3ddea5d4df3a9228f32f0a8d3.jpg)

(https://uploads.tapatalk-cdn.com/20210330/92f2c23f52b689077e1547c36227a15d.jpg)

The old one cut out, and new piece marked out ready to trim and fit

(https://uploads.tapatalk-cdn.com/20210330/31a470989e10334d4ea20646234573bb.jpg)

(https://uploads.tapatalk-cdn.com/20210330/e9fe76a68bfb6028a9f1367b8c2611a7.jpg)

(https://uploads.tapatalk-cdn.com/20210330/0fcb906ce29db6dbb9e0a6f734be865e.jpg)

(https://uploads.tapatalk-cdn.com/20210330/489bce4c43e54f2fbf41032102883334.jpg)

(https://uploads.tapatalk-cdn.com/20210330/2ac097779059effa391af1c958c53ccc.jpg)

Nothing like welding on a big flat area and then spending the next couple of hours slapping it up to get the wobbles out of it


Sent from my iPhone using Tapatalk

Hi Mal
 Fantastic work throughout. look forward to see finished results.
Who have you used for engineering?
I have a ute also. I've just picked up a VY with V6.
And so the journey begins.
Cheers Ross

Ross
All Vehicle Certification Services did my ute.
Randal HASWELL a great bloke to deal with.

https://au.linkedin.com/in/randall-haswell-a5087651

Finally finished off my fuel filler relocation. Decided to put it in the back.

Just a bit of press work and shaping to start with
(https://uploads.tapatalk-cdn.com/20210415/92563bb1b717e923b20a776ed913c7a1.jpg)

(https://uploads.tapatalk-cdn.com/20210415/aa163471b324e7e3becb2d8ef0c1360c.jpg)

(https://uploads.tapatalk-cdn.com/20210415/90ce5f343d9ab88425cee59a21b51ae7.jpg)

(https://uploads.tapatalk-cdn.com/20210415/49110c8614ddd07cf637b194646f84fc.jpg)

Then to fit it

(https://uploads.tapatalk-cdn.com/20210415/a426ddf32cfa1f2c52917f8db538646f.jpg)

(https://uploads.tapatalk-cdn.com/20210415/4057bde2edf0142671847b02ed38f12f.jpg)

(https://uploads.tapatalk-cdn.com/20210415/db54138b1a5d99c109f98e8285be22fa.jpg)

(https://uploads.tapatalk-cdn.com/20210415/ab4ea72b0f8127a7a86ebb564e996b4d.jpg)

A bit of messing around remaking the new filler tube into the top of the tank

(https://uploads.tapatalk-cdn.com/20210415/b27851678ca0733f1b566c0082519504.jpg)

(https://uploads.tapatalk-cdn.com/20210415/4d30e57bfac8eb1fccfa073c3cd49998.jpg)

Now for the cover up

(https://uploads.tapatalk-cdn.com/20210415/1ff4ae4f5c3beff5d81d4efa4d134569.jpg)

(https://uploads.tapatalk-cdn.com/20210415/d2d35bf4e3e69d7be8d723426c8479e6.jpg)

(https://uploads.tapatalk-cdn.com/20210415/95b14850aed1e3c46a801ded4942d275.jpg)

And pretty happy with how it all turned out


Sent from my iPhone using Tapatalk

Works well with the mustang tank


Sent from my iPad using Tapatalk

Nicely done Mal

Rear door made for access to the battery, electric power steering, electric air con compressor and air con evaporator. The door has gas rams to keep it open and closed. Works great.

(https://uploads.tapatalk-cdn.com/20210501/fdcddab17bdf7b93e846ded45aff507a.jpg)

(https://uploads.tapatalk-cdn.com/20210501/f480e4574d3cc25ad991e965327c7799.jpg)

(https://uploads.tapatalk-cdn.com/20210501/2da1165996c02d84564489bd44d04fab.jpg)

(https://uploads.tapatalk-cdn.com/20210501/f966b944328aa06bdbbc9b1d2bbe0ae3.jpg)

(https://uploads.tapatalk-cdn.com/20210501/b541234233efab503f0117eb9080cfb1.jpg)

(https://uploads.tapatalk-cdn.com/20210501/dbb7f3a054577d02a04f833ed7960232.jpg)

(https://uploads.tapatalk-cdn.com/20210501/f7504199e6ef2943a2aa623f90a6896d.jpg)

(https://uploads.tapatalk-cdn.com/20210501/68a9409254bdcc11a200f3bcf043ec4d.jpg)

Now just have to sheet it all off .


Sent from my iPhone using Tapatalk

Just catching up on the updates

She’s finally back on the rotisserie with just a few welds to finish off and then it’s off to the sand blasters

(https://uploads.tapatalk-cdn.com/20210501/c60b7a3791a879662f85ab06cc8bcd9e.jpg)

(https://uploads.tapatalk-cdn.com/20210501/17bee1e64c7c5ccb3034a0128c2614cb.jpg)

(https://uploads.tapatalk-cdn.com/20210501/d1638e86e6ded03ecc4ac84df0b4b7c7.jpg)

(https://uploads.tapatalk-cdn.com/20210501/805db219ca77326c51b6fc615d0ece12.jpg)

Quite overwhelming when I sit back and look how far it come


Sent from my iPhone using Tapatalk

You’re not wrong Malcolm. Amazing work.


Sent from my iPad using Tapatalk

Love it!
Thanks for all the updates.

While waiting on the sand blaster I did a bit more work in the tray.
I finished of the lid

(https://uploads.tapatalk-cdn.com/20210516/3f071bb330f8aaf54c5d70c979c25171.jpg)

(https://uploads.tapatalk-cdn.com/20210516/cc55f7dd052b358d2d928dd1752acbb6.jpg)

I used the same profile in the lid as the inside tailgate

(https://uploads.tapatalk-cdn.com/20210516/bd243d83a935b2fd94577dfc66ec0b9f.jpg)

(https://uploads.tapatalk-cdn.com/20210516/1076c643b114799019fce8047a539705.jpg)

(https://uploads.tapatalk-cdn.com/20210516/15e8187cbb130973f8136c8f8483e49d.jpg)

(https://uploads.tapatalk-cdn.com/20210516/b26c435191411efa267d82b24a5ea474.jpg)


Sent from my iPhone using Tapatalk

Picked up my bonnet and sun visor after getting the vents cut in.
Love the look, they did a great job (https://uploads.tapatalk-cdn.com/20210524/4520ada617423a74e5baea99a6275c22.jpg)

(https://uploads.tapatalk-cdn.com/20210524/963e59aa26932da3d06573ea6bf3f423.jpg)

(https://uploads.tapatalk-cdn.com/20210524/98928bd614e0fa58d86c93df4aa4fb3b.jpg)

