ollienewc

Ollie's 4Age Ke70 Wagon

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Awesome build. The attention to detail is amazing, hope I can do an engine swap half as good as you are.

 

Cheers mate! It's not there yet, but if you just stick at it you can surprise yourself.

 

I got the brake lines and accelerator cable made up, lines are still on the bench but the cable is all hooked up and fits nicely. Also rang a car audio place and they said extra foam on the firewall won't really do anything so that's good enough for me not to worry about it.

 

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Finally got around to swapping over that dizzy/cam angle plug, but I'm worried I might have introduced some interference, I could be way off the mark, but it hesitates and stutters pretty bad now. Hoping it's something else. Apart from that it went well and tucks away nicely under the coilpack plate, probably not the best place for the plug but hope it'll be all sweet.

 

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Pulled off the doors to get at the rust and paint the jambs, but I sorta wish I did this later once the rest of the bodywork was done. It makes sense to strip and paint them now while they're off, but they'll no doubt get scratched and chipped once they go back on to seal the car back up.. Ahh well.

Used a combo of sandpaper, wire wheels and strip discs to remove the rust I could get to, then treated everything with rust converter. Cleaned with wax and grease remover, wiped over with a tack rag and used etch primer in a can on the bare metal followed by a few coats of primer using the gun. Don't have photos yet but shot the colour on the next day. There's a few bad sanding marks that have come through but they're door jambs so I'll live with it. I'll try get photos of the colour soon.

 

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Ollie.

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Hey Ollie! Great thread you've got going here just read it start to finish, best one I've read tbh has exactly what I've been looking for to help with my build/daily, keen for this to be finished though will be a mad ride that's for sure, keep it up mate.

 

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Hey cheers Kurt! Legend, nice to hear others actually get something out of this haha.

 

Been pretty slack as usual, but I've finally blasted the doors and have a coat of primer on them.

I set up a blasting and spray booth in the corner of the carport that seems to work pretty well. Knocked up a frame and grabbed some curtain rail from the tip shop, and made some curtains out of clear builders plastic. I used washers every 200mm along the top and ran a strip of gaffer tape over that to reinforce, poked a cable tie through the tape and washer and looped it through the curtain rail sliders. Also made a floor with sides that come up about 700mm out of thicker black plastic, with ropes and velcro to suspend it all. The curtains hang inside this to catch all the blasting grit. I've got a supercheap extraction fan set up and a fluorescent light in there too.

 

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Stripped down all the doors, and that was not too fun at all, but got there in the end. I sanded the faces of the doors back with the orbital and 40grit, then moved them into the booth and blasted all door frames and edges making sure to get all the rust. Vacuumed and blew them out then wiped them all down. I then used rust converter, followed by a damp rag then metho to finish off.

 

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Also the door jambs in colour

 

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On 3/30/2017 at 8:10 PM, B-Lugg said:

Keen on an update for this one!

Ahhh yeah so been real slack with this, and the car too really.. Nice to hear people are still interested though haha

Slowly chipping away at things here and there though, but trying to smash some out while I've got time off over Easter. 

Doors were coated in epoxy (above post), roughly blocked to find the highs and lows (turned out they were pretty average), then bogged, another coat of epoxy, primer filler, blocked again working through the grits, then another coat of primer to cover where I rubbed through. That was rubbed back lightly with scotchbrite, blown down and cleaned ready for colour. 

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So first time round shooting the colour on the doors I ran out of thinners so couldn't lay the clear on, so after a few weeks I lightly rubbed it all back, sprayed another couple of coats of colour, then could put on a few coats of clear straight on top. Pretty happy with how they came out, and should finish up nicely with a cut and buff.

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Also refurbishing the worn out door hinges with new pins and bushes to stop the sag. I found cutting the pin in half and using a cold chisel to wedge one side out, followed by a punch back down the hole to push the other side out worked a treat. Then used a step drill to remove the old brass?/copper? bushes, and put a slight chamfer to hopefully help the new ones go in.

