Melly's EK wag find

[melly]

Used commonly to replace the big nut, original from HK on. It is fouling because it is a modification to the original single circuit master. Moving it over slightly shouldn’t cause binding of the pedal and Clovis mechanism. This is a common modification. I haven’t done it myself but plenty have, and I’m pretty sure they didn’t need to go replacing bonnet springs melly.

Righto now it makes sense Clay, thanks... needed to do a bit of research with dr google - reckon you're right there should be enough to play within the setup if i open up a couple of holes here n there! cheers fellas
FB ute fixer upper, EK van on rotisserie

[melly]

And so after another blunder highlighting my social media ineptness (I really should be getting my kids to do this shit), its back to posting this stuff in the forum where it is supposed to be ( my apologies to all)....after finally securing the services of someone who can weld properly, we made a start on getting the webers to fit.

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Being in a tight spot with some complex shapes (and limited Sheetmetal tooling available), old mate came up with an ingenious solution... enter one quarter piece of a 2kg gas bottle

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I know this mod wont impress everyone, but once tacked in a trial fit of the carbs had me grinning

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until it was time to trial fit bonnet
so hinge and gas strut mods now added to workscope

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and then after a long absence of the welder, he returned to close up (some of the holes)

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It was around this time that my old mate had to leave again- not before giving me a quick lesson on how to use the gasless MIG ive acquired- and handing over

[melly]

So from here

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it was a few quick trial runs on some offcuts i had lying around, to putting my welding and fabricating skills to the test

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and so this is where im at. The car is around 95% complete (thanks again to EKmart as id never even be close without it). I need to find some wagon Sunvisor brackets and lower tailgate hinges (the ones we salvaged Blacky are pretty knackered, but will get us home. I will need to drill out and oversize one of the hinge pins cause its flogged out). I think ive got pretty much everything else sorted on mockup, so its off to the brake and exhaust place next week to fit flanges to the extractors and run the rest of the pipes, then make up and run some new brake lines to the booster which ive relocated under the guard. When thats done, a good mate has offered his hoist and workshop for a couple of weeks so we can get the wiring in.

Hopefully the next update will not be as far away as the last one was...

Have a good pre- Nats weekend everyone, cheers,,,

craig melly

[Errol62]

Great progress Craig.

Sent from my SM-G781B using Tapatalk

[Blacky]

If those hinges are no good mate we can grab the ones off the other wagon ????

[FireKraka]

Hi Melly if your standard modified hinges are too big maybe have a look at V6 Conversion hinges mate

[Harv]

If EKMart is out of stock of wagon lower tailgate hinges, give me a yell. I've probably got a set here somewhere.

Cheers,
Harv

[FireKraka]

Pretty sure I have some here in Perth Melly if you need

[melly]

Thanks fellas, feel like I’m actually getting some forward traction again- I’ll bring the hinges with me to be assessed by the team when next we catch up… batten down the hatches guys the rains are comin

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[melly]

After another period of little progress have managed to achieve a few little bits n pieces so we could move to the wiring- battery relocated, new starter, dizzy, coil and a set of Bangin headlights. Wiring harness removed from car. Also got the handbrake sorted with a stand-off pulley mod. New exhaust system fitted. A good mate offered the use of his hoist, so off we went…

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while we’ve got the hoist I’m hoping to get the brakes sorted- can anyone help with pics or advice on best routing for front brake lines with booster relocation as pictured? Also like to wire in triple gauges and tacho while we’re at it- the high volume oil pump looks really close to the oil px sw- what’s the go with an adaptor so we can use idiot light and pressure gauge? Not much room to screw one in it seems? All help greatly appreciated as always!

Thanks guys,
Melly

[Blacky]

What master cylinder you using ? Run from master to booster then booster to the distribution block on the subframe for the fronts and straight from the master to the rear if you can.

Oil pressure adapters are available just about anywhere, Veales, Auto One, REPCO etc. I have one on the rattler to run idiot light switch and gauge

[melly]

download/file.php?id=17573
This one Blacky- PBR there’s some details back a bit in here, original drums on back. So plan is boosted front only, from MC front port out into the guard then from booster I’d like to know what route people have taken back thru the engine bay to get to the LHS? Some pics would be handy so I can get an idea of where to actually position them?

Cheers melly

[Harv]

Booster down to front subframe, to original location of tee-piece. Keep this line as close to the inner guard as possible, and clamp it about every 8" or so. Use two-way tee-piece to split. One (short) line to RHS front subframe into the original "flexible pipe meets steel line" joining bracket. Second (long) steel line across the bottom of the radiator, picking up the bendy retaining clips along the way. Finish this line at the LHS front subframe into the original "flexible pipe meets steel line" joining bracket.

Cheers,
Harv

[melly]

Thanks Harv/ Blacky that makes more sense I wasn’t even looking for attach points across the front. I could do with another car close by that I could use as a reference.

Cheers gents have a good weekend

Melly