Fordmods Logo

BenJ's EB DOHC T5 Ghia Wagon 

 

Page 83 of 201 [ 3004 posts ] Go to page Previous  1 ... 80, 81, 82, 83, 84, 85, 86 ... 201  Next

 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Mon Oct 19, 2009 11:23 pm 
Getting Side Ways
Offline

Posts: 5503

Joined: 20th May 2005

Gallery: 11 images

Ride: EB1 Fairmont Ghia T5 Wagon

Location: Seven Hills, Sydney
NSW, Australia

{USERNAME} wrote:
You hoon! Hahahahaha! Love it, the beasty is getting quicker by the day. Well done on the self changeover, another feather in your cap....


I suppose you will be wanting another stint behind the wheel now? LOL

Oh, and almost a self changeover, I did have a very strict supervisor LOL.

And thanks to ToranaGuy, KWIKXR and fiend for the kind words.

Cheers
BenJ

 

_________________

{DESCRIPTION} - Current Ride
{DESCRIPTION} - Previous Ride
My respect and thanks go to - snap0964, Paulmac, SWC and MRE-50L

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Mon Oct 19, 2009 11:26 pm 
Getting Side Ways
Offline
User avatar

Age: 63

Posts: 1584

Joined: 20th Mar 2005

Ride: EDL Fairmont Wagon/AU XR8 Ghia

Location: Riverstone
NSW, Australia

{USERNAME} wrote:
{USERNAME} wrote:
You hoon! Hahahahaha! Love it, the beasty is getting quicker by the day. Well done on the self changeover, another feather in your cap....


I suppose you will be wanting another stint behind the wheel now? LOL

Let me see... would I like another stint in a manual EL powered wagon with a Wade cam and 2.5" exhaust....it's tricky..... hang on a tick...... still thinking....... HELL YEA! :)

BTW, got me TV today, but thats OT - HA!

 

_________________

=1994 ED Wagon GLi body/EL Fairmont spec with *ALL* EL running gear.=
Build Thread: viewtopic.php?f=53&t=65695
=1998 EL Futura Sedan - The EF Fairmonts Replacement=
Build Thread: viewtopic.php?f=53&t=106588

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Tue Oct 20, 2009 6:30 am 
Getting Side Ways
Offline
User avatar

Age: 50

Posts: 1093

Joined: 29th Nov 2004

Gallery: 15 images

Ride: BA Ford Fairlane V8

Location: Lower Hunter Valley
NSW, Australia

Good work Ben, a cammed wagon is a very rare but a very good thing mate. Well done!! I wish my roster was more kind to me on the weekend, I'd love to have been able to go to Bathurst in mine.

 

_________________

Interested in a fair go for the {DESCRIPTION} area of NSW?

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 9:55 am 
Getting Side Ways
Offline

Posts: 5503

Joined: 20th May 2005

Gallery: 11 images

Ride: EB1 Fairmont Ghia T5 Wagon

Location: Seven Hills, Sydney
NSW, Australia

Hmmmm, I wonder what is going on here?

Image

BenJ

 

_________________

{DESCRIPTION} - Current Ride
{DESCRIPTION} - Previous Ride
My respect and thanks go to - snap0964, Paulmac, SWC and MRE-50L

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 9:59 am 
Getting Side Ways
Offline

Age: 40

Posts: 6746

Joined: 13th Mar 2006

Gallery: 10 images

Ride: SF5 Forester

Location: Bathurst
NSW, Australia

{USERNAME} wrote:
Hmmmm, I wonder what is going on here?

Image

BenJ


IT HAS BEGUN!!!


I think =P

 

_________________

R.I.P Tobias my son.

