fbekholden.com

Hi,
I have parked the hidden tailgate hinges for now so moved on the hard lid.
Thought this would a couple of days work but under estimated the complexity of the curves in the tub.

Due lack of tube bender, I decided to make the corner pieces.

I used a couple of suitable tins in the shed then made cardboard templates. Transfer these to 1.2mm sheet and cut out via cutting disc. Cleaned up the curves and place these in the corners to confirm I had it correct.
The corners are not regular simple curves so binned the lot and started again. This time marking the cardboard against the tub. Cut out each piece and welded together, sorry no photos.
Checked the back ones and happy with each but then I had to modify the front ones to follow the downward curve behind the rear window.
I should have just made a rectangular frame and not tried to be smart and tuck it in neat on the tub.

Too late now so pressed ahead.
Bend the front tube to follow the curve by using my small hand bench press.
I have it held together with every clamp that I have and will weld up tomorrow.
Safety tip - wear a face shield when using thin cutting disc.
This one of 2 that I smashed today. The other I could not find but it is in the shed somewhere.
Also the other disc grinder is fighting back after I knocked it off the bench a couple of time. It jumped and bit the back of my hand when I was holding a piece in my hand.
I did seek comfort and medical attention from Anne-Marie, my wife but got none, when asked if I was wearing gloves. I should have fibbed and said yes.

Cheers,
Roger

You got there mate and tube frame looks like a very good start. Clever idea to fabricate the corners, hadn’t thought of that. Reckon you could mount a wing on the back for some downforce.

Would need some serious struts but what about mount tailgate to hard lid and turn into a hatchback ute??


FB ute fixer upper, EK van on rotisserie

Hi,
The only down force will be from the beer and wine in the back.

Hatch back ute ????? may give it some thought.

Tubing is 25 x 1.6 mm so not too heavy. I will use gas struts and possibly side hinges. Could go with boot style hinge but would need to find something that would work.

I did a hard lid on a HJ Ute a few back that was over engineered. You could safety stand on it with a couple of mates.
This one will covered with marine 5 ply then an exterior vinyl to be decided.

cheers,
Roger.

How bout these rog?

https://manfredfrank.com/


FB ute fixer upper, EK van on rotisserie

Hi Rog great work on the hard lid mate I wanted to do one but after all the other stuff I had done I ran out of steam.
I spoke to Chopped when I was thinking about it and I think he said he used HQ boot hinges fixed under the parcel shelf also not sure if you are also on the FE FC forum but have a look at JBs Ute build the thread is 365 Weeks he shows the gas struts that he used and he came up with some neat pop down locks for the back corners.
Might give you some ideas but as I said you are doing great work.
Regards
Neil

Roger I bought a pair of the hinges above . Do you want me to send you a cardboard template of one so you could try on the tailgate?
Cheers Mark


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Thanks for the suggestions.
Mark - On my last visit to the wrecker there was a HJ sedan there but I did not look at the boot hinges. Will drop in tomorrow and see if it is still there. If not I will be in contact, thanks.

Neil - I have not been on the FE – FC forum yet so will have a look tonight. Also good to see what others have done.

Finish welding and grinding on the frame today. Heap lighter that to one I made of the HJ ute.

Off to golf tomorrow, first time since lock down.
Cheers,
Roger

4!


FB ute fixer upper, EK van on rotisserie

Looking good Rog - why not ditch the ply and go for a Aluminium option - the new cladding they have now has a alluvium waffle design inside so it's even stronger than the plastic stuff (Alucabond) - would be a lower profile than ply and a third the weight.
Would be a great surface to apply venial to as well - think there are various brands out there but Monoclad come to mind.

We have used Alucabond in our 4x4's for years for drawers and portable tables etc and the stuff is unbreakable and you can use it really easily - I even glued a couple sheets together to have a legless table that I could hang off the corner of by rear bumper.
Hinges will be tricky - are you going to put external hinges that bolt onto the back area behind rear window?

Thanks for the lead on composite aluminium sheeting as I had not considered this before.
I was thinking of blending the edges to have smoother transition from lid to quarter panels so routing wood was my thinking.
I could incorporate a rounded ended with a weather seal.

I did spend sometime on the FE-FC forum to other night following the build that, thanks to Neil.
The under rear window hinges look shed built so possible to reproduce or following some research I could use HD/ HR boot hinges. May need the modify but that is what we customisers do.

Also liked the quick release locking system from VPW, clean smooth and neat.

Cheers Roger

PS Clay - front 9 was good but stumbled on the back but good to be out on the course.

I have completed the hinges from the hard lid at last.
Thank you to Chopped for your advice and photos.
Thanks to Neil for the lead to FE-FC forum to see what one of the guys did to his ute.

Started with these off of a HJ sedan After a number of cuts and weld finished with these. As you can see a lot different to what I started with. No decision yet on the material for the hard cover but may go the way of aluminium composite but now thinking of a thin edge so the flow of the rear quarter is maintained. This will be covered in black vinyl and possibly padded.

The hinge mounts are 50 x 3 angle and cut sit under the parcel shelf. Added 40 x 3 brace to spread the load on the parcel shelf. I purchased the quick release pins but could not get black ones so now will anodise the silver ones to black.
Looks like I need to modify the rear corners to fit in these quick release pins. Rain coming so will pickup my tinkering on the tail gate hinges again.

Cheers,
Roger

You've nailed it rog. Be sure hinge mounts are braced to the frame.

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I went and checked this out in the flesh today. Very impressed with the hard lid, as well as some other clever custom touches I won’t steal Roger’s thunder on. I am awed at the hours you’ve put in on some of these Rog. I can see you sorting out those hidden tailgate hinges no problem, one day..………………………

Also a lot of interesting stuff in that shed, some of which I walked away with.


FB ute fixer upper, EK van on rotisserie

Thanks Clay for your kind words.
I will get the tail gate hinges sorted as it bugs me no end when I know it has been done before.

Happy to help out with stuff in shed that I'm going to use. If not on your ute then on your van.

Spend some time this morning talking to a company that makes slide out storage for tradie's utes and vans.
Thinking I may do something for under the seat to hold the loose junk that would sit on the seat, wallet, phone, glasses, etc.
I may need to reduce the hump under the seat as there is only 60 mm gap.

Picked up the soft bailey channel for the doors and some adhesive backed foam to seal the hard lid for Clark Rubber.
Still deciding what to use on the top of the hard lid and no add too much weight.
Completed the hold down and need a grind and clean up. The essential cup holders have been an interesting challenge, from centre consol to swing out under dash mounted but I think I may have a neat solution. Ex BMW, in-dash pop out. Actual mounting in the dash is undecided as yet. There is space above the ashtray but it is fairly close to the heater core and no room under the ashtray as the heater box to wide.

Cheers,
Roger

Nice work mate
Neil