Well it’s finally done, started pulling the dash out on Christmas day last – dash has been back in for a few months.
Been doing a lot of other mods in the meantime (e.g. the EL wagon CC install took a fraction of the time), and coming back to this one from time to time.
This mod was of the type to do in bits, as it was pretty taxing on the energy (and the mind) to do it continuously.

Being a mod that hasn’t been installed previously (AFAIK), it takes a lot of time, particularly as most of the heaterbox addons need to be relocated – blend door motor & vacuum solenoid unit, as the dash will not fit otherwise. So removing the heaterbox is a backward step. This is all trial and error, so hence the extra time.
The sunload sensor and upper dash need to be modified for fitting. The XH and E series evaporator inlet sensors are different, so an E series unit needs to be fitted to the heaterbox (cut open the heaterbox to fit it), so you don’t get E6 errors all the time. You need to run an EL ECU to get max cooling as well. And you need to work out the XH vaccy hoses and match them to the vacuum solenoid unit hoses – tan needs to be blanked off, as the XH demister actuator only runs a yellow hose. Otherwise, the XH heaterbox is identical to the E series.
Also broke the blend door flap shaft, so had to cut open the heaterbox to repair it – more fun.
Then on top of that, the dash unit needed to be designed and made, it had to replace the stock ventilation controls of course, and then there are the size limitations, and again trial and error, fit and refit. Again the main challenge with the dash unit is to make it look like a factory fit, hopefully that’s been achieved.
Anyways, enough rambling, pics below:

Before & After . . . . . . .


Wide shot showing Sunload sensor at the top, and a frontal view with half height switch on top right . . . . . .


During testing with an EL CC unit, and a lighting view - the car also now has a high series BEM, so has all 3 LCD screens dimmable . . .


Apologies with the pic quality, the setup looks pretty good (IMO) in normal light. The system does really work well in the smaller cabin - shame it wasn't a factory option.
Being familiar with the XH/EF/EL dash behinds, fitting an EF/EL dash to an XH would take some fairly heavy modding - I think the XH dash with the addons looks a lot better in terms of that 'factory' look . . . . .

Last edited by snap0964 on Tue Jul 04, 2006 11:26 pm, edited 2 times in total.

quality work as usual Ray

very snazzy!

far out thats outstanding mate gone to a lot of work there thats for sure

Yeah, thanks fellas . . . .

Pure genius Ray!

It looks like you'll have to purchase another car to expand your possibilities!

I guess i'll be looking upto you for some time!

ray, as usual fantastic work!

Yeah thanks Frase & Andrew.
Geez, dunno 'bout buying another car, have to enjoy the additions to the two I have now . . .

Last edited by snap0964 on Sun Jul 09, 2006 11:38 am, edited 1 time in total.

Thanks for the pics

thats awesome wonder how much harder it would be to get it to work in a XF? hmmmm nope to hard to think about it lol. but great work man

We should have the FOTY awards (Ford of The Year).

G'day

Looks great, thinking about a similar mod to my xf once the el motor and paints done.

But it will end up being years away

Cheers

Yeah, thanks again for the raps Guys . . . .

I wouldn't think the XF heaterbox would be greatly different than the XH heaterbox, so any E series CC heaterbox components + the sunload sensor should be able to be hooked up as per my mod.
You won't be able to use an EF/EL CC dash unit, due to the computer inputs, but you could use an EA-ED CC dash unit, and the main thing there is modifying it to suit somewhere in the XF dash. For more info read: http://www.fordmods.com/forums/viewtopi ... te+control .
This is Fordmods, so never say never . . . .

lol yeah i don't even have a working heater box. i live in darwin so no need for them up here lol all thou air con would be nice

Yeah, I spent a few years in the Cairns, Pt Douglas & Cooktown areas, so I know where you're coming from . . .
Especially the humidity aspect.