| So here's
the LOG BOOK so far... |
| JOB / PROBLEM |
SOLUTION |
NOTES |
| Whitewall tyres not easily available
in 70 profile (as per rear pair) |
75 profile on front |
Cooper Trendsetters 235x70x15 rear,
Khumo's on front. Then Nankang on rear (thicker white wall) |
| Valiant sedan seat set badly fitted (illegal) |
Ford XC bench
seats front and rear |
Vehicle already registered and complied as a 6-seater |
| Door mirrors are LHD angles |
pack out
with hard foam behind glass to extremes |
Ford never made a RHD LTD so mirrors, bonnet release
(passenger side), foot parking brake (far RH) and column shift
(interferes with upper fascia) are all in strange positions |
| Rear wheel bearings impossible to source in Australia
AND axle shafts have broken
1mm shims to pack out non-original wheel bearings |
make the
axle
shafts fully floating with 4mm pressed collars and Chev truck open
roller wheel bearings |
shafts were ground down and hardened collars ground to
suit the new inner bearing dia. |
| windscreen wiper arm linkage broken |
finally find ball-joint pivot nuts to suit |
commonly used on carburettor linkages |
| no brake
pedal rubber |
join two Falcon ones for correct length |
Roadworthiness only requires 'a non-slip covering' on
the brake pedal |
| interior light cover missing |
use a plastic Falcon one although too small |
original was a magnificent chromed affair |
| interior light door switches all missing |
Ford Fairlane ones fit |
wiring still lost in bodyshell |
| foot parking brake has no release lever |
rig up
remote trigger from old bicycle cable |
foot operated parking brake is next to accelerator |
| PRINDL no worky |
make a bright
pink pointer and glue it to the
column |
Roadworthiness requires 'a means of indication' for
P,R,N,D,1,2 |
| Wipers no worky |
clean and repair the enormous switch |
wipers have groovy intermittent setting and even
groovier 'slow park' when switched off so the blades disappear under the
bonnet line |
| need previous proof of registration to apply for
re-registration |
contact Police for 'stolen' details |
Funeral directors and previous owner very evasive of
the car's history |
| no fuel cap |
Falcon one fits |
at last an easy one! |
| front indicator lens holed (D5AB-13215-AB) |
repair with polycarbonate |
Rear red (US) turn signals were changed to brake and
tail lights while the reversing lights now serve as orange turn signals
(rather small!) |
| wiper water jet pipe split |
repair with 'heat-shrink' |
. |
| elec tailgate no worky |
rewire button |
straight switch - no relay |
| sidelights no worky |
clean up and replace globes in holder |
not standard US spec |
| rust holes in 2 door corners and rear wing |
kill rust & bog |
very little corrosion with being in the sun all its
life and locked up for the majority |
| no compliance plate |
engineering sign off & plate |
can now be registered after a RWC |
| rear number plate light no worky |
clean up fitting after years of neglect |
two lights original but one has been replaced with a
towing wiring plug |
| distributor
cap scrap |
Bosch |
The original Duraspark elec ignition has been replaced
with Aussie Bosch parts including the guts of the dizzy |
| emissions air pump seized |
remove |
all emissions gear removed as ADR's require them only
after 1978 |
| air
filter black as coal |
replace |
closest available for this pan is a V8 Holden one |
| main beam headlights no worky |
rewire switch which was shorting out through body shell |
the floor mounted foot switch has no fuse but one of
the many 'fusible links' within the main harness |
| oil black as your hat |
6 litres GTX |
looks like 'you-know-who' tried jacking the car up by
the sump - need panel beating (or a chrome one!) |
brakes pedal 'fades away' after 3 seconds of pressure -
leakage between the two
chambers in master cyl. |
master
cylinder bored and sleeved - 1" stainless i.d. |
Classic this one - previous owner told me that all the
brake linings had been replaced just before he took it off the road
because his brakes failed completely one day. |
| hydraulic
lifters rattling |
16 new ones at a mere $5AU each |
carbon build up around base inhibited easy extraction
and had to re-use valley gasket (D5AE-9C484-AC) |
| fuel pump
leaking around bowl crimp (common) |
new one |
the 400cu"
has the 351M block so a 351Windsor or Cleveland fits |
| Fascia
clock no worky and shorted out |
transplant
battery operated bedroom alarm clock innards and fingers until new
one is sourced (broken spindle, coils and points) |
12v clock coils had been shorting for years but never
troubled the fusible link (no fusebox fuse). After being unplugged, many
of the fascia components worked better and the the clock bulb came back
to life no it wasn't being shorted out! |
| Paint resembles surface of the moon in parts |
spray putty to
fill cracks and black acrylic aerosols until bare-metal respray in
20?? |
the grey paintjob was far too thick in places and as a
result, 1-2mm cracks and crazes spread on all horizontal surfaces over
time |
| rear end
has nasty 40mm MDF as floor and trim |
replace with 6mm ply and finish with custom arches and
carpet |
the rear of the car rose 30mm when all the MDF was
removed! |
| tailgate seal
= marzipan |
truck spec replacement |
no hope of finding a new one - or the failing upper
door seals (no frame) |
| sun visors missing |
Ford XD Falcon ones bridge most of the gap |
