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the eh Offline
#421 Posted : Friday, 17 March 2017 5:53:46 AM(UTC)
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The only area of the ute needing completion is the tray. Tonneau bow made and all the undertray hardware mounted, wired and finalised. Just need a floor and then a coat of tray liner and we're done.





the eh Offline
#422 Posted : Sunday, 19 March 2017 6:15:32 AM(UTC)
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Failed 4 out of 5 Brake Plate tests..

However you can only possibly pass one test . That's the main brake test with everything functioning correctly. All the other tests are carried out with something missing from the system. Even my hybrid handbrake system worked perfectly. In fact it met the test requirements with ease and then performed even better than expected..

The tests we "failed" were, FRONT BRAKES DISCONNECTED. Minimum peak deceleration had to be 20%, we made 26%. REAR BRAKES DISCONNECTED . Minimum peak deceleration had to be 50%, we made 65%. Finally BOOSTER DISCONNECTED. Minimum peak deceleration had to be 50% AT 500N pedal force, we made 57%. at 502N pedal force. Handbrake also passed by holding the car stationary in forward and reverse gears when a slight throttle is applied. So really we passed all 5 tests. A huge thanks goes out to John Desisto for carrying out these tests for me. A great guy and the owner of one of the all time great EH panel Vans. A car from a family of EH fans that I can say was and still is a huge inspiration to me and my love for these cars...







Dr Terry Offline
#423 Posted : Sunday, 19 March 2017 6:58:31 AM(UTC)
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Well done Scott. This vehicle is a credit to your resolve.

How did the 'disconnect' routine go, was it as easy as we discussed the other day ?

Dr Terry
If at first you don't succeed, just call it Version 1.0
the eh Offline
#424 Posted : Monday, 20 March 2017 6:05:55 AM(UTC)
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Originally Posted by: Dr Terry Go to Quoted Post
Well done Scott. This vehicle is a credit to your resolve.

How did the 'disconnect' routine go, was it as easy as we discussed the other day ?

Dr Terry


Using the method I described to you, open a bleeder we had total failure. As soon as the pedal was depressed it went to the floor. Luckily the handbrake worked brilliantly and stopped the car. We ended up fitting the blocked off tube to each circuit individually and obtained results identical to the sample results in the Transport for NSW regulations.

http://roadsafety.transp...ake_assessment_dl1.html

The workshop even rang the RMS Technical people and asked them how they recommend doing the "disconnect" tests. They recommended crimping the rubber hoses. I also spoke with another workshop that has done this same test regime for the same engineer and they also just crimped the hoses.

Interestingly we tried the same test on a VZ Commodore they had there. We opened a bleeder and ran the test, total failure on that wheel. However this car had ABS so the front circuit is split at the ABS therefore the other front wheel functioned perfectly and the car retained a working brake pedal. I don't believe the disconnect test can actually work if done as described. To me it appears as though if you have a failure in one circuit the internals of the master cylinder do not function in a way that allows the other circuit to function correctly and retain pressure.
the eh Offline
#425 Posted : Monday, 20 March 2017 6:17:52 AM(UTC)
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Nearly finished.

commodorenut Offline
#426 Posted : Monday, 20 March 2017 9:33:17 PM(UTC)
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So close now! The brake test rules must have been written by a bureaucrat..... with no practical experience.

I didn't realise you were "local" to me. I used to work around the corner from Malibu in the '90s, right beside the canal.
It's been years since I've seen some of those EH's around. The green EFI 5L wagon used to be a regular cruiser in the area.
Cheers,

Mick
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the eh Offline
#427 Posted : Tuesday, 21 March 2017 7:26:20 PM(UTC)
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Originally Posted by: commodorenut Go to Quoted Post
So close now! The brake test rules must have been written by a bureaucrat..... with no practical experience.

I didn't realise you were "local" to me. I used to work around the corner from Malibu in the '90s, right beside the canal.
It's been years since I've seen some of those EH's around. The green EFI 5L wagon used to be a regular cruiser in the area.


