EK Wagon project - Total rebuild

[WayneXG95]

Surely Tim has correct horns spare...

[Finny]

Yep, just doing the step by step process.
Will look at the frame plugs also Rosco.
Agree with getting the big stuff finished, just need to wait for extra hands to help.
Horns are all working so I'm happy with that.

Got the Splash guards back in place.



Discovered that you need to have the grill in place before you install the indicators.
Got good at installing them after the 4th time.



Had to repair one of the wires that had come out of the back on the connector.
Tricky little sucker, getting solder into the hole and the wire in place before it set.
The other side also needed to be dismantled as the spring was faulty and needed to be replaced.



When I removed the stabiliser bar, one of the bolts snapped off.
Drilled it out and recut the thread again.
Worked perfectly.



Front end all finished and bolted up.





Had to replace a few wires and connections and fix a few dodgy contacts.
Lights all tested and working on the front end.





Also redrilled the number plate holes so they are in the correct positions.
Got to keep Tim Happy.





Progressing, but I complete 10 tasks and find another to add.
Looks like changing over the extractors and the new exhaust will have to be next week.

[Finny]

This may be the year that I actually get to the Nationals at Cowra.

[Trev]

Also redrilled the number plate holes so they are in the correct positions.
Got to keep Tim Happy.

But the bottom of the plates should be level with the bumper.

[ben]

But the bottom of the plates should be level with the bumper.

Watch out the plate police are out again....lucky you painted behind the grill black or you would be in deep s@#$

Wagons looking great Finny, well done

[Finny]

That's it, why are the police all over me.
No more photos.

The plates are now attached to sliding brackets that allow it to move all the way from the top to the bottom.
I was actually scrolling through forum photos and noticed that only 1 to 10 have the bottom of the plate level with the bumper.
I also didn't like the sharp edge of the plate sticking upwards.

Did a lot more today.
But can't post any photos, so that's it.

[Finny]

What's the point if I don't show pictures.
Thought I'd tackle the rear cargo area glass.

The front windscreen was a piece of cake compared to these suckers.
Got to the corner and she would not pull out.
Went in the other direction and same thing happened in the other corner.





Before I could do this I had to attached some extra roof lining material to extend it so it lipped over these areas also.
That wasn't quick or fun.

Had my cousin over to look at the generator issue.
He was an auto electrician who did 12 months of his apprenticeship working on these systems.
And he knew his stuff. Thanks Tony.





The generator bushes had frozen , but the bearings and everything else was in excellent condition.
Stripped it down, cleaned and oiled and generating perfect output.
And best of all no permanent generator light on the dash.
And no more draining battery.

Finished off checking all the electrical connections, replacing old contacts and completing connections.
Headlights
Parking lights.
Indicators
Brake lights.
Wipers checked,
Horn.
Oil light
Temp light.
Cigarette lighter.
Interior light
Cruise Control,





No, that's wrong. I still need to attached the passenger door light switch.
Also got the return springs back on the brake and clutch pedals.
Fuel gauge now working, had the connections around the wrong way.



Rear vision mirror back on.
Actually kept the bracket but swapped the mirror for a night adjustable one.





Ticking a few more items off the list.
Just the rear windows that seem to be the biggest hurdle.
Wonder if there is a correct procedure for putting them in.
Might ask as a separate question on the forum.

[FeeBee]

Looks great Adrian!

the black out looks perfect

re-order your plates as slim line for front and back. and you won't have to worry whether they hangover the top or bottom

[Finny]

re-order your plates as slim line for front and back. and you won't have to worry whether they hangover the top or bottom

I did consider that also.
Maybe down the track.

[WayneXG95]

Surely Finny's just trying to wind me up

[rosco]

Can't help you with side windows, Finny - never had anything to do with them - Don't know if Stewart had any issues with his..?

Yes - those blasted sway bar retainer bolts - stupid idea to fit a captive nut inside of the sub-frame section.... you can guess why these rust in, and yes - please chase up those blanking plugs.... best $1.95 you ever spent....

I'd leave those red motor engine mounts on the x-member - they look like Rares ones circa '80's, small and square.

Is your tank half full - or half empty? - probably would suggest draining the tank to find out where the gauge needle sits...... lots of people been in trouble thinking they've still got a gallon left...
Mine "bounces" when it's down to less than a gallon - when it stops moving after that - I'm in the do-do's...

I removed the complete pair of leads from each indicator bulb holder - and re-wired them with new leads - yes, those those blasted terminals were tricky - but were a breeze on the bench. I found it easier to make up new bulb contacts and solder them in before fitting - then simply pushed them through the spring, into the housing and fitted new terminals to the other end....... hindsight, eh - magic thing...

All looking great - and yes, surely - Cowra is well and truly an easy timetable..... always will have "little bits"... every car does.... none of us have one which doesn't need something... or we'd like to do something - to....

frats,
Rosco

[Finny]

Left the car out in the sun (Yes Tim, I do listen sometimes)
And tried the windows again, but started at the sharp pointy corner.
Managed to damage one rubber but I'm sure I can glue it back together.

Both rear windows are in , and I do NOT want to do it again.



I will get back to those other items Rosco, but think it may be easier to get it registered first and then work on all the fiddily bits.

Aiming for Safety Certificate and Rego on Friday (This week), but still have a bit of work to complete tomorrow.
Tentatively optimistic......

[rosco]

Great work, Finny - those "fiddly bits" will keep you young for years....
Yes, fingers crossed for you for Friday... there will probably be stuff you'll need to go back for, don't stress - don't argue.... you'll get there, just bite them off one at a time and you'll have this great project officially mobile....

Too bloody hot to do anything but annoy people on the internet today... spent all day bleitzcrieging my habitual sites.... there's just so much I want to get out and do... but 43 today and 45 tomorrow - this old retiree just can't afford to get crook from the heat....

So, I guess the little pocket notebook is getting a flicking over... I still have mine from '83 when I planned out the big project - gosh! 31 years back.... and still fixing those "fiddly bits".....

If anyone has frightened me away from a wagon - it's your experience with those dastardly side windows!

frats,
Rosco

[EK JAY]

well done finny there a real pain in the @#$% to get in
spent 3hrs nearly on one window in the red wagon
by myself I might ad
didn't want to do the other side by myself
so rang my old man to give me a hand and we had it in
in about 10 minutes nothing like a extra pair of hands and abit of experience
when it comes to that stuff

[rosco]

Mention the words - FB or EK Holden to a windscreen mechanic.... and watch their face go pallid!...... akin to taking a pork chop into a Synagogue....
They have become accustomed to the fit, heat and cover process..... our stuff is hard work - and there's no room for not fitting it exact...... blasted cut and paste windows of today, like so many other "intricate" and attained skills needed to maintain our buses...... fast going into oblivion...

frats,
Rosco