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- #161
Got these goodies stripped down and pressure washed. They're ready for blasting now.
My HJ61 Rejuvenation (1 Viewer)
- Thread starter Fifty Hertz
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- #162
This morning I cleaned up the rear wiper gear and packed it with fresh grease. Also did a small weld to fix the cracked cover plate near where it attaches to the body.
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- Thread starter
- #163
This afternoon I cleaned up the tailgate internals, mostly using the ultrasonic cleaner I bought a few months ago. It's small but it sure beats cleaning bits by hand!
Anyway I was then ready to get the lower tailgate reassembled.
Shiny new parts!
It went together ok. Starting with an easy bit before getting into the doors.
Anyway I was then ready to get the lower tailgate reassembled.
Shiny new parts!
It went together ok. Starting with an easy bit before getting into the doors.
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More pics!! Im in perth too, il keep an eye out for you..
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- #165
The upper tailgate got assembled a couple of days ago. No photos of that but it's done. Yesterday the parts for the Disco front propshaft arrived, so I finished the rebuild on that and got it back in the car. Running fine again.
Also yesterday the new rear cargo windows arrived from Emu Wing. Super excited about these as they are a complete retrofit lift-up (gull-wing) window kit, allowing much better access to the rear deck. Opened them up this afternoon, intending to fit them.
Unfortunately it seems that I'm missing the pinchwelds that go over the bodywork, so I couldn't proceed with gluing in the frames.
I decided to go ahead and fit the lower tailgate.
I should really have waited, as having it on will slightly impede access for other jobs. But I just needed to get something bolted on! I plan on getting the upper tailgate installed tomorrow, and possibly the rear light units. Then the rear end will be mostly done.
Also yesterday the new rear cargo windows arrived from Emu Wing. Super excited about these as they are a complete retrofit lift-up (gull-wing) window kit, allowing much better access to the rear deck. Opened them up this afternoon, intending to fit them.
Unfortunately it seems that I'm missing the pinchwelds that go over the bodywork, so I couldn't proceed with gluing in the frames.
I decided to go ahead and fit the lower tailgate.
I should really have waited, as having it on will slightly impede access for other jobs. But I just needed to get something bolted on! I plan on getting the upper tailgate installed tomorrow, and possibly the rear light units. Then the rear end will be mostly done.
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- Thread starter
- #166
Yeah mate, they'll be coming as the project progresses. It's getting close now
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- #167
Yesterday was pretty productive. First up I got one of the EmuWing opening rear window frames fitted. I decided that it should definitely have a pinchweld fitted over the sheet metal edge, so I bought some from Clark Rubber. The surround then goes over top of this and is glued in with Sika 252 polyurethane adhesive.
In preparation for refitting the upper tailgate, I ran in some new vinyl hose for the washer jet.
In preparation for refitting the upper tailgate, I ran in some new vinyl hose for the washer jet.
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- Thread starter
- #168
Time to reinstall the upper tailgate! I was working solo here so I needed to make up a lifting frame to hold it in position. It's supported from the lower edge, with some wooden blocks at each end forming a sort of retaining channel that the lower edge rests in.
Then there is a "spreader bar" above the top edge, to keep the lifting ropes clear. This goes up to a couple of marine blocks slung around a rafter. A couple of adjusting load straps allow the the tailgate to be tilted. So with a combination of lifting and tilting, plus moving the car back and forth, I was able to manoeuvre the tailgate into exactly the right position to align the hinge bolts.
After that it went together pretty easily.
Then there is a "spreader bar" above the top edge, to keep the lifting ropes clear. This goes up to a couple of marine blocks slung around a rafter. A couple of adjusting load straps allow the the tailgate to be tilted. So with a combination of lifting and tilting, plus moving the car back and forth, I was able to manoeuvre the tailgate into exactly the right position to align the hinge bolts.
After that it went together pretty easily.
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tmxmotorsports
SILVER Star
Great building thread thanks for sharing
- Thread starter
- #171
Got the left-hand EmuWing frame glued in place.