(https://uploads.tapatalk-cdn.com/20210524/436d21912c8a7c275094fb426fbdabae.jpg)


Sent from my iPhone using Tapatalk

Finally got the ute to the sandblasters, a couple of hours later and it’s all done, then home to get primed.
She’s starting to go ahead in leaps and bounds now.(https://uploads.tapatalk-cdn.com/20210524/845288be85fb0262c46f16394253819c.jpg)

(https://uploads.tapatalk-cdn.com/20210524/91cb6d1352c12be954489ce04ce2f3bb.jpg)

(https://uploads.tapatalk-cdn.com/20210524/9ac3cb2bbcc8329a610a06d052eb9314.jpg)

(https://uploads.tapatalk-cdn.com/20210524/a51a63fede253cedce635b92b7a35501.jpg)

(https://uploads.tapatalk-cdn.com/20210524/75f27a6b576ba8c1cef2c478580c7997.jpg)

(https://uploads.tapatalk-cdn.com/20210524/f1d1f094c52cf6d3535207bb20f2ba55.jpg)

(https://uploads.tapatalk-cdn.com/20210524/368de3c2aab71e9579d29734c96af490.jpg)


Sent from my iPhone using Tapatalk

any updates Mal ????

 I was wondering how he is going as well BLACKY It has been a while since his last update hope he is doing better than me

There are some updates on Facebook - https://www.facebook.com/groups/862124657272742/user/100000074020024/

Sorry guys, can’t keep up with the updates and have been posting on the modified FE FC Facebook page


Sent from my iPhone using Tapatalk

we thought you'd been banned from the forum  ::)

Hey all, been a fair bit done to date.
All the floor is finished.

(https://uploads.tapatalk-cdn.com/20220211/4802c2c7079fe6b69aaa65f1024b2a1f.jpg)

(https://uploads.tapatalk-cdn.com/20220211/c9efd1d9412a52ad673b62d516340fb4.jpg)

(https://uploads.tapatalk-cdn.com/20220211/35ea3d586939d00a190c7b6dc41de67d.jpg)

The air con, battery tray and power steering pump is in the hatch area behind the seat wall

(https://uploads.tapatalk-cdn.com/20220211/2ca677b1e908fa6e4fea7f84b6dc8b9c.jpg)

(https://uploads.tapatalk-cdn.com/20220211/be23ebeac38a43ac1d89e1649fd90b2d.jpg)

(https://uploads.tapatalk-cdn.com/20220211/1969ae1f5612784f5af031de29aafaed.jpg)

(https://uploads.tapatalk-cdn.com/20220211/bc01b1d963e3d70309a6f30f7d4eea8f.jpg)


The lift up floor in the back is done.

(https://uploads.tapatalk-cdn.com/20220211/a75b5a4774a6f7703e86d7229a0951aa.jpg)

I made quick release hinges for the lift up floor lid

(https://uploads.tapatalk-cdn.com/20220211/f355a3e6dc39c823cd06db50feb14545.jpg)

(https://uploads.tapatalk-cdn.com/20220211/66f69c8852884f154f87e2457c1c7626.jpg)


(https://uploads.tapatalk-cdn.com/20220211/1fcb11fb7d52f45b5f3e28c12306a3b7.jpg)

(https://uploads.tapatalk-cdn.com/20220211/7930c26910b00dc1a8de1dc40c9deb7f.jpg)

(https://uploads.tapatalk-cdn.com/20220211/933247378ddbd8afcf420ca6b6b07480.jpg)

(https://uploads.tapatalk-cdn.com/20220211/5ef9a13df9f0798b4991d7ca3d369270.jpg)

The strips I made for the back I had chromed

(https://uploads.tapatalk-cdn.com/20220211/8a891680763cb1c603b9a5a2add8739c.jpg)

I made polished stainless rods to hold the tailgate to replace the old rusty ones.
Each side was made up of 5 pieces all welded together and then polished.

(https://uploads.tapatalk-cdn.com/20220211/725647c25f3fc6c96328827beae3072c.jpg)


(https://uploads.tapatalk-cdn.com/20220211/ff63142bcd1d90f5a9d725bbd69857d2.jpg)

(https://uploads.tapatalk-cdn.com/20220211/547f253f41f2ea278a4ac2e5fc690ceb.jpg)

(https://uploads.tapatalk-cdn.com/20220211/3c507f4aded2ae6e902957f9c1e89315.jpg)

I’ve repaired the tailgate inside and out and the tail light panel

(https://uploads.tapatalk-cdn.com/20220211/471d19ace0313555517d1f92f7afaa39.jpg)

(https://uploads.tapatalk-cdn.com/20220211/ff2811a2e7d6c9cee323e54cbf52f977.jpg)

(https://uploads.tapatalk-cdn.com/20220211/4a7b4bc82a61a1dab647848e9f1fb665.jpg)

(https://uploads.tapatalk-cdn.com/20220211/42797eb2c76b09f9fd65e6f9beed3866.jpg)

(https://uploads.tapatalk-cdn.com/20220211/a35c9759e90a955325a65fc574982c43.jpg)

I also made up these little trims to go on top of the tail lights. These were ground down from sedan trims.

(https://uploads.tapatalk-cdn.com/20220211/2a0746ce12cdbc86bd2c6ba80a693156.jpg)


(https://uploads.tapatalk-cdn.com/20220211/6150dc3f21c1e85b00b3f43ada0b5bcc.jpg)

(https://uploads.tapatalk-cdn.com/20220211/5ad0b813b49e93dd9cbd61b8fe431adc.jpg)

I made and fitted hidden tail gate hinges

(https://uploads.tapatalk-cdn.com/20220211/1cbdd31a6420d0c17c8c5ac3fec5b64d.jpg)

(https://uploads.tapatalk-cdn.com/20220211/ef9dc97c174c123300dbad98588d1617.jpg)

(https://uploads.tapatalk-cdn.com/20220211/571e4a3cbf7b5518b3a6478180122048.jpg)

(https://uploads.tapatalk-cdn.com/20220211/03a5cb63ca8f5b0511ed4dc4f0903206.jpg)

(https://uploads.tapatalk-cdn.com/20220211/23d77ef434b4bd6398617e11c781e6ca.jpg)

(https://uploads.tapatalk-cdn.com/20220211/16b7f4a43d2d6493bab897271a323983.jpg)

(https://uploads.tapatalk-cdn.com/20220211/cfbb934e33ca954b50a84cce7d7711bc.jpg)

(https://uploads.tapatalk-cdn.com/20220211/5f65d255fcbc215b284b4fa0fe78683c.jpg)

(https://uploads.tapatalk-cdn.com/20220211/c4a47109ee4815c8ac3df419c38b8c95.jpg)

(https://uploads.tapatalk-cdn.com/20220211/7422f7f629b34ebbd62d9e1507271cca.jpg)


I’ve made a hard cover for the back that’s operated by electric rams.

