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| ToranaGuy |
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Mine was partly due to the heavy clutch & partly due to the LPG mongo drilling the hole for the LPG loom too close to the clutch cable's hole, weakened the firewall right where it needs it's strength. I tapped mine back into shape, made up a brace from 40x3mm bar & welded it to the firewall. No more flex issues.
 Cheers ToranaGuy
_________________ I am the ToranaGuy!|74 Lh Torana Turbo|78 Hz PanelVan|86 Mighty Boy Ute|93 EB2 Ghia,GT Mockup,5spd,LPGI,Full Leather|2 x EB Xr8 5spd's|FS [VIC]: Wrecking - Eb XR8 - Parts available |Build Thread|Ebay Items - Ford Parts| |
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
haha nice work. just checked the firewall on the donor wagon and it has a huge crack diagonally across it and they just got 80mmx80mm gal tin sheet and put 2 rivetts in it HAHAHA. they didnt even try to bend it back up or to close the tear up, has to be the worst repair job ever. i found the thread on troymans strengthening plate and its F**k tops so il try and buy one off someone or make it myself. guna need it cos im going the HD clutch option.
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| ToranaGuy |
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You know why the pop rivets? Because it's a PITA to weld the firewall & the lazy bugger who did the repair either didn't have a welder, couldn't beg, borrow or steal one & settled on the pop rivets. The way mine was torn, and that i didn't want to remove a lot of crap from the engine bay, meant the plate is on the dashboard side of the firewall.
I had to pull the dash & peddle box out, pull back the carpet & sound proofing, it was welded with a mate holding a water squity bottle & squirting the underlay as splatter hit it to keep it from catching fire.  Carpet turned out fine, just a bit wet, but i let it dry out before fitting it back in properly.Troymans is a good reinforcing, you should be right with it. I know you could get a firewall brace piece from ford at one stage..... Cheers ToranaGuy
_________________ I am the ToranaGuy!|74 Lh Torana Turbo|78 Hz PanelVan|86 Mighty Boy Ute|93 EB2 Ghia,GT Mockup,5spd,LPGI,Full Leather|2 x EB Xr8 5spd's|FS [VIC]: Wrecking - Eb XR8 - Parts available |Build Thread|Ebay Items - Ford Parts| |
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
ok so i pull the T5 out today and gave it a got clean up (pretty happy cos it was only road grime and mud the gear box wasnt leaking at all, not even the output shaft seal. after i cleaned it up i went to buy some 'ford blue' engine enamel but they were sold out and it was $16 a can, then i saw next to it that the pink enigne enamel was on special at $2.99 a can (i wonder why haha). anyway so i bought 2 cans of pink and spraying the gearbox and bell housing HOT PINK. i had to do it, something about hot pink t5 had a ring to it. pics to come haha
on a side note the clutch i pulled out looked like it had a worn LuK pressure plate and a much newer looking exedy clutch plate? why the hell would someone cheap out and only replace a clutch plate? at least the pink g/box will much my new exedy sports clutch and pressure plate
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| huggiebear |
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haha now if people ask why you call you car a "she" you can tell them to lay on the ground, loom up between its legs and look at its pink bit
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
hahaha brings a whole new meaning to those stickers that say show us your pink bits hahahah
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
so since i posted last i painted the boot garnish black and used niteshades on the tailights. i also finished the T5 conversion after a little issue with it not starting because one of the pins backed out of the plug on the coil. well what can i say its awesome!!! feels like the car lifts up though gear changes and it puts the power down alot better! actually put my foot down coasting out of a servo driveway today and the car spat me sidewards onto the street and diagonal up the road. i was like....wow hahah.
also while doing the conversion i replace the welsh plug and rear main seal, the welch plug had TOTALLY rusted though but wasnt leaking because it 100% sealed upto the sandwich plate, so when i removed the plate and poked at the film the coolant started to drain hahaha. noticed that all my large welsh plugs are weaping too. got a few questions to ask of anyone that has done the conversion. shouldnt there be some form of pedal stopper for max pedal height and a return spring for the clutch pedal? ive adjusted the pedal so uits the same height but the weight of the pedal sitting there would be slightly engaging the thrust bearing on to the clutch plate, shortening its life? should a cut and weld the neutral switch bracket off the manual pedal box and fit a spring? looks like it may have had a spring before but when i got the 'donor car' the pedal was busted and no spring or gearknob. PICS TO COME!
