flyingbrick

flyingbricks HZ Ute- moar floar!

112 posts in this topic

Cleaned up all the sharp edges and went back to bare steel on the important glued faces then painted everything in epoxy.

Finally glued into place. There's also rivets top and bottom where they can't be seen.

The washers were glued onto the new panel so that the two edges were easy to align.. I'll knock them off when the glues dried and all the rivets are in.

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Finally got new front discs. A few things to do before front brakes are done-

Machine hubcentric sleeve to center wheels and disk to hub (disk is a little too big in ID for the hubs spigot)

Redrill disc PCD

Draw adaptor plates for calipers and have laser cut.

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Iv been plodding away at this.

Redrilled the disks to Holden hq/chev PCD (modern mills have sweet digital readouts that make this very easy)

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I laid everything out on the lounge floor and sat everything together. I made a cad drawing and printed it 1:1 scale, cut it out and test fit it, then tweaked and repeated 5-6 times.

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Iv done something slightly unusual and decided to trim the bottom of the steering arm mounting boss so that the plate can go under it (and will be clamped down by the arm too)

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because this gives me a far more professional looking shape than this:

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I have also added onto the bottom of my adaptor plate the steering lock stopper as this has been cut off the end of the steering arm too (they did this in the above photo also but didn't add the stopper)

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Then I transfered my best template to sheetmetal and made sure it still fit ok.

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Then had a single item laser cut to again check everything lines up as expected. It's pretty damn good!

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I do need to spin up 4x spacers (to go between caliper mounting cradle and my adaptor, at the moment it's got a stack of washers) get some pads and then hopefully can document everything and send it away for tech approval ( or something)

Huge thanks to Clint for answering my questions!

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Putting the wife through fertility treatment so money has been tighter than usual but managing to do cheap shit occasionally.

I removed the bent grille in top center of the dash (is it for a single speaker?)

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Sent some bits off for gold zinc plating

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Drilled some holes in my fuel tank mounting frame as it's way too sturdy/heavy. Will get this gold zinc plated too

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Also did some trading and bought some fiberglass front guards (need to get these north from invers somehow!) And also a fiberglass nosecone that was made locally.

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I have been pushing myself to spend more time in the shed... So another 5 patches down.. no more left around the windows!!! :-D

A few pics..

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I'll try this again :-)

Pushing myself to get this done. 

 

Today I tackled the floor. First I made a template using card stuck down with Ali Express magnets, cut out of 1.2 panel steel, removed the old rusty crap (messily) and am now taking my time to adjust things and get positioning right using clicoes to hold things down temporarily.

 

If you don't have any- GET SOME as they are absolutely invaluable!

I beat the beads in with a ballpean..Happy with how it turned out so far as it's far more than I have ever done before!!

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The rear cab mounts/ front deck mount things had rotted through all along where they were welded to the chassis. Various patches had already been done and the only option was complete replacement.

 

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(Lol..Cat added one extra brown hole to this photo.)

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Probably mentioned these heaps but had them laser cut out of 3mm steel (significantly thicker than factory) and then folded at work during smoko.

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I cut the old mount off on one side and used it as a template to mark cut and fold lines on my new pieces.

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Have acquired a TIG welder to use at home. The GOOD body guys use Tig to weld up their panel steel- the benefit being far less material to clean up and a much softer weld that you can hammer (I'm told MIG will crack) 

The professionals don't even use filler wire- their gaps are so minimal that they can fuse the panels together and planish the seam out so that virtually no grinding is needed!

I'm nowhere near that skill level but made my first decent part for the driver's side patch that I stuffed up earlier. This part is a front corner and it is a mirror image of the factory floor on the passenger side (I have nothing on the driver's side left to copy)

As I don't have one of those fancy contour tools I used very low tensile bent wire (I think it's gas welding filler wire) to transfer and check shapes.

 

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More stuff back from the platers, hinges, axle spacer things and a few brackets.

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Drilled lots of holes everywhere.

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The handbrake took a bit of planning (used CAD)

There is 10mm between each hole and the sides of all the holes (except for the last big one) are all in a straight line :-D

Holes cut with a combination of rotabroach tooling and normal drillbits in a mill for no other reason than because I can.

 

Oh and used big blocks of steel, a press and a hammer to fold over the curved bottom lip on those chassis bits.

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And yucky. This is why the old ones had to come.off

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Ordered the correct door hinge bushes from Jonseys garage in Hamilton after measuring my hinges and finding imperial equivalent. They have an excellent website and they sell a range of hinge bushes for less than HALF the cost of buying an actual HQ/WB specific set (just $3 a bush)

They were the ONLY source I could find in NZ so I'm very impressed...It's surprisingly hard to find small bronze tophat bushes!

http://www.jonesys.co.nz/clips-fastners/pins

During lunch I tig welded the bottom of the handle and after a bunch of measuring milled in these finger dimples- work days go faster if ya skip smoko and focus on little projects like this.

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Had a very stressful Thursday morning and was too worked up to go back to actual work so did the driver's side floor piece. Shaped the opposite side of my MDF former, pinned my steel down with a pair of nails and tapped it round while watching TV. My pleats are getting much nicer now. Fewer pleats and larger seems much tidier than lots of little ones.

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And then I had a pair!

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Still lots to go :'-(

Having a decent hammer and tools makes this a whole lot faster and easier. It's amazing how much you can push mild steel around to adjust the position of folds and joins....A very fun learning experience.

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Wire wheeled out some dirt and rusty, ground off the spot weld bumps and the rusty remains of the old skin and then hammered everything straight again.

Now the passenger side needs the same.

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