The green wagon is Franks and the brown panel van belngs to John. John used to own the mechanical workshop however sold it a few years back to his nephew. John came in on the Saturday to do the brake testing for me. Great EH guy..
the eh Offline
#428 Posted : Wednesday, 22 March 2017 6:07:15 AM(UTC)
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A few jobs knocked over. Rear parcel shelf fitted. Passenger side door trim partially fitted. I still can't get the clips at the front and rear of the trim to stay in the plastic plugs in the doors. They just pop straight out. The drivers side trim will have to be remade. The board I gave to the trimmer was mdf and it has water damage. As soon as I put any pressure on it the mdf collapsed. A quick trip to Bunnings for some 3mm plywood and a new board has been made.











the eh Offline
#429 Posted : Sunday, 9 April 2017 2:13:16 PM(UTC)
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I have already started on a brake upgrade for the ute, even before it's on the road. I am not at all happy with the brake pedal feel.. I bought a BA Falcon 9" booster off eBay and had it split so that I could change the firewall mounting bolt pattern to match the 7" unit currently fitted. I also need to modify the input shaft to fit the EH pedal. The only other thing need to be changed is the bonnet hinge. It will need to be trimmed near the lower firewall mounting bolt.





the eh Offline
#430 Posted : Thursday, 20 April 2017 5:27:24 PM(UTC)
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BA Falcon booster mods done. Once welded and reassembled it SHOULD bolt straight in in place of the current 7" unit.











the eh Offline
#431 Posted : Friday, 21 April 2017 3:14:09 PM(UTC)
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Booster welded and now bead blasted ready to go back together next week. Gear shift boot glued and the holes in the floor drilled and ready to install once the glue dries







the eh Offline
#432 Posted : Tuesday, 25 April 2017 12:25:10 PM(UTC)
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Well that was a short days work. I got the 7" booster out of the ute in 20 mins so I thought I was on a roll. Then when I held it up next to the Falcon unit I realised I have't shortened the input shaft anywhere near enough. Now the booster is reassembled and repainted that's a pain. Not sure of the best way to sort this out. I think I may have to get the booster split again. Grrrr..







the eh Offline
#433 Posted : Tuesday, 25 April 2017 3:45:26 PM(UTC)
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Even though the booster shaft needs to be modified I thought I should fit it up and check everything else. Well it bolts straight in. Haha. All I need to do is modify the PCV system, Totally redesign the accelerator cable and pedal and modify the bonnet hinge. Easy!! I shouldn't have expected it to go too easily.









the eh Offline
#434 Posted : Saturday, 29 April 2017 6:46:23 PM(UTC)
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New larger 9" booster fitted and plumbed. Getting the input shaft linked to the pedal took a bit of effort and some creativity in the lathe but we got there. We needed to remake the accelerator pedal and modify the hinge due to the bigger booster now being in the way of just about everything. The ticking noise is just the PCV valve. It can't go back in as it's too big to clear the booster. A new stock Delco one will fit fine..











the eh Offline
#435 Posted : Sunday, 7 May 2017 9:06:37 AM(UTC)
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Steering uni joint cotter pin replaced. First new one I fitted snapped before I even got it tight. Not happy. Luckily I only needed one and they come in a pack of two. Hot dog mufflers tacked in place ready to be fully welded and painted. IT IS THE FINISHED AND READY FOR FINAL INSPECTION..













the eh Offline
#436 Posted : Saturday, 13 May 2017 5:08:36 PM(UTC)
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All back together. I need to swap the drivers side bonnet hinge spring to the smaller one as this on now rests against the master cylinder reservoir and causing it to leak.





















the eh Offline
#437 Posted : Sunday, 14 May 2017 6:07:41 PM(UTC)
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Here's a project a mate is working on and I am working with him to get them final machined. Customised EJ-EH steering wheel centre caps. Any design and/or colour you want. This prototype is going on my ute project.







Edited by user Sunday, 14 May 2017 6:26:45 PM(UTC)  | Reason: Not specified

the eh Offline
#438 Posted : Saturday, 20 May 2017 5:12:09 PM(UTC)
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3" dump pipes gone. 2-1/2" tailpipes going on. I used a 3" V Band clamp though and modified one side to fit the smaller tail pipe. This means that I can easily refit the 3" dump pipes for "off road" use














the eh Offline
#439 Posted : Monday, 22 May 2017 7:11:14 AM(UTC)
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Todays effort. Decided to go up and over the diff..




























commodorenut Offline
#440 Posted : Monday, 22 May 2017 7:30:14 PM(UTC)
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Glad I'm not the only one who cops injuries when working on cars.... :)
Cheers,

Mick
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