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BA/BF front crash bar replacement & Kframe swap 

 

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 Post subject: BA/BF front crash bar replacement & Kframe swap
Posted: Wed Jan 20, 2021 4:53 pm 
Getting Side Ways
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Is anyone interested in the process of replacing the front bar for smash repair and am also swapping the K-frame.
As in drilling all spot welds to remove the damaged part and replace with a good piece from an undamaged vehicle.

In the photos you can see that someone hit something front on before I bought the car and then recently the front passengers corner,you can see the difference between the two in the photos.

 

 

Attachments:
File comment: This is my old BA with the FG inlet manifold and full exhaust with venom cat and competition pacemakers,this now my wife's car
IMG_20210120_14148.jpg
IMG_20210120_14148.jpg [ 110.71 KiB | Viewed 12 times ]
File comment: This is the new bar from a BA sedan of the same color luckily.
IMG_20210120_23197.jpg
IMG_20210120_23197.jpg [ 107.54 KiB | Viewed 8 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Wed Jan 20, 2021 6:03 pm 
Tyre Shredder
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johnnyeHCF wrote:
Is anyone interested in the process of replacing the front bar for smash repair and am also swapping the K-frame.
As in drilling all spot welds to remove the damaged part and replace with a good piece from an undamaged vehicle.

In the photos you can see that someone hit something front on before I bought the car and then recently the front passengers corner,you can see the difference between the two in the photos.



Somebody kissed a tow ball; id be interested, i have one that i may replace down the track thats folded in the same way, although it cant be seen with the bonnet down and the front bar on so is it really a issue? :lol: :lol:

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Sun Jan 24, 2021 11:50 pm 
Getting Side Ways
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Ride: EF-XR6/XG-6/XE-V8- project

So with nearly 40°C have been working on this in the evening and in the night when it's cool.

Tool's needed.
Cordless drill or drill.
Some good sized hammers.
Center punch
Chisel (I use an old railway spike)
Drill bits/spot weld drill bits.
Gasless MIG
Angle grinder(cut wheel/flap wheel etc)

 

 

Attachments:
File comment: Tools
IMG_20210123_57542.jpg
IMG_20210123_57542.jpg [ 77.72 KiB | Viewed 7 times ]
IMG_20210120_14148.jpg
IMG_20210120_14148.jpg [ 110.71 KiB | Viewed 6 times ]
IMG_20210123_0136.jpg
IMG_20210123_0136.jpg [ 77.26 KiB | Viewed 6 times ]
File comment: Start of drilling the spot weld out using the cutting tool but ended up drilling through.
IMG_20210123_43537.jpg
IMG_20210123_43537.jpg [ 42.56 KiB | Viewed 7 times ]
IMG_20210123_40774.jpg
IMG_20210123_40774.jpg [ 112.87 KiB | Viewed 6 times ]
IMG_20210123_48993.jpg
IMG_20210123_48993.jpg [ 68.53 KiB | Viewed 6 times ]
File comment: This is the driver's side after the bar is removed.
IMG_20210123_58143.jpg
IMG_20210123_58143.jpg [ 64.49 KiB | Viewed 6 times ]
File comment: This is the passenger corner that needs massaging back into shape.
IMG_20210123_6930.jpg
IMG_20210123_6930.jpg [ 67.72 KiB | Viewed 7 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Wed Jan 27, 2021 6:33 pm 
Getting Side Ways
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So using a thin type chisel,as I mentioned I use a old (think it's a railroad spike/correct me if I'm wrong) which I sharpen with a flapwheel/angle grinder.After all the spot welds are drilled the chisel is used to separate the two pieces of metal spotted together with a good sized hammer. The thinner the chisel is the less it will distort the metal..
So just for this one front bar there are 18 spot welds,I found it easier just to drill straight through the welds rather than using the spot bit and none of the weld spots are likely to line up between the two bars so shouldn't be a problem when spot welding back up.
Like I mentioned the Kframe is being swapped for one with good bushes,while I'm at it I'm doing the sump gasket due to oil leaks,and also replacing the OG struts and springs with new struts and King springs-standard height.