(https://uploads.tapatalk-cdn.com/20220211/25bd4e43d1b3baf87ee64c3b4845b320.jpg)

(https://uploads.tapatalk-cdn.com/20220211/2d598636663497bfa7e096ac5f863e5d.jpg)

(https://uploads.tapatalk-cdn.com/20220211/01c5e75e60633bef4cd48295e631aa33.jpg)

The hinges took a fair bit of working out but I ended up using VN Commodore bonnet hinges

(https://uploads.tapatalk-cdn.com/20220211/952f226a3bd97382983c77233b31e1eb.jpg)

(https://uploads.tapatalk-cdn.com/20220211/69ea09d1096ce5ba76bf2f5e761b055b.jpg)

(https://uploads.tapatalk-cdn.com/20220211/4169a4f3ac3be264ad8f35a51f95f88c.jpg)

(https://uploads.tapatalk-cdn.com/20220211/9e1de9bdda19bd4af9c5f49a7545c341.jpg)

Instead of using gas rams on the lid I used linear actuators

(https://uploads.tapatalk-cdn.com/20220211/2e174f4b7dbba94c963cbd548755bb1b.jpg)

(https://uploads.tapatalk-cdn.com/20220211/238af9b35861e4d8c9979c582cfddc79.jpg)

(https://uploads.tapatalk-cdn.com/20220211/cd2a81aaff1fdbe8aa93a1def9989ba2.jpg)

Then I designed and made quick release top actuator brackets in case the electrics failed. These were operated by a cable similar to the bonnet release cable. When you pull the cable the top bracket drops down and allows you to lift the lid by hand.

(https://uploads.tapatalk-cdn.com/20220211/96fb928b7f80c0de094c2ff63ec4e26b.jpg)

(https://uploads.tapatalk-cdn.com/20220211/73db58052239290ff76cd24450e1f4c5.jpg)

(https://uploads.tapatalk-cdn.com/20220211/abd7e7b06d8e87687af52918fbdb4527.jpg)

(https://uploads.tapatalk-cdn.com/20220211/7bd63b9163099e1074c34cbc3653ae8d.jpg)

(https://uploads.tapatalk-cdn.com/20220211/60b11137c8eed887cd000456188afc9c.jpg)

(https://uploads.tapatalk-cdn.com/20220211/f2b2ec579645450a58e450d6ab3f454a.jpg)

(https://uploads.tapatalk-cdn.com/20220211/ede54b11694115aace37f01f3379d02d.jpg)

(https://uploads.tapatalk-cdn.com/20220211/6bd415ed9c5db75d29f28ff78b530b08.jpg)

(https://uploads.tapatalk-cdn.com/20220211/26d8a59f213c27935747861def03bfa7.jpg)

(https://uploads.tapatalk-cdn.com/20220211/364df8c27af9dafe19ebd1bcf98650b2.jpg)

(https://uploads.tapatalk-cdn.com/20220211/31dfe78bc1adf0e32ca197f3007264b0.jpg)

The top will be covered with water proof vynal.






Sent from my iPhone using Tapatalk

Brilliant Mal , just brilliant..Vern

Your design and engineering work is brilliant.  Absolutely stunning

Thanks Malcolm for going to the trouble of posting it on here. Looking on Facebook isn’t the same. Custom work with the tailgate and hard lid is brilliant. The rest of your work is simply outstanding of course. Inspiring stuff.


Sent from my iPad using Tapatalk

Great engineering Mal keep posting. Love your work


Sent from my iPhone using Tapatalk

All I can say is WOW absolutely amazing work.

Thanks guys for the supportive comments.
Another little bit I made was a stainless trim to go around the number plate recess.
This I made out of 2 EJ Holden cowl-panel moulds.
The 2 trims were cut into 3 pieces and welded together with stainless wire in the mig.

(https://uploads.tapatalk-cdn.com/20220212/21f9931b5d7388933c44be177e4fbf2f.jpg)

(https://uploads.tapatalk-cdn.com/20220212/fe5b4877d47ded8a275648855e9f6131.jpg)
(https://uploads.tapatalk-cdn.com/20220212/77fb53d87dba2dc7052b64b67759c15a.jpg)

(https://uploads.tapatalk-cdn.com/20220212/d64d8775e5d0f04a3232c5786790f14e.jpg)

(https://uploads.tapatalk-cdn.com/20220212/9d0b597df161f1e7f5176e6f41669357.jpg)

(https://uploads.tapatalk-cdn.com/20220212/31ac1cd3a41790521fad8b9c640a565b.jpg)

(https://uploads.tapatalk-cdn.com/20220212/99c84eed744f96ab99bed4a0ebf16ed2.jpg)

(https://uploads.tapatalk-cdn.com/20220212/0203f063591a8d261091e90bbc765c26.jpg)

(https://uploads.tapatalk-cdn.com/20220212/e65e05d85f77b88c2276582bf929d3df.jpg)


Sent from my iPhone using Tapatalk

Just finished off the release cable for the hard cover.

(https://uploads.tapatalk-cdn.com/20220214/34bdd5e8aac18791ba097cc70e92fb61.jpg)

(https://uploads.tapatalk-cdn.com/20220214/9b26e783f42afac8db3c4457ae949426.jpg)

(https://uploads.tapatalk-cdn.com/20220214/d8b7fc4da7686add332b250d80ab4eb5.jpg)(https://uploads.tapatalk-cdn.com/20220214/906f4b79fa3166b18ee24bf38bfc0bed.jpg)

(https://uploads.tapatalk-cdn.com/20220214/3e79ebad61303a9509ddab5937692c76.jpg)


Sent from my iPhone using Tapatalk

Great work Malcolm. Free room and board at my place any time you are in Willunga mate!


Sent from my iPad using Tapatalk

Thanks mate, I’m planning on putting some K’s on the old Ute when she’s done.


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Shameless plug for the FB EK nats at Nuriootpa June long weekend


Sent from my iPad using Tapatalk

Got my new gauges for the Ute.
They look great. Came from Classic Instruments in the states.

That will be my next job I think doing the mods to the dash to fit the instruments

I had the made with the red needles.

