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28 Pages«<56789>»
the eh Offline
#121 Posted : Tuesday, 11 June 2013 3:10:41 AM(UTC)
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pulled the boot trim panels out so I can get them back to the trimmers. I'm not happy with the fit so there will be a bit of a trim and refoam in certain areas. I will also get the spare wheel cover made..


the eh Offline
#122 Posted : Sunday, 16 June 2013 11:31:42 PM(UTC)
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Rebuilt and repaired PBR C6 style calipers were an ebay bargain. New pads and caliper kits cost a few bucks. The adaptor brackets were another ebay bargain because the seller didn't know what he was selling. These came attached to a servicable set of VT calipers with braided hoses. Rotors are 343mm VT HSV. The total cost for those monster size upgrade is about $300. This is a quarter of the price of smaller kits sold by the EXPERTS.






The One Tonner project looks like nothing is happening. However the engine and transmission are now ready. The brake system upgrade is sorted and nearly ready to go. Once the weather gets warmer I'll get stuck into stripping the cab off the chassis and detailing/rebuilding the chassis and suspension.



the eh Offline
#123 Posted : Sunday, 16 June 2013 11:32:56 PM(UTC)
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Whilst the boot trim panels are out I added the battery master switch that I had never gotten around to fitting. This will sit in behind the arm rest in the rear seat. It's a modified Bosch unit rated at 250amp continuous and 2500amp starting (5 seconds). I placed it in the earth circuit to make fitting easy and safer. I also upgrade the earth cable from 3 gauge (previously it was only 250mm long) to 0 gauge as it is now over 2 metres long.



the eh Offline
#124 Posted : Sunday, 23 June 2013 6:50:36 AM(UTC)
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EJ and EH wiper motor conversion under way. My previous versions have been one offs however I now plan to sell a few so I'm making up a set of jigs to speed the process up. I used a spare firewall and some centreing pins to find all the relevant measurements.



Edited by user Sunday, 23 June 2013 6:51:46 AM(UTC)  | Reason: Not specified

the eh Offline
#125 Posted : Sunday, 30 June 2013 4:04:20 AM(UTC)
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Drivers side boot trim finally getting the battery master switch housing permanently mounted in it. This is the housing that holds it all together. Once the trim is on a machined trim ring neatens it all and matches the nitrous connector in the passenger side panel.



Trim panel reinstalled to check alignment. All good so it's back to the trimmers for retrimming.



Main boot panel has had a 3mm MDF skin glued to it to allow me to regap it. I was never happy with the way it fitted so this should solve any issues that existed.

the eh Offline
#126 Posted : Friday, 12 July 2013 7:16:55 AM(UTC)
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Wiper motor conversion supplies. Almost ready to produce the first batch



Working out the Commodore motor mounting bolt PCD.



the eh Offline
#127 Posted : Sunday, 14 July 2013 3:06:35 AM(UTC)
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Got the prototype mounting plate made today. It will allow 5 positions for the motor. I sorted the wiring last night. This motor is harder to get working without the commodore BCM. Wiring is sorted but needs to be made still. There will be a small black box that goes under the dash. This replaces the BCM in the Commodore. The original EJ,EH wiper switch will stay and everything will look original, EXCEPT the motor obviously.







the eh Offline
#128 Posted : Monday, 15 July 2013 2:57:58 AM(UTC)
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I didn't like the look of the black 10lb Nitrous bottle so I decided to strip it, polish then brush finish it. Well Stripping alone took 3hours. The paint was too thick to sandblast off. Then if I tried to sand it aggressivley it would melt and clog the sander. So it was slow and steady with the DA sander then into the sand blast cabinet. Now it just needs polishing and brushing



Ever wondered what hi tech wizardry is engineered into the pickup tube of a Nitrous bottle. Well here it is. 3/8" annealed copper connected to a brass compression fitting.

Edited by user Monday, 15 July 2013 3:00:01 AM(UTC)  | Reason: Not specified

the eh Offline
#129 Posted : Monday, 5 August 2013 11:22:39 PM(UTC)
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2013 NSW All Holden Day






the eh Offline
#130 Posted : Friday, 16 August 2013 5:07:51 PM(UTC)
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Nitrous bottle makeover came out OK. What a pain in the neck it was removing the black paint from the bottle. It was thick and soft so clogged the sander easily. Blanket is made from heatproof material so should help keep thins warm.



the eh Offline
#131 Posted : Friday, 30 August 2013 3:15:21 AM(UTC)
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After a great and successful Golden Anniversary show on Sunday I had an eventful drive home. The EH developed a rattle in the motor that became chronic just as I arrived home. I was not sure what it was, all I could tell is that it was somewhere in the bottom end. I snapped this picture this morning which I think answers my noise question. There are some unwelcome dents in the transmission cover that I am sure have been caused by one of the torque converter bolts coming loose. I think I need to sack my mechanic (me). I will get it pulled apart on the weekend an hopefully it's only a new bolt with a nice application of Loctite and it's all fixed.