 

 

Attachments:
File comment: I re-sharpen this whenever it starts getting blunt,best tool for this job too.
IMG_20210127_5281.jpg
IMG_20210127_5281.jpg [ 50.71 KiB | Viewed 4 times ]
File comment: Struts and king springs/standard height.
IMG_20210127_41725.jpg
IMG_20210127_41725.jpg [ 72.87 KiB | Viewed 12 times ]
File comment: K frame
IMG_20210127_49601.jpg
IMG_20210127_49601.jpg [ 117.65 KiB | Viewed 8 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Wed Jan 27, 2021 6:42 pm 
Getting Side Ways
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So I thought it be time that I showed you all my awesome Ford Jedi Skills,it takes many moons to perfect this technique,as you see in the photos I'm using my Ford Jedi Force to hold the engine up whilst the K frame and then the sump are removed.
Absolute concentration is imperative otherwise my head be pancaked! :wink:

 

 

Attachments:
File comment: "Much Force Needed"
IMG_20210127_8169.jpg
IMG_20210127_8169.jpg [ 67.7 KiB | Viewed 7 times ]
File comment: The Force is with the engine-"I Hope".
IMG_20210127_16781.jpg
IMG_20210127_16781.jpg [ 79.99 KiB | Viewed 10 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Wed Jan 27, 2021 7:28 pm 
Getting Side Ways
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Haha nah it's just done using one of these,works extremely well.

Damn'should have left it to see if anyone believed in my awesome power!

May the force be with you all!

 

 

Attachments:
File comment: Engine and trans support bar 500kg
IMG_20210127_3972.jpg
IMG_20210127_3972.jpg [ 92.81 KiB | Viewed 12 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Wed Jan 27, 2021 9:21 pm 
Getting Side Ways
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Ride: EF-XR6/XG-6/XE-V8- project

How cool are these,Webco struts with King Springs standard height,$300 delivered,not bad for good quality to your door.

Will be using the polyurethane bushed mounts,these things I believe were made by Technico torque master. Is all I know.

 

 

Attachments:
File comment: Love the good ol yellow KING SPRINGS
IMG_20210127_6276.jpg
IMG_20210127_6276.jpg [ 77.46 KiB | Viewed 5 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Fri Jan 29, 2021 9:10 pm 
Getting Side Ways
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Hey guys,I'll get the photos sorted of the Kframe removal etc,atm it's gone from 40° days to constant rain,so getting the front struts and springs done,halfway through

 

 

Attachments:
IMG_20210129_58619.jpg
IMG_20210129_58619.jpg [ 43.8 KiB | Viewed 5 times ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Fri Jan 29, 2021 11:00 pm 
Getting Side Ways
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So the Kframe removal is starting with removing the airbox etc and the expansion tank and then the struts from the top and then undo the nuts off the top control arms from inside the engine bay. Then there's a few electrical braces for the starter wire that you need to disconnect from the Kframe,then the steering rack and the power steering lines from the rack.

 

 

Attachments:
File comment: Undo strut and upper control arm.
IMG_20210129_14749.jpg
IMG_20210129_14749.jpg [ 71.3 KiB | Viewed 6 times ]
File comment: Jack and trans jack thing with home made Eseries Kframe removal tool
IMG_20210129_42996.jpg
IMG_20210129_42996.jpg [ 85.67 KiB | Viewed 6 times ]
File comment: Jack and trans jack thing with home made Eseries Kframe removal tool
IMG_20210129_58673.jpg
IMG_20210129_58673.jpg [ 85.42 KiB | Viewed 7 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Sat Jan 30, 2021 8:55 pm 
Getting Side Ways
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Even though we are using new struts and springs,you still need to pull the old struts and springs apart as we need the tops for the new set,out of both Kframes the strut tops were all good,but out of 4 engine mounts 3 were totally separated.

And if anyone is wondering YES these spring tools when they slip can actually kill you,had it happen twice just with these springs. Any moisture at all and it has the potential to want to slip,very scary when it happens hey!

 

 

Attachments:
File comment: And holly crap,not sure of the difference when it comes to being Heavy Duty but had to use 4 spring tools as 2 was not enough.
IMG_20210130_20233.jpg
IMG_20210130_20233.jpg [ 61.92 KiB | Viewed 9 times ]
File comment: Engine mounts were almost nonexistent in both BA Falcons.
IMG_20210130_39582.jpg
IMG_20210130_39582.jpg [ 32.98 KiB | Viewed 6 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Sat Jan 30, 2021 9:33 pm 
Getting Side Ways
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Gallery: 16 images

Ride: EF-XR6/XG-6/XE-V8- project

Robert_au wrote:
johnnyeHCF wrote:
Is anyone interested in the process of replacing the front bar for smash repair and am also swapping the K-frame.
As in drilling all spot welds to remove the damaged part and replace with a good piece from an undamaged vehicle.