(https://uploads.tapatalk-cdn.com/20220215/40a44786b63935dfab2afc52e356999e.jpg)

(https://uploads.tapatalk-cdn.com/20220215/6851fad8ff9727572525c68464c7a14a.jpg)

(https://uploads.tapatalk-cdn.com/20220215/8d97be14efa221e77b6568be75ff4a0e.jpg)


Sent from my iPhone using Tapatalk

Finally finished off the new dash, started with separating the inner and outer sections
.(https://uploads.tapatalk-cdn.com/20220302/8e89c2ceb810c3385092991f94a7ba39.jpg)

Then fitted the new speedo, this just needed a bit of trimming to make the hole about 3mm bigger all round

(https://uploads.tapatalk-cdn.com/20220302/0f0859b58b686fc71ca26261fe43b638.jpg)

(https://uploads.tapatalk-cdn.com/20220302/b21df715d558bf33228908874bf44f5b.jpg)

Then made the new section for the other gauges and warning lights

(https://uploads.tapatalk-cdn.com/20220302/53bedf055e9160eb4265e960b9124839.jpg)

(https://uploads.tapatalk-cdn.com/20220302/49414bace3625f2603fa1069fa75f115.jpg)

(https://uploads.tapatalk-cdn.com/20220302/f58fdde66cabdb85b484ff055ed9e879.jpg)

Then welded them in

(https://uploads.tapatalk-cdn.com/20220302/d059b793eb072e7bd86be0afc9baa7ee.jpg)

(https://uploads.tapatalk-cdn.com/20220302/a34f0016a4f4b2ee4bed9af17d93298b.jpg)

Next was to modify the plastic facia. I wanted to keep with the original look.
The facia was cut into 5 pieces to start with.

(https://uploads.tapatalk-cdn.com/20220302/a65ac3f812fff634d86e2ebb1a6b3880.jpg)

(https://uploads.tapatalk-cdn.com/20220302/e8b5588cbf4bf22d007b2ae956902ad9.jpg)

(https://uploads.tapatalk-cdn.com/20220302/578e993649cb03cc47d5c3e252aee128.jpg)

(https://uploads.tapatalk-cdn.com/20220302/ac1a8f204d50b9d94c2ae1372cf8d63e.jpg)

I sanded all the inside and outside of the plastic and taped it in place to the dash where it had to go. I then joined it all together with normal body filler. I also filled in the back for a bit more strength.

(https://uploads.tapatalk-cdn.com/20220302/ba1419e0c518184695196254eea90d37.jpg)


(https://uploads.tapatalk-cdn.com/20220302/6bc5e90b01b2f5b87299906c564001f2.jpg)

(https://uploads.tapatalk-cdn.com/20220302/da09ef5ec6be60525f0d60ffd69a4b85.jpg)
(https://uploads.tapatalk-cdn.com/20220302/53c104d115858652793aaffd659d33aa.jpg)

(https://uploads.tapatalk-cdn.com/20220302/0279183a2bd1413cfb5787658be115a4.jpg)

(https://uploads.tapatalk-cdn.com/20220302/c5203faeb5492a5534f97ca54cb65f58.jpg)

(https://uploads.tapatalk-cdn.com/20220302/e0580eefe65ee0549deba5d75bba40fc.jpg)

(https://uploads.tapatalk-cdn.com/20220302/95ef2d51a88dc5184642a3af73404356.jpg)

(https://uploads.tapatalk-cdn.com/20220302/f4779df16862632530d79bdb75be6944.jpg)

Once the facia was finished I did a bit of tidy up on the dash panel

(https://uploads.tapatalk-cdn.com/20220302/26e96520dbc1932707ebc884bf05d3ec.jpg)

Starting to take shape

(https://uploads.tapatalk-cdn.com/20220302/48efd4d0384d52374450a6b9adfb1d32.jpg)

(https://uploads.tapatalk-cdn.com/20220302/653a11841c6f9c1831c52707ed66d2c3.jpg)

Then for a bit of primer, I also sprayed a bit of black on the facia to show how it will look all finished

(https://uploads.tapatalk-cdn.com/20220302/eaf553ad29c6f698821e1d9eed86e508.jpg)

(https://uploads.tapatalk-cdn.com/20220302/b56a9c1f730a3e61f5814bfacd39b21a.jpg)

(https://uploads.tapatalk-cdn.com/20220302/1a00f818439be22a62168385fa59be4e.jpg)

(https://uploads.tapatalk-cdn.com/20220302/4b47f84951ec726b8c8fad51af63e0a2.jpg)

Thanks for looking


Sent from my iPhone using Tapatalk

I'll take one!
This looks great Mal, a lot of thought and work there has paid off

Oh my... your skills are amazing. What is your trade?
Nick

Hey Clay ..Free board in Willunga hey ??? Well he's gotta go thru Sydney , North West in particular to get there , he will get the penthouse at back of workshop , Uber eats , fridge of XXXX , we don't touch the stuff "much" ...multiple test drives , he just has to run a 3 month multi skills workshop for us ..Vern

Thanks guys.
Nick, when I left school all I wanted to be was a panelbeater, couldn't get an apprenticeship anywhere. Ended up getting  a trade as a wood machinist and did that for 10 years. In that time I did paint and panel work on the side.
Then I got a job in a major smash shop in Brisbane as a painter, did that for about a year or so then moved to Redcliffe in a small panel shop as a painter.
Buy this time I had built up enough equipment and moved to Hervey Bay and started up my own smash repair shop. Ended up with 6 staff, and a tow truck doing everything from major smash work to full resto's. Did that for 13 years, in that time I got my papers for trade qualified for painter.
Ended  up getting the shits with it all as it took up all my time leaving  nothing for my own projects and family.
I went back to night college and studied, got myself fit, learned how to touch type, this was all while running my panel shop.

Then got out of the panel shop and  joined the Qld Police and have been there in Highway Patrol ever since, 19 years.
Now I enjoy playing with cars again, building my own stuff in the back yard with less than 12 months before I retire from QPS.

Mal

Awesome Mal,

Shit how old are you 100?? :D :D.

I hate seeing stuff like this, makes me feel bad about my dodgy work! Lol, awesome build.

Ok so I’m still cruising along slowly.
I had a bit of trouble with the tailgate and tail light area, being that they sold me the wrong primer so to be on the safe side I ended up blocking it all off and respraying it.
They said the primer I had on it would be OK but as I had to get more primer I thought I’d put the right stuff on everything.

(https://uploads.tapatalk-cdn.com/20220501/75ad9136b0550245c6809490802abe57.jpg)

(https://uploads.tapatalk-cdn.com/20220501/c4616529ec1224a70f47535c3c37e7c3.jpg)

(https://uploads.tapatalk-cdn.com/20220501/db8f7a365dc3da97287441bb0e4f8bab.jpg)


Also I cleaned up the bonnet skin and the front and rear inner pieces and got them primed.

(https://uploads.tapatalk-cdn.com/20220501/67dbd0406e601f55b49747f3322bbbd7.jpg)

(https://uploads.tapatalk-cdn.com/20220501/9417102912167fa030704537f9d25d1e.jpg)


I welded up the seam on the rear inner support and straightening that up.