original ones had vanity mirror and light |
| Aeronutronics
push button radio no worky |
complete rewire |
12v feed has green/yellow wire! |
| radiator cap brown |
introduce coolant for the first time and change hoses |
universal
hoses - 26" each |
| thermostat
housing corroded (D7AE-8594-AA) |
Cleveland
chromed one as replacement - 90deg bend but ok with univ hoses |
drill out for after market WATER TEMP gauge sender (no
gauge fitted as standard - what supreme confidence!). There is an
'engine' light though on the dash |
| no jack |
XC jack just about lifts one corner |
bumper bar lifting eyes but the RH front one is behind
the licence plate! |
| sway bar link bushes flat |
replace with polyurethane ones (red) |
same as XC falcon |
| rear shock absorbers rattling |
replace upper mounting rubbers |
old air shocks fitted but stems too long |
| sway
bar/chassis bushes split and gouged |
replace iwth polyurethane ones (blue) |
(D2OA-5484-FA) Same as Mitsubishi
Pajero |
| upper
trailing arm bushes flogged out |
MOOG ones sourced through specialist |
old ones had to be drilled and smashed out - *caution*
new ones uni-directional
(MOOG 62638 - Clevite silent bloc) |
| knobs
on interior door handle winders cracked, missing or yellow with
age |
fabricate
hardwood ones
and fit to old winders |
stain to match fascia wood |
| auto tranmission last serviced 80,000 miles ago |
clean bill of health + selector shaft seal changed |
C6 auto - service kit common |
| power steering high pressure line weeping |
new hose fabricated by mobile technician |
pricey but easier to remedy than a Pitman Arm seal (as
initially suspected) |
| nasty CLUNK from transmission when brakes applied |
brake shoe bottom adjusting wheels both loose |
initially suspected diff, then UJ's, then transmission,
then upper trailing arm, then body mounts - how embarrassing |
| double
roof rack (for wreaths and flowers) fitted then 'lost' |
XC 'Wagon one fits |
holes left on roof where the double was |
| left hand front door
release
handle loose |
re-tighten two bolts |
replaced foam which covers release hole |
| LH door glass not sealing properly - guide becomes
loose |
re-position the
mis-alignment
(due to door slams) |
original grease replaced on all moving parts |
| LH
door casing
clips loose |
repositioned |
cardboard
casing is showing signs of old age |
| Alternator
brushes
worn |
shaped new ones to fit |
Alternator since replaced with Bosch 60amp (including
internal regulator) |
| single wrong exhaust to be replaced |
dual
system fitted |
11metres
of 2 1/4" pipe required |
| electrical system quirky |
body
earth added to improve electrics |
slight improvements |
| Horn stopped working |
mount had
fatigued
and snapped off |
clean
up surrounding area |
| cooling
fan cowling loose |
fixing holes fractured, huge cable ties utilised |
drilled mounting holes in cowling |
| Battery
tray showing corrosion |
Kill-rust application |
|
| radiator
holed LH side |
solder hole with rad out (brass sides) |
a bolt on the
condenser
bracket rubbed through the side of the radiator |
| radiator
mounts showing
corrosion |
'Kill-rust' applied |
rubber
mounts due for
replacement
/ fabrication soon |
| front
brake pad squeal |
removal and
capture
dimensions for re-line |
glaze up a treat during the summer |
| not only will it look fantastic, a
front sun
visor will scoop air in
through
the frontwindows |
centre stay fabricated to eliminate flutter |
the roof plan is basically the same as an XB or XC
Falcon. The centre and side mounts are
custom made
in SS and fasten throught the A-post (padded under the trim) |
| rear
wind deflector to clear dust off tailgate window at speed |
can only be fixed with extensive relief to the inner
roof skins |
the 70's
Fairlane
visor has a slightly more curved profile but the gap is taken up
with the rubber gaskets (x5) |
| flasher
unit burned out due to a short in the rear wiring |
Tridon
HD12v units still plentiful |
RHR indicator wiring found the jack handle and heated
it up nicely! Now I don't worry about the harness 'fusible links', cuz
if that dain't melt one, nothing will! |
| getting fed up with having to use GM paper air cleaner
elements |
go mad and set up the 2V with a
K&N high
flow pan. It was meant for a 351W but fits fine |
unbelievable difference in pick-up and general zip!
Gear changes also even smoother. Re-routed the breather pipes down the
side of the transmission. Must be the best bolt-on goody ever - on hard
acceleration I can now actually hear the litres of fuel splashing into
the carby... |
| front shocks well sloppy |
Pedders off-the-shelf pair after the usual
'show-and-tell' |
upper
mounting holes worn |
| front wheel bearings due perhaps? |
standard
procedure for a change.
Rotors getting
thin |
the
top of the outer races were badly pitted to the indent of the
rollers after being out of service for an extended period. They were
almost rusty! |
| rear
axle LH bearing fails and leaks past seal into drum. Could almost
feel the rollers
grinding! |
grind off the
old shim
and
FKC
'RW901R' bearing pressed onto axle shaft with
retaining
ring. Axle housing needs opening out to take the OD |
the old shim was nearly destroyed after about 500miles
of driving on it. Looks like the case hardening failed from being too
tight a fit? Lots of metal in diff. Strangely, the RH modified set up
remains perfect after 18,000miles |
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