i have an xc bonnet with humps and no vents if you wanna swap me for one with vents, lols

lol there is one up here with no vents for 25 bucks.. a bit of rust on the frame work, but i wouldnt use it anyways

Actually, yes.

I was dropping off the better half. TAXI duties are a large part of the Wagons duties LOL

Cheers
BenJ

Last week I went down to visit SWC and check out the progress on the AU door handles.

SWC had found an isse with the door, where it appears there was a depression in the skin on the door I gave him to work with, and then when combined with the heat from welding had sucked in the area around the handle. We sussed it out and then with some carefully applied force with a small crowbar, convinced the depression to feel a bit better about it self and come out a bit and join the rest of the door. Some fibreglass bog filler has been applied to the area around the handle and it needs some bog now to finalise the levels.

This is how it looks at the moment with the handle bolted in.





Looking very promising at this early stage.

Then looking down through the top of the window opening I noticed how far the door handle was protruding into the door cavity, and when I compared to the window runners I could see we were going to have some real issues.

I took the door home to apply some BenJ creative thinking and to engineer a solution.

This photo shows the glass in place with the AU door handle shell minus the handle mechanism.



As you can see the glass is going to hit the back of the shell. Hmmmm.

This photo shows the assembled AU handle and look how far the lever protrodes past the back of the shell. The red line in this photo represents where the glass would be when wound down.



This creates a bit of an issue I think.

I analysed the physical movement required for the door latch to release when the handle is lifted. The actual lateral travel was approx 4-5mm before the release catch allowed the latch to open.

The arc created by the factory position of the actuator rod from the handle to the latch was more like 15-20mm and there was a lot of freeplay prior to the release catch becoming engaged by the actuator rod.

So I grabbed my dremel and drill and set to hacking . . . . . urrr, ahhhh applying carefully measured and calculated cuts to the AU handle.

What I ended up with was this.

Before


After


And the other side and the raised ridges on the back also got the treatment.

Before


After


The finished modified handle and actuator rod.



I also shortened the AU actuator rod.

To test the function I used a marine cable clamp to connect the AU and EB actuator rods, and by setting the release latch to partially open, there is sufficient travel to allow the door catch to open.

The actuator rods will be welded together before final assembly.

The drivers door handle will get the same mods, but luckily as the rear door handles are under the quartervent windows, clearance is not an issue.

****************************************************************
Other news is that the Wagon passed it's yearly Pink Slip inspection and registration has been paid, so that is one headache out of the way.

I have also received a new Power Steering Pressure switch. I will install that along with a new Pump when I purchase it soon.

I have also started prep work on the BA Bumper Bar.



Hope you are all well.

Cheers
BenJ

lookin' good there BenJ

i was about to suggest something about the handle but then i scrolled down and seen you beat me to it lol.

looking damn good ben

looks like alot of trouble for not very much gain..... EF/EL handle would be an improvement and alot easier

with all the welding and bogging involded fitting the AU handle, i would be inclined to setup shaved door handles instead, now that would look smoooth

Thanks fellas. Quite happy with how this is coming together.



I already have EL External door handles on the wagon. I did consider shaved doors, but on the photoshops I put together it just didn't look right. In addition the practical aspect of having door poppers to open the door wasn't going to work for my wife. She would break her nails all the time, which would make her unhappy, and consequently, ME unhappy. Not Good!!!!

There really is as much welding and bogging with this mod as there is with shaving the handles.

The end result will look factory and trick, while still maintaining full functionality, and average Joe will think they were made this way.

Cheers
BenJ

its all the minor detail that i love about this car...

Looks like you have made good progress with your AU door handle mod Ben

I know its a matter of personal choice as always, but I am incline agree with FordFairmont.

They do clearly look smoother and hardly stick out. But I am thinking to look at the car after it is done it may not be a very noticeable mod, especially being a black car and the amount of effort going into the mod.

Argh....... I will wait till the door is finished before I cast final judgment Sorry mate, Keep up the good work.

Josh

I think you guys are missing the point.

I LIKE the fact that this sort of mod is easily overlooked. It is like the EL/NL interior. Unless you know E Series falcons, you wouldn't know that it is different from the way it came out from the factory.

Subtle mods are just as good as stand out mods, and my car has both.

Shaved door handles have their place, and I have pics of an ED Sedan that has has it done. However, the catch is you still have to find a way to open the door mechanically. The traditional way is to use small poppers sticking out the top of the door. Unless you can blend this in really well with the weather strip on the tops of the doors, and make it practical for anybody to use, then it is not a complete solution.

Remember that the Wagon is a daily driver, and there are three other people that use the other three doors all the time. There is no way my Wife or Daughter would put up with the small poppers needed to open the doors.

Cheers
BenJ

indeed benj there are so many mods that seem factory the average dude wouldn't pick them - it's stealth mods 101!

Yes I did overlook that point buddy



I think shaved door handles are wank IMHO and would much prefer to see you continue with your work on the AU door handles

I think you have a done a great job with this mod so far Ben. Even if I dont like something you have done, you know I am a fan of your work and always watch with interest.

How boring would your thread be if there was only positive comments to read all the time

Cheers

So this is the current car!

Like what you have done with the interior lighting, very similar to mine with the door cards/handles.

Time for a bit of an update.

AU Door Handles.
Now that I have sorted the function of the handle, and I know it will open the door, the Front Passenger door is back with SWC for a bit of panel finessing. Once he has finished with it, when he has the time, the other three doors will also receive the AU handles. Then I can prep and paint them.

***************************************************
Front Grill FORD Badge
For a while now I have been looking for some Black Ford Badges. The EB Falcon Ford Badge has the good old Ford Blue as the background, which stands out quite a bit against all the Black and Silver.

I found some 'Black' Ford badges on Ebay UK, and for just over $20 had two sent over to the colonies. Unfortunately, while these look black inside, as soon as take the outside, it is obious they are a very dark blue. BUGGER. The seller was happy for me to return them, refund me and cover my postage costs. In the end I elected to keep them, as they are the darkest Ford badge I could find.

Here is a comparison of the two badges.



As you can see, the new badge on the left looks like it could be black.

I had some spare EB Grills so I painted up the badge mount in Black Pearl and clear coated it.

While doing the change over, I grabbed a pic of the front of the car with the badge removed.



Doesn't work for me.

Here are a couple of pics of the new badge fitted. I really need to paint the rest of the grill now.




At night, it really does look black.

***************************************************
New Gear Knob
I have noticed over the last couple of weeks that the leather on my SAAS gear knob has come loose. I think the hot days we have had has stuffed the glue holding it to the knob.

Taking the opportunity to go for something a bit different, that will work with my interior plans, I found a nice Billet Aluminum SAAS gear knob. This one is shorter than the old one and has a nice solid feel to it.




Hope you are all well.

Cheers
BenJ

Last edited by BenJ on Thu Feb 18, 2010 3:18 pm, edited 1 time in total.