(https://uploads.tapatalk-cdn.com/20220501/2464569eb322ca73965631c6634286c9.jpg)

(https://uploads.tapatalk-cdn.com/20220501/cf57ecb8cc88236313c3db9b2a876c51.jpg)

(https://uploads.tapatalk-cdn.com/20220501/fa7af43ea7965f16aebfac9131f213c5.jpg)

(https://uploads.tapatalk-cdn.com/20220501/af4802163e356e00ade61aecfd4d6811.jpg)


And now it was time to turn it around and start on the other end, firewall.

(https://uploads.tapatalk-cdn.com/20220501/a21423e26303749082f31e0b899cf9ab.jpg)

(https://uploads.tapatalk-cdn.com/20220501/7b22fb4d39f3532d031d6c7322b269b0.jpg)

(https://uploads.tapatalk-cdn.com/20220501/5b1f26d7a43dc4ef48ecdbaf079db045.jpg)


(https://uploads.tapatalk-cdn.com/20220501/8b64475b57bc1cc1c1a768f3d7498430.jpg)

(https://uploads.tapatalk-cdn.com/20220501/25154d1f17809a5195b00b74c590643a.jpg)

(https://uploads.tapatalk-cdn.com/20220501/1840c698f85ec1408b4204d4039ba3cf.jpg)


Nothing a skim of filler can’t fix.

(https://uploads.tapatalk-cdn.com/20220501/52646603464fca704409cff36d7d3027.jpg)

(https://uploads.tapatalk-cdn.com/20220501/7512ed2cab02713bd0a7892bddc76108.jpg)

(https://uploads.tapatalk-cdn.com/20220501/6281721a8539b397dbcd65ca084e47ca.jpg)

Now just started on the door openings, getting them tidied up, any dints, spot weld indentations ect.


Sent from my iPhone using Tapatalk

Mal W
      How is the progress on your ute going been a while  ???

Been tinkering with a lot of little stuff for a while now.

Recessed electric aerial in the rear quarter.
Along with a polished stainless surround trim.

(https://uploads.tapatalk-cdn.com/20221020/431ffa37d18b861270feb51115d8ff3c.jpg)
(https://uploads.tapatalk-cdn.com/20221020/9b13641145764f9ce7e520d97190b06b.jpg)
(https://uploads.tapatalk-cdn.com/20221020/15cbe9677e69ca440a7631336d6dd54d.jpg)
(https://uploads.tapatalk-cdn.com/20221020/bf8f70a6621b96485dc6e11c9de01e69.jpg)
(https://uploads.tapatalk-cdn.com/20221020/68374b01b6487b5669024d38412c2c33.jpg)
(https://uploads.tapatalk-cdn.com/20221020/ea83ab87695437cd0ebe1e112c06fec3.jpg)
(https://uploads.tapatalk-cdn.com/20221020/5cc4d5913cd272080fecd9e42f559d0c.jpg)
(https://uploads.tapatalk-cdn.com/20221020/71316fb4354f8044c10d1224626cfffc.jpg)
(https://uploads.tapatalk-cdn.com/20221020/7f5887f63c5a5083834e617f6777fa7a.jpg)
(https://uploads.tapatalk-cdn.com/20221020/3933ab8b47d6534efafa4e1fed47397a.jpg)


Sent from my iPhone using Tapatalk

Next was adding a bit of bling to the rear wheel arches.
Stainless stone protectors, these are off a HR Holden.
Took a lot of hammering to modify to fit the FC.

(https://uploads.tapatalk-cdn.com/20221020/fcb25062f22f4812f233e918ee9962bf.jpg)

They are quite difficult to work as they are only thin stainless.

(https://uploads.tapatalk-cdn.com/20221020/92a236922b35a6363fe964c5be85398c.jpg)
(https://uploads.tapatalk-cdn.com/20221020/5e962a8587e8376f0a29f4db7fadd77d.jpg)
(https://uploads.tapatalk-cdn.com/20221020/098ed6550025ffd04af7447457ca9217.jpg)
(https://uploads.tapatalk-cdn.com/20221020/200fab7a4af36873d0324f881b858b9d.jpg)
(https://uploads.tapatalk-cdn.com/20221020/be32fa7dc71331c2d41be5acd542e326.jpg)

These are the originals, the crease half way up is what I had to flatten out.

(https://uploads.tapatalk-cdn.com/20221020/c5ccb25eb7d4f858d7afa55edba531a9.jpg)
(https://uploads.tapatalk-cdn.com/20221020/07b48c8bb5b4927c203436b4569fdb74.jpg)

Pretty happy with how these turned out.


Sent from my iPhone using Tapatalk

Next was the cover for the tailgate latch. Was going to get an original and chrome it, but I thought I’d have a go at making one out of stainless.

(https://uploads.tapatalk-cdn.com/20221020/7f452e3346040b74093b4fde115661d3.jpg)

Once again a lot of hammering. All done by hand

(https://uploads.tapatalk-cdn.com/20221020/b9437dcb112d4dc4994909de7ae0d71f.jpg)

Polishing took just as long to do as it did to make it.

(https://uploads.tapatalk-cdn.com/20221020/2251d8581fa2ee35f80bec5be8a12d83.jpg)
(https://uploads.tapatalk-cdn.com/20221020/432795b3241f2219700a5609fe4d8d9d.jpg)

The end result was quite pleasing

(https://uploads.tapatalk-cdn.com/20221020/a81bab219709d8ef05e6077c1e11f459.jpg)

I’m thinking I will attach it with heavy duty velcro so I don’t have to drill holes in it.

(https://uploads.tapatalk-cdn.com/20221020/843f205c80d1b5d2483bbb021ac776dc.jpg)


Sent from my iPhone using Tapatalk

I love your work Mal this is going to turn out to be one really nice Ute.

Also done a modification to the original bench seat by converting it to full electric.
I used the seat bases from a commodore Calais.