I wasn't quite done at that. I backfilled with a second application of Sikaflex, to fill the gap between the frame and the body. I carefully masked up the body panels first so that the glue line is nice and neat.
Peeled the masking tape off straight away, let the glue flash off for half an hour then smoothed it down with soapy water.
View attachment 1674186
I wasn't quite done at that. I backfilled with a second application of Sikaflex, to fill the gap between the frame and the body. I carefully masked up the body panels first so that the glue line is nice and neat.
Peeled the masking tape off straight away, let the glue flash off for half an hour then smoothed it down with soapy water.
View attachment 1674186
- Thread starter
- #172
Looks pretty neat!
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- #173
So this morning I wanted to get the front and rear bars off for blasting and powder coating. Upon going over the front bar I found that the lower mounting holes that bolt to the front of the chassis rails were rather distorted. These spots:
It's actually 2 prices of steel sandwiched together, but they weren't joined all the way around. I bashed them back into shape the best I could then welded the front edges together. This will stiffen it up a bit.
I also decided to re-use the original side steps. The aluminium will polish up ok but the brackets need some attention. So I took those off as well and dropped the whole lot off to be powder coated. Fortunately he can blast as well and I'll have everything back by the weekend.
It's actually 2 prices of steel sandwiched together, but they weren't joined all the way around. I bashed them back into shape the best I could then welded the front edges together. This will stiffen it up a bit.
I also decided to re-use the original side steps. The aluminium will polish up ok but the brackets need some attention. So I took those off as well and dropped the whole lot off to be powder coated. Fortunately he can blast as well and I'll have everything back by the weekend.
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- Thread starter
- #174
I dropped the EmuWing glass off to Tint-A-Car yesterday afternoon and they called to let me know that they're ready. Which meant I could finish the installation. I got the right-hand window fitted up.
Unfortunately the supplied self-adhessive weather strips weren't long enough, so that's as far as I got today.
Unfortunately the supplied self-adhessive weather strips weren't long enough, so that's as far as I got today.
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- #175
After getting the second window installed, I noticed the the hinge mounts distort a lot as the windows are closed fully. Upon closer inspection with the glass removed again, it seems that the geometry is such that the hinges reach the limit of their movement before the window is fully closed. Check out the angle in these photos.
With a few washers installed in the right places, I managed to get the hinge faces aligned parallel to the glass in the fully closed position.
1 washer under the moving face.
2 washers under the mount.
This got the hinges and glass properly aligned.
With a few washers installed in the right places, I managed to get the hinge faces aligned parallel to the glass in the fully closed position.
1 washer under the moving face.
2 washers under the mount.
This got the hinges and glass properly aligned.
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- Thread starter
- #176
Despite doing this, the hinge mounts still moved by 8-10 mm when closing the window. It seemed like they needed some additional bracing to the body to stiffen them up.
Problem solved!
Problem solved!
red66toy
Supporting Vendor
Seriously great work. Quick question, what type of SikaFlex did you use? I am going to want to glue in some OEM sliders soon. Thanks!
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- #178
I used the Sikaflex 252 that was supplied with the EmuWing kit and it's perfect for the application. It's a high strength polyurethane adhesive/sealant. Has good gap filling qualities and it smooths out nicely using soapy water, similar to silicone sealant.
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- #179
It's time to clean and prep the remaining parts. I want to get everything off for painting before I go back to work at the end of the week.
All these bits need to be painted.
I started by having a go at stripping the chrome off. Using hydrochloric acid. I've left the headlight surrounds in overnight, so I'll see it's working soon.
The wheel arch flares need some work also.
All these bits need to be painted.
I started by having a go at stripping the chrome off. Using hydrochloric acid. I've left the headlight surrounds in overnight, so I'll see it's working soon.
The wheel arch flares need some work also.
- Thread starter
- #180
This is some of the damage that needs fixing.
One of the mounting points on the front left is completely torn off and missing.
Several captive nut holes are damaged.
A couple of the ends have cracks.
And this mounting bolt was torn off.
One of the mounting points on the front left is completely torn off and missing.
Several captive nut holes are damaged.
A couple of the ends have cracks.
And this mounting bolt was torn off.