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 12:31 pm 
Getting Side Ways
Offline
User avatar

Age: 44

Posts: 1475

Joined: 5th Nov 2004

Ride: 98 EL Falcon - Last of the EL's

Location: Muswellbrook
NSW, Australia

:shock: your a braver man them me cutting a dirty great hole in your roof :lol:

 

_________________

why are women like clouds? eventually they f**k off and its a really nice day.

telling the truth is just lack of imagination

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 1:02 pm 
Getting Side Ways
Offline

Age: 71

Posts: 3574

Joined: 11th Jan 2009

Location: Smithfield
NSW, Australia

{USERNAME} wrote:
:shock: your a braver man them me cutting a dirty great hole in your roof :lol:


Huh? I thought the hole came with the kit? :shock: ( :mrgreen: )
Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 1:07 pm 
Fordmods Junkie
Offline
User avatar

Age: 61

Posts: 2903

Joined: 26th Nov 2008

Yeah!!!

Get that sunroof in Ben 8-)

Ill check back later on to see how you went.

Cheers
Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 6:25 pm 
Moderator
Offline

Posts: 14489

Joined: 7th Nov 2004

Ride: AU XR8

Location: a shit suburb in sydney
NSW, Australia

so ben hows the sunroof coming along? :mrgreen: :) :lol:
Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 8:57 pm 
Fordmods Junkie
Offline
User avatar

Age: 61

Posts: 2903

Joined: 26th Nov 2008

{USERNAME} wrote:
I bet he's still out in the driveway by torch or candlelight tinkering away with it :D


LOL, I bet your right mate.
Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 9:03 pm 
Getting Side Ways
Offline

Age: 29

Posts: 3344

Joined: 19th Dec 2008

Gallery: 1 images

Ride: el fairmont ghia

Location: Farleigh
QLD, Australia

{USERNAME} wrote:
{USERNAME} wrote:
I bet he's still out in the driveway by torch or candlelight tinkering away with it :D


LOL, I bet your right mate.

i bet he's still at swc place

 

_________________

{DESCRIPTION}
Image
did someone call 9 1 HOLY s**t?

Last edited by mitchell g on Sat Oct 24, 2009 9:03 pm, edited 1 time in total.

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 9:03 pm 
Fordmods Junkie
Offline
User avatar

Age: 61

Posts: 2903

Joined: 26th Nov 2008

Ben text this to me earlier on today, hope you dont mind Ben :wink:

Image
Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 9:08 pm 
Technical Contributor
Offline

Age: 67

Posts: 6815

Joined: 22nd Jun 2005

Gallery: 8 images

Ride: EF Fairmont

Location: Campbelltown
NSW, Australia

{USERNAME} wrote:
I bet he's still out in the driveway by torch or candlelight tinkering away with it :D


I'll take that bet
Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 9:28 pm 
Getting Side Ways
Offline

Posts: 5503

Joined: 20th May 2005

Gallery: 11 images

Ride: EB1 Fairmont Ghia T5 Wagon

Location: Seven Hills, Sydney
NSW, Australia

You are a bunch of funny buggers LOL.

Pics and story soon.

BenJ

 

_________________

{DESCRIPTION} - Current Ride
{DESCRIPTION} - Previous Ride
My respect and thanks go to - snap0964, Paulmac, SWC and MRE-50L

Top
 Profile  
 
 
 Post subject: Re: BenJ's EB T5 Ghia Wagon
Posted: Sat Oct 24, 2009 11:29 pm 
Getting Side Ways
Offline

Posts: 5503

Joined: 20th May 2005

Gallery: 11 images

Ride: EB1 Fairmont Ghia T5 Wagon

Location: Seven Hills, Sydney
NSW, Australia

As you hopefully will have figured out, today was sunroof day.

Before I continue, once again I must give a big THANK YOU to SWC for his assistance in cutting a big bloody hole in my roof, and for fabricating the brackets etc, and also thanks to Snap, MRE-50L and LP for their assistance, input and advice.

So, just how do you install an electric sunroof into an E series?

Step 1 - Remove all unwanted interior parts.

Basically this means to pull out the hood lining, interior lights, sun visors, interior plastics and wiring that may get in the way. I also removed the middle roof brace.

Step 2 - Work out the position for the sunroof to be in.