Firstly I stripped the seat and cleaned up the frame



(https://uploads.tapatalk-cdn.com/20221022/f30cdd74801393d78f31fd9712dcd383.jpg)
(https://uploads.tapatalk-cdn.com/20221022/42c0bfa6428f95890f64c29d7ddda1d5.jpg)


I cut one of the seat runners in half and extended it

(https://uploads.tapatalk-cdn.com/20221022/9aaf742833619470f9e758c45a9201d7.jpg)

(https://uploads.tapatalk-cdn.com/20221022/ca5b05eb680c1076f9837a8783fc9cf0.jpg)

Had to make up some new feet

(https://uploads.tapatalk-cdn.com/20221022/1df117a97586c7af9a9facfa14794068.jpg)

(https://uploads.tapatalk-cdn.com/20221022/9f06b7a6c2428a93a87990a64ada206e.jpg)

I then mounted the side hinges before cutting the seat frame

(https://uploads.tapatalk-cdn.com/20221022/19b5c56515289e3a17a2f82c4ce1603d.jpg)

Next the back motor

(https://uploads.tapatalk-cdn.com/20221022/1b27b4994a8aba16f76afa41367f9c3e.jpg)

(https://uploads.tapatalk-cdn.com/20221022/6a7104dc8ed89c0f1cbbaf0c416536e1.jpg)

Then cut the frame

(https://uploads.tapatalk-cdn.com/20221022/754631ac613fd153a5e43b0a8c45f47e.jpg)

(https://uploads.tapatalk-cdn.com/20221022/b7602cd44663e151a7081a0bec5735eb.jpg)

(https://uploads.tapatalk-cdn.com/20221022/27b013039b7a1b477a3ab6e475bb6dc1.jpg)

(https://uploads.tapatalk-cdn.com/20221022/949da240abbb3bb2fbe25ab1e534204d.jpg)

(https://uploads.tapatalk-cdn.com/20221022/eccbebf67608707dc9274dd854acb4cc.jpg)

(https://uploads.tapatalk-cdn.com/20221022/9262b6a7748bd0eb5d810649670e2834.jpg)

And it all works great. Electric slide forward and back, height adjustment and back tilt.


Sent from my iPhone using Tapatalk

I think you must have a engineering degree as well as all the other qualifications you mentioned in a earlier post great work Mal keep it coming

As an engineer I beg to differ - an engineering degree doesn't teach you practical skills like this.  Mal's work is more in the realm of genius.

Rob

I will agree to that in my working life time i have meet so called professionals that didn't know shit from clay as i'am sure a lot of you know there isn't anything like hands on  to get it done

Very clever Mal

Thanks for the comments guys.

Ok a bit more catching up.
I made the opening and closing of the air vent electric by use of an actuator I had.

Tha actuator was 100mm stroke and I needed to reduce that movement to 30mm.
So that meant pulling it apart, cutting it down in length and moving the micro cut off switches. A fair bit of messing around.

(https://uploads.tapatalk-cdn.com/20221022/1ccc5b8ff40e7ae4304065e948a2cd5d.jpg)


(https://uploads.tapatalk-cdn.com/20221022/43dba0be8cd47ebb8955eddb55bdbb0e.jpg)

I made up a bracket to mount the actuator to and fitted that in the original position of the old opening handle

(https://uploads.tapatalk-cdn.com/20221022/4a80d246a09f8a38908dff4d8205e9c9.jpg)

The wiring was a real pain as I didn’t have a diagram for it.

(https://uploads.tapatalk-cdn.com/20221022/1349f9dfbdcdfe1cd1135a624040ed0c.jpg)

(https://uploads.tapatalk-cdn.com/20221023/715d9b2b55fd51da0d74f2717406418f.jpg)



Sent from my iPhone using Tapatalk

Agree with the others Mal. And Billy, I’ve known plenty of graduate engineers in my day and still have trouble telling them from shit.
Cheers,
Clay 8 )


Sent from my iPad using Tapatalk

Congratulations on your skills fantastic stuff. Have you considered selling the Wheel arch covers and the Vent actuator?
Cheers
Graham

Maybe when I’m finisher the Ute, I might look at making a few things.

Latest thing I’ve been working on is my under dash panel.
This will house AC vents and a few switches.

As usual one thing leads to another. With what I was wanting to do the glove box when open would hit on the lower dash panel.

So I had to change the hinge position of the glovebox. This was done with stainless butt hinges and remade stainless side brackets.

(https://uploads.tapatalk-cdn.com/20221024/5d3b305b72a0986aa36cccdd489ed073.jpg)

(https://uploads.tapatalk-cdn.com/20221024/c695ea511193cdc9206e3946751f6e83.jpg)

All polished up, just needing to be bent to shape.

(https://uploads.tapatalk-cdn.com/20221024/6b7025d8a0bf7ad99cd020987471e908.jpg)

(https://uploads.tapatalk-cdn.com/20221024/6e9ebd23d3785fac398d0ef820864085.jpg)

(https://uploads.tapatalk-cdn.com/20221024/bbea70d8f9aef8be45b4edab0b87a115.jpg)

(https://uploads.tapatalk-cdn.com/20221024/61b7eb15579b9fbbb7ae209e40be957d.jpg)
 
Then with that done I remade the radio surround so the sides were a bit deeper and would fit flush with the under dash panel.

I made this out of stainless and polished it. I like making these smaller bits out of stainless as it saves on the chrome plating.

(https://uploads.tapatalk-cdn.com/20221024/0df8623a4d60c493676f99fa9ba6157c.jpg)

(https://uploads.tapatalk-cdn.com/20221024/96bce978b81ef4da4be7c225c15d1409.jpg)

Just welded up the corners by using stainless wire in the mig, linishing it back and polishing it.

(https://uploads.tapatalk-cdn.com/20221024/1e8fcfd55252f093ff47cbbc7ee2ad2a.jpg)

(https://uploads.tapatalk-cdn.com/20221024/48f1d057cb2e17cdbba73cb67846060c.jpg)

(https://uploads.tapatalk-cdn.com/20221024/a85d915ced2c627c1a5bff4a20f3cf26.jpg)

Original and remade

(https://uploads.tapatalk-cdn.com/20221024/98f36c327db36095cdfdf04a8ffa814f.jpg)

(https://uploads.tapatalk-cdn.com/20221024/bfc8034a5b5284c6de44c0b7051605a4.jpg)

(https://uploads.tapatalk-cdn.com/20221024/f326605e4ce7f11889bba036072ab722.jpg)
 
Now onto making the lower panel.
As usual I made a cardboard pattern of what I was going to make.

(https://uploads.tapatalk-cdn.com/20221024/8bdfbbf1f546948e52d5279d06616f99.jpg)

(https://uploads.tapatalk-cdn.com/20221024/90744cd8ae6af2be6740f75af9414ae6.jpg)

(https://uploads.tapatalk-cdn.com/20221024/9a41673be1fdd47baf71708cf64ec780.jpg)

(https://uploads.tapatalk-cdn.com/20221024/ac528edc97a6e5694bddfdaca0250c9b.jpg)

With the two bits made it was just a matter of welding it together.

