EK Wagon project - Total rebuild

[Devilrod]

With the trim Finny, get a damaged piece and have a play around. I used a soft hammer (nylon) with a piece of red gum cut down to size and a combintation of pliers/vice grips with thin plastic on them to avoid too much marking.

[Finny]

Thanks for the feedback.

Blacky, I was trying to check the cable side first, I have 2 spare speedo's so maybe I should swap that next and if it's still a problem than it's probably the cable.

Harv, I often seem to be working on my own. I did try to see what was happening but you do need that extra person. Will jack it up and try again. It may be suspension, steering linkages or something else. Warning noted, I have already had the column out and know the spring connection you mention. I finally got it on but it was an absolute pain and not something I want to repeat. I'll check the bolt when I under the car.

And finally I have a damaged moulding to practice on. So I'll keep trying. I need to cut a section off one end and somehow bend the end so it comes to a point or angle and try to get it to look semi-original.

Knocked off a few more items off the list.
My wife now tells me she wants seat belts, but I'm not fully convinced.
Even though I go to put one on each time I get in, its nice to know I don't have too, and reminds me of my original car.

[WayneXG95]

Get the seat belts Finny, it's not you it's the other driver.

[WayneXG95]

Whats been happening Finny?

[Finny]

Whats been happening Finny?

Lots of stuff but not too much on the Wagon.
Have had her out for a couple of drives, getting further each time.
Seems to rev a lot at 100klm, but maybe that's normal. Or I have a diff that's geared too low.
Seat belts are done for the front seats.
Replaced the speedo and it now works beautifully. Steady and quiet.
Gearbox still leaking a bit so I need to replace the other seals.
have pulled off the door trims and need to either find some original red/silver ones or get new ones.
Steering has had a few more adjustments and is getting better.

Have also found that after a longer drive, she doesn't like to turn over.
It's like the battery is flat, but once she has cooled down it turns over and starts fine. So I think it's some expansion issue.

[Finny]

Thanks Tim.
I'll keep an eye on it, Very Interesting.

[Craig Allardyce]

Finny,
one other might be too much static advance on your timing. As the engine warms and you get expansion on the piston there'll be a slight rise in static compression hence why it may be slightly harder to turn over when hot. Also if you have extractors you might be getting a lot of heat soak into the starter although I've never seen this as an issue on these engines. I'm not sure of the build spec on your engine but you could just knock back your timing by a few degrees to see if that makes a difference before looking at changing out your starter.
One other to think about too would be a minor loss of coolant into the/a cylinder causing a hydrostatic lock. Is there signs of water in oil or excessive steaming from the draught tube?
Hopefully its just something minor.

[Craig Allardyce]

Craig usually the timing being that way causes harder starting when cold, and easier when hot?
Hard hot starts are more symptomatic on 6v electrics. My FJ can be a bitch hot, walk away for 10 minutes and it'll go. only times I have had similar symptoms in a 12v FB-EK has been either a poor earth, or failing or dirty brushes and com end.
Tim

Thanks Tim.
Like I said, hopefully is just something simple like the starter as you mentioned. I was just offering up some other advice for Finny to look out for i.e. maybe to check something simple first before going down the path of doing his starter. This is just from my experience in the trade......

[Finny]

I'll ask my cousin the sparky to have a look at the starter and will also check the timing.
I haven't noticed it again since, but I haven't been for any longer drives.

Now working on some if the interior items.
Picked up a old radio, it is complete and working, but I pulled off the face plate to check for alignment.


Now onto the front speakers, which I ended up mounting on the kick boards.
Made up new ones so I didn't have to cut into the originals.
Added some 4 inch 200w speakers that seem to allow a good space away from my feet.









All done, however I need to pull the passenger side off again as I still haven't connected the wire to the back of the door light switch.
Also received a sign for the back, in matching silver.



And the wife is a little happier with seat belts re-installed in the front.



Now she wants the door trims back on, so she can lean on the arm rest.
Next thing she will want a mirror in the glove box.

Still more happening, and lots on stuff has arrived in the last few days.

[oldnek]

Coming along nicely Finny, the end is near..

[Finny]

I wanted a nice stereo for the wagon, and ended up with a 200w, 4 channel, USB and aux inputs, full remote control, Bluetooth and full iPhone control (No CD).
The Radio (or at least what looks like the radio ) is finally installed.
It may not be a Holden original but it looks period correct and makes the dash look complete.



This is what I used.
Cut up an old radio frame, and utilised some surplus Volume and Tuning dials.
Took a while to shape the frame to fit correctly into the dash and use the face plate.
Moulded some black plastic to fit into the frame and used a paperclip as the station marker.
Also mounted a red led strip inside the unit, across the top.



All connected up, but I may need to paint inside the bottom so the red light doesn't reflect so much.
I thought the red would go best with the theme for the car.





I've run the power to the on/off switch, and have attached a power wire coming out, so that the "Real" stereo can be turned on/off via the switch.
All the rest will be hidden up behind the dash, and controlled via the remote control.
Now I'm just waiting for my son to do the final installation of the new stereo.

[Finny]

After finishing the radio, I needed to finish the rear speakers.
That meant finishing the wheel arch covers.
That meant trimming back the others to allow for the added thickness.
What starts as a fairly simple task, takes several hours.

I also wasn't happy with the wires running over the wheel arch's, which would show under the carpet.
One side was just the stereo wire and the other was all the normal wiring plus the stereo and another power cable.
Or at least make it difficult to lay down flat.
So I re-routed all the wires though the hole near the base of the pillar and straight through into the rear quarters.
Spent a bit of time getting a wire through first so I could tape and pull the others through.
You can see the wires going into the hole at down at the bottom of the picture.



Still haven't finished cutting and joining the wheel arch area, but It's getting roughly into shape.
I'm using ABS sheets behind all the side and door trims, so they will never rot away again.

[Blacky]

Looking great Finny

[WayneXG95]

Very cool mate

[FeeBee]

looking very tidy mate