Dave's Orange Betty EK Sedan

[Orange Betty]

Just starting a new thread for my build to get around the title of the last one:
http://www.fbekholden.com/forum/viewtop ... 11&t=23058

and to mark a milestone.

So Orange Betty (OB) was blasted and is now primer grey but I didn't do much since September last year as I was building myself a rotisserie. Took a long time as I only get a few hours each day of the weekend but was good welding practice and successful. But despite mounting OB on the rotisserie and taking her for a twirl I've just got her level and taken the front rotisserie mount off. I had removed the left hand outer sill and cut out what was left of the bottom of the A-pillar but heeding the advice of forumites I decided I shouldn't 'fix' anything until I had the subframe and doors on and could check that everything aligned.

So I made up a dolly (ie?) for the subframe and test fitted which was ok, but before fixing the bottom of the A-pillar which is quite daunting, I thought I'd tackle an easier 'fix' for the first try and do the subframe and body mounting points. The one specifically:

LH subframe wall att.JPG (145.72 KiB) Viewed 1432 times

And hence the milestone, OB's first bit of actual repair!

OB first fix.JPG (153.12 KiB) Viewed 1432 times

Had to chase quite a few holes I blew in the old metal which I suspect is a lesson in making sure I cut out to good metal to start with.

Dave

[Brett027]

Good on ya Dave. Looks like you are doing a neat job as well. Thanks for sharing progress.

[Errol62]

Looks like your on track Dave. Good place to start. All those sandwiched panels are a rust trap. One of the harder parts I found when I did this on my van was getting decent penetration at the top where the windscreen surround joins. Important this bit is nice and strong. Another hard bit was holes in the recessed bit.

Look forward to following progress.
Cheers
Clay


FB ute fixer upper, EK van on rotisserie

[In the Shed]

G'day Dave,

Good to see your into it. Plenty of help here with folk who know the ins & outs of these old cars. Will be watching with interest.

Regards
Stephen

[Blacky]

Good stuff Dave, tackling an easier part first is a good way to both learn and gain confidence in your own abilities- and as my panelbeater father in law tells me - it's only metal , if you balls it up just cut it off and try again !

[59wagon]

Good work Dave and goodonya' for having a crack. As Blacky said, it's only metal

Looking forward to more updates and photos.

Cheers,

John

[Orange Betty]

Slowly, slowly. Fixed this on both sides:

Fixed 1.JPG (36.31 KiB) Viewed 1274 times

also fixed the subframe sides where they attach to the body i.e. these bits (wings?)

wing fixed.JPG (32.65 KiB) Viewed 1274 times

and put the subframe back on to get things aligned, at three points anyway:

subframe on.JPG (40.55 KiB) Viewed 1274 times

So I can now work on the bottom of the A-pillar

A Pillar repair.JPG (40.05 KiB) Viewed 1274 times

Brett027 has used the Stark sections to fix Wilma and which look very neat http://www.fbekholden.com/forum/viewtop ... ks#p238622 but they are expensive.

I'm in no hurry and like the idea of fashioning a 'Frankenstein' fix so think I'll attempt similar to Leroy the EK ute here (page 2 I think) http://www.fbekholden.com/forum/viewtop ... 15#p227856

My rough plan is this:

LH subframe to inner sill.JPG (33.15 KiB) Viewed 1274 times

actually extending the back of subframe attachment point across the cross member and onto the face of the inner sill. Then fashioning the outer sill attachment point as for Leroy the EK ute.

A pillar repair 1.JPG (40 KiB) Viewed 1274 times

Appreciate any and all advice as to whether that sounds reasonable.

Cheers

Dave

[Blacky]

Good way to learn mate, not really a very visible spot so if its a bit wobbly who cares as long as its solid

The Stark panels are good - but spendy

[Errol62]

Good work. You’ll figure if out. Rare Spares has the bolts and they aren’t cheap around $40 the set. Stewart’s Old Timer build has some good detail on this and you could look at my EK Panel van build.


Sent from my iPhone using Tapatalk

[Brett027]

Good to see you're back in the saddle Dave. I know you've had a good look at Clays EK waggon build and also the Old Timer build on the forum and they are both fantastic resources for us all. Sing out if you want me to come over and hold something etc. Wilma is becoming quite demanding recently, so it would be good to leave her for a bit and consort with Betty

[Orange Betty]

Cheers guys. Looking at what others achieve in their builds gives me confidence to give things a go, and as Blacky points out it will be hidden so doesn't have to be too pretty.

Brett will send you a txt to arrange meeting with Betty.

Dave

[Orange Betty]

Hi all, so a bit more progress. As per previous posts I thought I'd just do simple bend in some flat bar to be the inner sill extension and to bolt the outer sill through to the subframe. But as I was mocking it up it became apparent that the design of the standard inner sill extension allowed for somewhere to join all the other panel work to (yes I usually only figure this stuff out on the run...). So I thought I'd throw in a few bends here and there:

Templates.JPG (34.3 KiB) Viewed 1126 times

Didn't quite get it right the first time or second time or even the third time but the third was close enough for me to add on a few of the tighter bends as an afterthought, to mirror the bottom of the inner sill. And so have ended up with something almost like a bought one:

Final 2.JPG (43.27 KiB) Viewed 1126 times

Have just screwed the front flange of the x member for now as it was too hard to get to and didn't mate nicely with my plug weld holes. Then bent up some 2mm flat bar to match the profile of the rare spares outer sill and my best guess at the A-pillar profile and hey presto, a semi-sound structural repair.

A pillar brace.JPG (39.14 KiB) Viewed 1126 times

Enough to get back onto the rotisserie to tidy up, do the panel work and get to fitting the outer sill!

Dave

[Blacky]

nice work mate, is extra satisfying when you fab up something yourself that works rather than just buying one out of a catalog.

[Errol62]

Good progress Dave. I’m with blacky on the satisfaction factor. I use tek screws quite a lot to hold things in place, weld up, remove screws and replace with plug welds.


FB ute fixer upper, EK van on rotisserie

[FireKraka]

Nice work Dave, don't forget to put a crush piece in between the inner and outer mate.

Neil