(https://uploads.tapatalk-cdn.com/20221024/1f14cf75ddc2370f7a7a3f6e8c9e5d6f.jpg)

(https://uploads.tapatalk-cdn.com/20221024/6c2fd046c54463e5d5a41e381bdeb233.jpg)

(https://uploads.tapatalk-cdn.com/20221024/d14eb4494e408d76368c59f257c151b3.jpg)

(https://uploads.tapatalk-cdn.com/20221024/7a496f4ee9563684ecb5102d87c99bb7.jpg)

All welded up and smoothed off.
Fits like a glove

(https://uploads.tapatalk-cdn.com/20221024/8f628c79f242e784b6aed7b1242d238a.jpg)

(https://uploads.tapatalk-cdn.com/20221024/3bc320e945b663da0f5e815bb6d2a324.jpg)

(https://uploads.tapatalk-cdn.com/20221024/6023c6322ec81885f2a106a1adfa0eb0.jpg)

(https://uploads.tapatalk-cdn.com/20221024/86efecbda3d2a3cdebc6d251b0858b12.jpg)
(https://uploads.tapatalk-cdn.com/20221024/ca7d246bc47653d8e5019c7d74238a5e.jpg)

Really happy with the look.
As you can see now the glove box lid is no where near the lower section.

(https://uploads.tapatalk-cdn.com/20221024/22b7c48a8a193da865ab683b65e27ff8.jpg)

While I was around the dash I made a panel to house a couple of speakers behind the speaker grill.

(https://uploads.tapatalk-cdn.com/20221024/d12a0f31154dd59a31c3bb551398d2f2.jpg)

(https://uploads.tapatalk-cdn.com/20221024/afdcf8d01f88f70fe4758ae4f904f5b4.jpg)

Last of all I made a surround to go around the remote reservoirs hiding under the ash tray lid.

(https://uploads.tapatalk-cdn.com/20221024/655d32da3b5c379e52a79a8397785275.jpg)

(https://uploads.tapatalk-cdn.com/20221024/64ff6b0c5e09af509f5f603cb8b8bd19.jpg)

(https://uploads.tapatalk-cdn.com/20221024/a02d3930b140308141564cddf34429c6.jpg)

That’s all for now, thanks for looking.


Sent from my iPhone using Tapatalk

SPECTACULAR Mal,
The period look with the mod cons is fantastic.
Keep up the great work. Hope to see it on the road some day soon.

Cheers Stewy   8)

Time for an update
Inside the tray is all repaired
RH rear quarter & sill is repaired

(https://uploads.tapatalk-cdn.com/20230302/7d5dae746e7ee2b337062129fcd32a9d.jpg)

(https://uploads.tapatalk-cdn.com/20230302/e81d5cb4435c3285433ded686fe27674.jpg)

(https://uploads.tapatalk-cdn.com/20230302/ffa7b6ee8a38ace00a2774f789e2dcc1.jpg)

(https://uploads.tapatalk-cdn.com/20230302/dbda76050bc0ce6f3b50a976a444b029.jpg)

(https://uploads.tapatalk-cdn.com/20230302/4f97ff8419c41a796dd1ea3d30fafc11.jpg)

(https://uploads.tapatalk-cdn.com/20230302/9f46999c5bcb8b38bae0b23c3a8aeee9.jpg)

(https://uploads.tapatalk-cdn.com/20230302/a333e0b5cf38b4f9793b7186fbc93305.jpg)

(https://uploads.tapatalk-cdn.com/20230302/af28842e6b20ee79c8dc2a52ddc12fd2.jpg)

(https://uploads.tapatalk-cdn.com/20230302/3527233d82a5c973d56a215877c10851.jpg)


Sent from my iPhone using Tapatalk

Finally have the engine rebuild started also.
So far I’ve de-burred the engine block and heads.
Also done the heads, ported & polished.
Intake manifold ports matched to heads, intake and timing case cover smoothed ready for ceramic
coating.(https://uploads.tapatalk-cdn.com/20230302/eb29a3a68f4a2a071f0f785c1341fd66.jpg)

(https://uploads.tapatalk-cdn.com/20230302/1ab625494f101b9b53b79405b1241574.jpg)

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(https://uploads.tapatalk-cdn.com/20230302/959ed9ba09dda0b92ddbec2d975f83ef.jpg)


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 Looks  a treat Mal, did you do the porting and polishing yourself ? Be careful when you put the lifters in mate  :o  :'(

Yeh i did it myself
Got to watch those lifters, a trap for young players  ;D

 G'day Mal, guessing you are retired now , this thing has probably got plates on it the way you work - how about an update mate ?????

Wow I have been dragging the chain on the updates.
Well Iam now retired and looking forward to getting back into the ute.
Not a lot has happened really.

Motor is finished, and I didn't put it together, the machine shop did.

Will get some progress pictures sorted out over the weekend and get everyone up to date.

Mal

Well it’s to hot today to go out to the shed so time to try and update my build.

I did the tube for the wiring into the doors for central locking, windows ect.

First I got some large stainless bolts and turned down the heads and drilled the centres.

(https://uploads.tapatalk-cdn.com/20240122/1995e9dd0d098edd93021ac5a40a2194.jpg)

I also machined down the nuts so they weren’t so bulky.

(https://uploads.tapatalk-cdn.com/20240122/b0879210673804d13797fef17cf3bfb3.jpg)

(https://uploads.tapatalk-cdn.com/20240122/ed5cee0056540b44fa1c90c0469d7979.jpg)

And the tubing is from Bunnings, good old shower tubing.

Next was fitting them into the doors and pillar.
As when the door and pillar is so close I made up recessed sections and welded them in.

(https://uploads.tapatalk-cdn.com/20240122/d35e58db015d7a81b04eba278f07cbdb.jpg)

(https://uploads.tapatalk-cdn.com/20240122/f79ed5fb9e308b29bf7b78401b2a977d.jpg)

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(https://uploads.tapatalk-cdn.com/20240122/bf9484bc466596903b044ca95fe405c0.jpg)

(https://uploads.tapatalk-cdn.com/20240122/7315e69d32717f964011e57bf53eb42b.jpg)

(https://uploads.tapatalk-cdn.com/20240122/871a075ccabdad0f21c02b7999750a46.jpg)

(https://uploads.tapatalk-cdn.com/20240122/09857e399865ccf82cd64565187394e2.jpg)

(https://uploads.tapatalk-cdn.com/20240122/5c6a4498403d022c626305f79b745ba6.jpg)

(https://uploads.tapatalk-cdn.com/20240122/da8ed7928ef1bf4683b79600e17008bc.jpg)

It all works a treat.


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I ended up doing a fair bit of messing around gaping the doors to get a nice consistent gap.

(https://uploads.tapatalk-cdn.com/20240122/c03a3501f67eb8bf62da044954fada72.jpg)

(https://uploads.tapatalk-cdn.com/20240122/5ef0bf6f5a29ea74c5fd942d46159749.jpg)

(https://uploads.tapatalk-cdn.com/20240122/c4550073161f68282bce614cbe10211e.jpg)

(https://uploads.tapatalk-cdn.com/20240122/d248e9a7b7ce9d8ea9dc6824932a547b.jpg)

(https://uploads.tapatalk-cdn.com/20240122/391e1a64d4eeaddf27e242d3714ed84b.jpg)

Still a bit of fine tuning to do.