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Decided to weld up a few seams in the rear where I'd already tried to bog, but was worried it wouldn't take long to crack and ruin the paint. Not the prettiest by any means, but hopefully will do the job. Just coated them with etch primer for now, I'll be putting a skim of bog over them once I do the rest of the bodywork and have epoxy down first.

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Also just realised that I moved it under it's own power for the first time on christmas day, as a little present to myself haha. Realised all I needed to do was install the handbrake cables, so that was nice and easy. I also finally got around to modifying the rear of the exhaust to fit into my wagon, luckily I was just able to chop it up and use what I had to make it work. Fabricated up one hanger, and bought one off the shelf that I modified. Pretty stoked with how it sits, nice and solid with hardly any movement, but still using rubber mounts. Didn't get any photos making it, but I'll try grab some of it installed 

Few other things like installing the dash frame, deciding to go flat front/quads, treating rust in new guards and welding up the holes from where fender mirrors were installed. Need to get off my arse and buy the rest of the front end, but that ain't going to be cheap, as usual :( 

Probably take me another few months to do another update, but I'll try do smaller more regular ones or something.

Well done if you've made it this far, Ollie.

Edited by ollienewc

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Got the hinges primered and painted over the last few days, just going to wait for the paint to cure for a week or so then go about pressing in the new bushings and pins.

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While I was painting the hinges I thought I'd test out painting some instrument cluster trim the same colour as the car, turns out to be real similar to the plastic in the dash pad. Have to see how it all looks once the rest of the dash is in, but I reckon I'll run with it.

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So I bought a tacho dash a while ago that had the needles and the redline on the tach coloured in with texta, looked real average. Managed to take it off with thinners, but it also ate into the white markings below. Not too bad but I can see that it's now a bit fudged. Repainted the needles red, but I still need to repaint the centre circle matte black to match the rest. Anyone know of anywhere to get the backing made up? quite like the red, would be nice to replace the orange and the white 'redline'. Any input much appreciated. Although the clear plastic front also has a small crack.. so if anyone has a complete tacho dash they'd like to part with that'd be great too.

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Haha they look mad ugly! Definitely need more practice, but all good fun. Repairing the rusted out rear quarters will be interesting..

Oooooh I like the sound of that, I'll see what I can find. The youtube link doesn't work (takes me to my vids), but I found your thread and assume it's what's on there. Looks very neat indeed, nice work man. And thanks heaps for the info, nice to have something a bit different

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One of mine failed once. I just replaced the entire sensor in the tank and it worked again - I think I picked up the whole thing for like $10.

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Epic work on your Wagon Ollie, has given me the inspiration I needed to get out there and work on mine after about a year of having no time/moaning about how I've pulled it to pieces and done nothing haha. Cheers and keen to see more of this!

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On 5/16/2017 at 9:12 PM, ragify said:

Epic work on your Wagon Ollie, has given me the inspiration I needed!...

Hey cheers Oli! Wish i could find some inspiration myself! Really struggling for motivation in these colder months. I have been chipping away ever so slowly though. 

Here are the hinges with the new bushes pressed in and assembled. They came up alright but some are quite stiff as they got a bit bent out of shape pulling them apart. They should loosen up a bit after they're all bolted on.

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I've been working on patching the rust in the rear arches, I put it off for ages but didn't end up being too hard once I got stuck into it. I ended up cutting up a spare set of front guards I had, just using small sections of the arches to try match the basic shapes instead of starting from scratch. 

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Basically just cut out the cancer, roughly cut out a replacement piece from the spare guard, placed it behind the hole and used black spray paint to trace the required outline. Photos are easier than words.. It's my first time doing any of this so it was never going to be too pretty haha. 

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...

 

Edited by ollienewc

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...

 

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I've still got a fair amount of body work to do, but it's nice to have this part of it done at least.

Cheers, Ollie.

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Hey Ollie, 

I have just read the whole thread and i have to say AWESOME job man!  I recently picked up an 82 KE70 sedan and have been working on getting it licenced.  Ive converted it to manual with a K50 and I'm in the process of replacing the sway bar bushes etc.  

Anyway great job mate, I'm looking forward to seeing some more updates.

Cheers

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