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| huggiebear |
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there IS ment to be a spring on the pedal box, i bought one from ford.. a whopping $4..
i do believe that the clutch pedal sits a little higher then the brake pedal |
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
what form of stopper is there cos at the moment i can grab the clutch pedal and pull it up to the steering column.......
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| huggiebear |
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im not sure at the moment, ill have a look at my pedal box tomorrow when im at my parents house and ill sus it out
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
so basically i had a knock/grinding noise for the LH rear wheel a couple of days before i did the manual conversion. when i was putting the gearbox in i saw the very outside edge of the rotor went metal on metal with the pad so i assumed that was the noise and the rotor was just badly warped but it got louder. i check if the wheel was loose with a wheel brace and did the shake test on it and it was fine. today while driving something went clunk and the car wanted to pull left hard so i pulled over and 2 of the studs on my spacers had snapped so i pulled my rattle gun out the boot and tried to tighten the other 3 but they werent going any tighter. i limped home on the backstreets the last 3 kms and went to take the wheel of, one nut came off ok and the other 2 i had to break off to get the wheel off. basically the spacers studs had stretched like a redskin lolly and broken (they seem soft as for studs). so im rocking a 14" steel spare now and il replace the studs on the spacer with some descent ones. but im thinking this is a warning. i really like the BA XR6 17"s i got on now but i wana F**k off the spacers STAT. might just get some 15" steelies and drive on them and sell the 17"s until i get some replica pre - au ford rims.
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
DAMN!!!! theres a 3.45 LSD outta an ED xr6 disc to disc on ebay for $200 but its pick up from newcastle, if it was anywhere closer to canberra id be bashing his door down !! have to keep looking
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
*dial up killer*
Update, this is the car as of last weekend. (didnt have a gear knob but it turned up the day after the pics, its an 8 ball as i didnt have a standard gearknob). also still have to get the body mould tape of and then paint the mould and re-fit them.      and heres my christmas present to myself, cant fit it yet as im in the middle of making a hybrid EL/ED centre console with front half ED and fromt just infront of window switches back wtih be EL console and lid. will post pics when finished   
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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| gogetta |
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nice clean boxcar you got there....
but one thing i dont get is why u own an xtrail as well when this is your daily??? why would anyone waste 20+ grand on that? also whats the appeal to you of the VW?? not knocking just curious
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| pissed'N'broke |
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Age: 38 Posts: 251 Joined: 9th Sep 2009 Ride: ED falcon gli - XR6 replica Location: Canberra |
thanks its not too bad.
was a nissan mechanic and they are good to drive and never have any major probs (then i spent some cash on it and it scares afew commodore owners haha). the missus drives the xtrail to work and i drive the falcon. then when either are in bits or getting something fitted i can use the other one. when the vw's back in action il just drive the falcon or the vw to work but mainly drive the vw on the W/E's always loved aircooled VW's since i was a kid and its the reason i became a mechanic (@ a VW/NISSAN dealer). always wanted a beetle and then looked at a type 3 and their heaps better to drive than a beetle (twin carbies etc). new vw's are cool to drive too but expensive to fix and maintain and they break down alot hahaha.
_________________ Ford ED Falcon Gli, T5 conv, Twinlight lights, exedy sports tuff clutch, modified EA front grill, ED XR6 complete interior, 19" speedy graphites, monroe gt shocks, kingspring superlows, CAI, ported tickford head, 3:45 LSD. |
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