This is a two step process, which involves looking at the aesthetics externally, and analysing the practical limitations of physically fitting the sunroof cassette.

To achieve this I borrowed MRE-50Ls cut out from his sunroof install to visualise where I thought the best position would be from the outside.

Then we used some strapping to hold the cassette up close to the roof and work out how much leeway we had. We found that the next brace back limited how far to the back of the wagon we could go, and after settling on a satisfactory position for the cassette inside, we then lined up the cutout on the outside to match the front of the opening.

Image
Image
Image
Image

Step 3 - Mark the roof area to be cut.

Once I was satisfied with the position of the cutout, we needed to make a template. This could be done using some cardboard and trace out the size of the opening or remove the glass and trace around it. In our situation, I grabbed the cutout from MRE-50L and sat it on the glass area, and found out it was almost perfect. TADA, a template.

We then used the template to mark the roof. After measuring left and right, front and back to centre the template we then laid masking tape down before clearly marking the CUT line.

Image
Image

Step 4 - Cut a bloody big hole in the roof

There are a variety of tools that can be used for this task. We had several discussions regarding this and settled on using a 4" Grinder with a 1mm cutting blade, and a jigsaw for the corners.

SWC wanted to start with a corner, so a pilot hole was drilled, and the hacking commenced. SWC found the jigsaw was making easy work of it, and decided to do the complete cut with it.

No turning back now!!!
Image
Image
Image
Image
Image

Step 5 - Make brackets to secure the cassette in place.

As you may have noticed, Wagons have a higher roof line than the sedans or Fairlanes etc. This meant that any sunroof brackets I could have obtained from sedans would be the incorrect size and shape. The plan always had been to make brackets.

To do this, we hoisted the cassette back up into place and then used a number of G-clamps to secure it in place. This allowed us to exactly position the cassette in position using the new hole. The rear of the cassette was supported with a length of PVC pipe

Now that we have it locked in place, SWC made up the brackets for the rear of the cassette. This required the rear roof bracing to be notched in the corners to allow the cassette to sit flush with the roof. Then the new brackets were made and tek screws were used to fasten it together. Then the front brackets were fabricated, followed by a pair of middle brackets.

We then powered up the sunroof and conducted a couple of tests to ensure that the hole was big enough. This identified a clearance issue, and a further 5-7mm was then cut out of the right hand edge of the hole as it was fouling on the glass as it tilted up.

Image
Image
Image
Image
Image
Image

Step 6 - Glue the cassette in place

Now that the cassette is can be firmly attached to the roof frame, the roof skin needs to be glued to the cassette skin. SWC recommended a Selleys product, Adhesive + Sealant, Polyurethane. This was liberally applied before the cassette was lifted up for the final time into place, and all the brackets tightened down. Clamps were again used around the hole opening to clamp the skin against the cassette while the adhesive cured. As this would take a while, SWC improvised and used some door flashing as a temporary clamp around the edge. This was left in place for the drive home.

************************************************************

There are a couple more steps which I will cover tomorrow, after I get pics of the the relevant areas. At this stage, I have partially wired up the sunroof so the Wagon can be secured, and Snap and LP ran the four drain tubes so if it rains the water will not fill up the car.

Here is a couple of quick photos of the partially finished job.

Image
Image
Image

Cheers
BenJ

 

_________________

{DESCRIPTION} - Current Ride
{DESCRIPTION} - Previous Ride
My respect and thanks go to - snap0964, Paulmac, SWC and MRE-50L

Top
 Profile  
 
Display posts from previous:
Sort by  
 Page 83 of 201  [ 3004 posts ]  Go to page Previous  1 ... 80, 81, 82, 83, 84, 85, 86 ... 201  Next

Who is online

Users browsing this forum: No registered users and 6 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

 

 

It is currently Thu Dec 26, 2024 1:25 am All times are UTC + 11 hours

 

 

(c)2014 Total Web Solutions Australia - Australian Web Hosting and Domain Names