In the photos you can see that someone hit something front on before I bought the car and then recently the front passengers corner,you can see the difference between the two in the photos.



Somebody kissed a tow ball; id be interested, i have one that i may replace down the track thats folded in the same way, although it cant be seen with the bonnet down and the front bar on so is it really a issue? :lol: :lol:


Hey Rob,sorry for not answering earlier,regarding the "Previous Tow Ball Kiss" certainly it didn't need anything except for the cosmetic replacement of front bumper etc. But after the side on front impact-from what I can tell the drivers side frame rail is straight but the passengers side is pushed in slightly. Was worse before removing the front bar and sort of flexed back a bit but not totally,will get it sorted though before the new bar goes on.

 

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the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Mon Feb 08, 2021 10:04 pm 
Getting Side Ways
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Okay so trying to get back to this,I planned to swap the Kframe 's as it was cheaper but more labor intensive,the Kframe removed from the donor BA had really good everything whereas the one we were removing had nearly every bush totally destroyed,then I just had to get the good brakes which included slotted rotors braided brake hoses and I swapped the calipers over as they were in better shape.As the Kframe was coming off it seemed like a really good time to do the sump gasket as it has been leaking for a long time.

 

 

Attachments:
File comment: Sump gasket and ultra blue
IMG_20210205_18386.jpg
IMG_20210205_18386.jpg [ 80.31 KiB | Viewed 6 times ]
File comment: Kframe ready with new struts and springs plus engine mounts.
IMG_20210205_51992.jpg
IMG_20210205_51992.jpg [ 81.12 KiB | Viewed 4 times ]
File comment: Putting in Kframe
IMG_20210205_5486.jpg
IMG_20210205_5486.jpg [ 79.16 KiB | Viewed 4 times ]
IMG_20210205_9883.jpg
IMG_20210205_9883.jpg [ 69.5 KiB | Viewed 5 times ]
File comment: Getting everything back in position for the Kframe to go in,including lining up the engine mounts.
IMG_20210205_5559.jpg
IMG_20210205_5559.jpg [ 71.86 KiB | Viewed 5 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Mon Feb 15, 2021 3:35 pm 
Getting Side Ways
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So after the sump gasket and the Kframe are back on,I reshaped the damaged corner and then started test fitting the new bar using the lower spot weld holes to line it up flat and straight and then adjust all the tabs in towards the new bar.Once it's as close as it can be all the areas are cleaned using a flap wheel/angle grinder,wax and grease remover and then weld through primer on all bare metal surfaces and in between those before welding together.
Then using various vice grip's-are moved around pulling everything together whilst welding together through the old drilled through spot welds with the gasless mig.

 

 

Attachments:
File comment: Test fitting and getting everything back in place.
IMG_20210214_53768.jpg
IMG_20210214_53768.jpg [ 54.94 KiB | Viewed 1 time ]
File comment: Cleaning up the metal before priming.
IMG_20210214_5553.jpg
IMG_20210214_5553.jpg [ 70.64 KiB | Viewed 1 time ]
File comment: Weld through primer,got mine from K & C Harris.
IMG_20210214_16593.jpg
IMG_20210214_16593.jpg [ 80.52 KiB | Viewed 1 time ]
File comment: Weld through primer on.
IMG_20210214_40406.jpg
IMG_20210214_40406.jpg [ 64.94 KiB | Viewed 1 time ]
File comment: New bar welded on.
IMG_20210214_40617.jpg
IMG_20210214_40617.jpg [ 76.55 KiB | Viewed 2 times ]
IMG_20210214_19803.jpg
IMG_20210214_19803.jpg [ 56.65 KiB | Viewed 1 time ]

 

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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Mon Feb 15, 2021 4:11 pm 
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 Post subject: Re: BA/BF front crash bar replacement & Kframe swap
Posted: Mon Feb 15, 2021 4:30 pm 
Getting Side Ways
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Ride: EF-XR6/XG-6/XE-V8- project

Mad2 wrote:
all looking good! ... no problems refitting the k member?



Hey Mad it wasn't as bad as I thought it would be,once I got the old wooden Kframe tool locked on tight to the transmission jack tool (this allowed me to adjust the angle/pitch)with some big cable ties I just had to line everything up one side at a time and then a bit of gentle up and down till the engine mounts lined up,managed to get it back in by myself too.

 

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