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Rust and dint repairs on the doors.

The left door is done and wasn’t to bad as far as rust and dints go, the bottom inner fold had to be replaced as it was to far gone.

The door still needed a light skim to get it right.

(https://uploads.tapatalk-cdn.com/20240122/4c30937ada7aed69b32348b696466960.jpg)

(https://uploads.tapatalk-cdn.com/20240122/b842d6da0bd9af9becafedd9a37efa3c.jpg)

(https://uploads.tapatalk-cdn.com/20240122/a483c457be7842327405848b9c3f0325.jpg)


The drivers door was a different story.
The original door had to be replaced and the only one I could find was a sedan door. It was rusty but straight.

The top of the door was cut off and replaced with the Ute top. The front lower corner was rusty, the outer lower section had to be replaced and the inner rear also had to be replaced.

(https://uploads.tapatalk-cdn.com/20240122/eda726f0f18fe7121bb162061609e710.jpg)

(https://uploads.tapatalk-cdn.com/20240122/765cdcb294b2a252ba3293be307a6e25.jpg)


New lower outer section made and ready to fit

(https://uploads.tapatalk-cdn.com/20240122/8ae979f45f2cfe531f62d390571b1d9e.jpg)

(https://uploads.tapatalk-cdn.com/20240122/26af9e618d40906e88e0fc309482c8e6.jpg)

(https://uploads.tapatalk-cdn.com/20240122/8cdf75d126a96424889b7d81c494e5c9.jpg)

(https://uploads.tapatalk-cdn.com/20240122/ccf3ee120da2e7c994ba449c63b0944f.jpg)

(https://uploads.tapatalk-cdn.com/20240122/10702f31ec3c838064b0e104b54beea5.jpg)


Now for the inner section.
I had another old door that had a really good inner section so I’m fitting that whole section.

(https://uploads.tapatalk-cdn.com/20240122/9c760c0980edbac07b01de2d58328675.jpg)

(https://uploads.tapatalk-cdn.com/20240122/f569edd568f0274bc7623bf16fef709e.jpg)

(https://uploads.tapatalk-cdn.com/20240122/1bc186901bb14342f640d97df38899b3.jpg)

(https://uploads.tapatalk-cdn.com/20240122/8285add5cc9b3b2176d8fdf9e7dacca4.jpg)

Basically this is where this door is at now,  with everything cleaned up and ready to fit.


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While I’ve been working on the doors I’ve been fitted other necessities as well like the power windows, central locking and for something completely different, power quarter windows as well.

(https://uploads.tapatalk-cdn.com/20240122/14006de0125b1bfaf8bb48fdceb48cef.jpg)

(https://uploads.tapatalk-cdn.com/20240122/76221cc7b7341782542e9ad0ed34fec4.jpg)

Power windows and the door lock actuators were pretty straight forward, the power quarter window took a bit of messing around.

I got a new pair of power seat motors from a Holden Vectra to use for the windows.


(https://uploads.tapatalk-cdn.com/20240122/7ff8aefc3ce08568abbc3ca76ec13dd3.jpg)

I had an old door that I cut the inside out of so I could see how I had to make the bracket and how it was all going to work.

(https://uploads.tapatalk-cdn.com/20240122/a5af67df9c02cc9d73b3d831bde3d884.jpg)

When I made one bracket, I also made a mirrored image of it for the other side door.

(https://uploads.tapatalk-cdn.com/20240122/8279c9524e20622525274dd99f5dfabf.jpg)

Motors mounted to the brackets.

(https://uploads.tapatalk-cdn.com/20240122/85da8bf1fbbb9dc778dca5fc95250b7f.jpg)

On the bottom of the original window frame I built up with weld and ground down so it would fit into the drive section of the motors.
Also reinforced with weld the shaft where it joins the frame.

(https://uploads.tapatalk-cdn.com/20240122/9c6c3ac41ffd62593748679ed1ddc487.jpg)

(https://uploads.tapatalk-cdn.com/20240122/5646499e4c4ee1750fee17411ff20a89.jpg)

(https://uploads.tapatalk-cdn.com/20240122/caadf6f8007f8af5d19ad1d79d67c37e.jpg)

(https://uploads.tapatalk-cdn.com/20240122/c31256ac1101d8d4a9d2551e8be84d5d.jpg)

All fitted together and now just had to make small brackets to secure the shaft to the outer frame.

(https://uploads.tapatalk-cdn.com/20240122/71d406746826fea307b3188e46613f41.jpg)

To operate the windows I bought crank style switches so I could use the original window winder handles.
I used these switches for the windows as well as the quarter windows.

(https://uploads.tapatalk-cdn.com/20240122/f102ef12df8f4d121a1f786e1e0d89fc.jpg)

For the handles I used original ones for the main windows and the shorter version of the originals for the quarter windows.

(https://uploads.tapatalk-cdn.com/20240122/f3bed9edade1b0475678d06a42d13026.jpg)


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Fantastic work there, I love seeing the engineering that goes into peoples projects, it's the stuff you can't appreciate at a car show!!!

Some great engineering there to get those quarter windows operating electrically. I expect your quality work is underpinned by plenty of patience.

Some builders get clever and replace the front quarters with one piece fast glass, but you do this! Outstanding work as always Malcolm. Also, I thought I had seen the door tubes available as a kit, but you go and make your own. I wish I had half your skill.


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Thanks guys, I really appreciate the comments.

Exactly Gman, I think that's the most interesting part of building a car. Once you cover all the work up with shiny paint people just look at the big picture and hardly notice all the detail work that goes into building something a bit different.

Joll, doing stuff like this, patience is the name of the game. Even better now I'm retired.

Errol62, I originally looked into the one piece windows but it was going to be a LOT of modifying as the top door hinge was in the road.
When you got a lathe and a fair assortment of tools, making the small things puts that personal touch on it I think. (And I enjoy doing it of course).

 Thanks for the update Mal , always enjoy your posts and marvelling at your craftsmanship.

 I have a set of manual quarter window cranks for the 2 door EK I have been building since forever but making your own powered units from scratch is next level and then some  :o :o

Nothing like a bit of a challenge Blacky.
I put electric quarter windows in my 57 chev as well, but they were a lot easier as they originally have the crank style quarter windows. With that one I got a pair of motors out of an old cadillac and they were so close they just about bolted straight on.

Mal ..You are a master craftsman , no doubt ..like Errol said , I also wish I had that skill for body work , ...Vern ...