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XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :) 

 

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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Thu Oct 01, 2009 8:36 pm 
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couple of picks of the cutting

 

 

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Main Cut Side on.jpg
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Initial Cuts.jpg
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Thu Oct 01, 2009 8:39 pm 
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Some of the welding on Benj's bonnet

 

 

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EBXBGT Bonnet Outside from rear.JPG
EBXBGT Bonnet Outside from rear.JPG [ 61.21 KiB | Viewed 60 times ]
EBXBGT Bonnet Outside from front.JPG
EBXBGT Bonnet Outside from front.JPG [ 62.2 KiB | Viewed 53 times ]
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Thu Oct 01, 2009 8:49 pm 
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Idea also when you put you bulge on is to leave the washer jet holes covered and install your washers like this. Hoses are run under the grill, just use a small needle to adjust the jets.

 

 

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Passenger side RIght hand shot.JPG
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Passenger Side from Engine Bay.JPG
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Drivers side Side on.JPG
Drivers side Side on.JPG [ 64.89 KiB | Viewed 54 times ]
Drivers Side from Engine.JPG
Drivers Side from Engine.JPG [ 69.34 KiB | Viewed 49 times ]
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Sun Oct 04, 2009 11:44 am 
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Location: Newcastle
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washer jet idea is good, gets them off bonnet,saves cutting holes in it after you join them :D thanks heaps for all you advice :D
im hoping to make a start on the bonnet next weekend. 8-)

 

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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Sun Oct 18, 2009 12:18 pm 
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hit a wall, not so much a wall but i found body filler/bog in the tips of the bonnet
so i now going to go back on the hunt for another fairmont bonnet
as i dont want cheap fix bonnet on my car, ONLY METALS :lol:

 

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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Tue Oct 20, 2009 5:31 pm 
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i have a free bonnet for you if you want it.
only thing is it has speed holes in the grill and its missing clear coat in places from a pressure washer.
its dirty from the dust storms.
i hate sneaky bog :x

 

 

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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Tue Oct 20, 2009 7:59 pm 
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Ride: 1998 ef gli falcon

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hey, do you know if this will fit a standard ef gli?
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Tue Oct 20, 2009 8:08 pm 
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Location: Newcastle
NSW, Australia

mystro wrote:
i have a free bonnet for you if you want it.
only thing is it has speed holes in the grill and its missing clear coat in places from a pressure washer.
its dirty from the dust storms.
i hate sneaky bog :x


PM Sent :lol:


91 wanna be wrote:
hey, do you know if this will fit a standard ef gli?
hey, do you know if this will fit a standard ef gli?


im pretty certain it wont fit.
i have a complete EF wagon that you could get parts off tho, on ebay atm. PM for details

 

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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Tue Oct 20, 2009 9:54 pm 
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91 wanna be wrote:
hey, do you know if this will fit a standard ef gli?
hey, do you know if this will fit a standard ef gli?


im pretty certain it wont fit.
i have a complete EF wagon that you could get parts off tho, on ebay atm. PM for details[/quote]

would have to change the head lights and maybe the front bar.
bonnets are cheap .
i have mont headlights cheap if you want them pm me
that green bonnet is now lay3dlows to fulfill his lust for the bulge . :lol: :mrgreen: :lol:
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Wed Oct 21, 2009 4:51 pm 
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thanks, but i found a nice bf xr boss bulge to fit the ef at kurnell kustoms.
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Wed Oct 21, 2009 8:25 pm 
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91 wanna be wrote:
thanks, but i found a nice bf xr boss bulge to fit the ef at kurnell kustoms.


Didn't know they were lost :lol:
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Wed Oct 21, 2009 9:16 pm 
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Ride: el fairmont

Location: hoon capital bendigo
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nice bonnet mate i make the same sort of thing my self for different ppl as well as guards the bonnets sell for 1500 each and thats them supplying the material also not sure on what you use to cut the metal with but i use air hack saw (to keep the heat down) and not sure if you mentioned it to the ppl here but make sure you tacks have time to cool down before you tack again other wise you'll warp the metal and its no fun panel beating when you dont have too... :D
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Wed Oct 21, 2009 9:22 pm 
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SWC wrote:
I agree, do not sandblast as you will regret it later. better to use a good quality paint stripper, remember, you only need to strip where you are going to weld as the section under the bulge will be cut out and give yourself 50-75mm clean metal for welding. When I did Troymans Bonnet Bulge iI used gasless MIG 0.9mm wire and found this very effective. When you cut out the Bonnet use thin cutting wheels in a 4" grinder and don't force it through as you will cut the bonnet bracing, better to leave in place at this point. When you are happy with the cut out fit the bulge. I like about 0.5-1mm gap, you will understand why later. Then procced to tack weld the bonnet in, about every 25mm or so. when you have completed this you will find that all the gap has closed up, you may even need to open the gap before completing welding with the cut off wheel. When completly tacked and you are happy with the joints begine welding, only about 25mm at atime per side as it will generate to much heat. As you stager weld around the bonnet the previous sections will cool and allow you to continue, if you feel the bonnet is getting to hot, take a break and let it cool. do not cool down with water as this will cause buckling. If you blow a small hole, leave it and come back later when it is cool and just tack fill it. It is steel so there will be no issues. When fully welded and it comes to grinding the welds, TAKE YOUR TIME, to much grinding gereates heat and heat will buckle the bonnet, do a bit at a time, lightly all the way round till you are happy with the finish. When fully welded you can then cut out the Fairmont bracing and add the BA Bulge bracing if you have it, if not leave the Fairmont bracing in needs the strength, also if you cut out the bracing without replacing it is illegal. Good luck, if you need any further assistance give me a yell.

not sure on your laws here about the brace but i know in sa you can cut it as long as you have the center one there as i have showen on a bonnet i have made
Image
Image
just another heads up what i use to cut the weilds is a air sander just to keep that heat down
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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Wed Oct 21, 2009 9:46 pm 
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its a bummer your not close by, i dont really wana do this job my self. would much like to not stuff it up, but anyway ill use all the advice i can get and take my time.

 

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 Post subject: Re: XR8/GT bonnet Bugle on EL Fairmont Bonnet, ALL METAL :)
Posted: Wed Oct 21, 2009 10:44 pm 
Oompa Loompa
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Ride: el fairmont

Location: hoon capital bendigo
VIC, Australia

yeah measure twice cut once, just the key is keep the steel cool not to much heat, this is my tacks to start this is a guard though

Image
Image
and this is it sanded with air sander nice fine edges
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