Edited by user Saturday, 31 August 2013 6:56:11 AM(UTC)  | Reason: Not specified

the eh Offline
#132 Posted : Sunday, 1 September 2013 6:06:13 AM(UTC)
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The torque converter cover is off and here is what I found. My amateur diagnosis was a torque converter to flexplate bolt had come loose and was rattling it's way around in the inspection cover. I WAS RIGHT. However all 3 converter bolts had come undone. So there was no drive connection between the transmission and engine yet I drove the car home. I guess the heavens were being nice to me. I found 1 bolt in the bottom of the cover, a second, as seen in this pic was still in the flexplate. This would have been the one making all the noise. The third one is nowhere to be found. I have searched everywhere and cannot see it. I cannot see where it has broken through the bellhousing/ cover etc to get out and disappear onto the road. It's a mystery. I will borrow one of those arthroscope type cameras on Monday and have a look up the top of the bellhousing to see if it's jammed up there somewhere. I have now run a tap through the converter bolt holes so will also have a look at those threads to make sure they are servicable. The original bolts were 8.8 grade so I'll see if I can get some 10.9 or higher, cover them in loctite and put it all back together.




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#133 Posted : Saturday, 7 September 2013 4:57:30 AM(UTC)
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This weekend I put an end to my loose converter bolts.

the eh Offline
#134 Posted : Monday, 9 September 2013 2:09:36 AM(UTC)
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Torque Converter bolts replaced and now working perfectly.




OK, new bolts fitted everything back together, give the Loctite a chance to cure, had lunch, life is good. Start the car and WTF the noise is still there. I can't believe it. As I turn the engine off there is a brief metallic noise that I heard twice whilst driving home from the Silverwater show. I had a very long and hard look for my third missing converter bolt before things went back together. I used the camera pictured below to get in and around the converter, into the starter drive housing, look on top of the webbing on the block. NO BOLT to be found. Where was the third bolt?
I was left with no choice but pull it down again. So instead of ripping the exhaust off again I thought I would undo the inspection cover and get the camera in to have a look. Guess what I found MY THIRD MISSING BOLT. Got the bolt out with the magnetic pickup tool and refitted the cover. Start it up and HAPPY DAYS. What a day.




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#135 Posted : Monday, 16 September 2013 6:15:57 AM(UTC)
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Here it is. Finished prototype Commodore wiper motor into EJ-EH. I'm open for comments/suggestions/discussion from anyone. All that's missing from the pic is one 3/16" bolt that will be needed to mount the adaptor plate to the cowl. I still need to create an instruction sheet also. Should be done in a couple of weeks.
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#136 Posted : Monday, 16 September 2013 6:20:33 AM(UTC)
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New header plates and machined primary pipe adaptors. These adaptors will be welded to the header plate from inside for a neat final finish






greenhj Offline
#137 Posted : Monday, 16 September 2013 11:22:31 PM(UTC)
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did you make the header plates?

Edited by user Monday, 16 September 2013 11:23:04 PM(UTC)  | Reason: Not specified





[email protected] NA
now being rebuilt with less cam, much less comp, and enough turbo to smash a holden block to bits..
the eh Offline
#138 Posted : Tuesday, 17 September 2013 2:35:30 AM(UTC)
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No, I purchased them from Liverpool exhausts. They are VL/VN GPA plates hence the round ports. These are for 1-3/4" pipes. I am going to cut them into individual pieces so I will end up with 8 seperate plates. This is the only way I can get a tuned length setup and still be able to remove them without taking the motor out.
quote]Originally posted by greenhj
did you make the header plates?


[/quote]
greenhj Offline
#139 Posted : Tuesday, 17 September 2013 6:28:46 PM(UTC)
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ah ok.

Seperate pipes can be a bugger, they like to move around.




[email protected] NA
now being rebuilt with less cam, much less comp, and enough turbo to smash a holden block to bits..
the eh Offline
#140 Posted : Saturday, 21 September 2013 4:55:54 AM(UTC)
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Agreed. I may end up pinning each plate to the head. Before I cut it down I will drill a hole in the plate near each port and then into the head. I will then use a roll pin in each hole to ensure each one is aligned. At the collector end I will have tabs welded to 2 pipes and the collector. There will be straps between the tabs positively holding the collector in place.
quote:
Originally posted by greenhj
ah ok.

Seperate pipes can be a bugger, they like to move around.
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