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4.0 Zephyr conversion 

 

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 Post subject: 4.0 Zephyr conversion
Posted: Wed Oct 17, 2012 10:43 pm 
Stock as a Rock
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Location: Darwin
NT, Australia

4.0 SOHC and T5 conversion on 1959 lowline MK2 Zephyr.

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2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Thu Oct 18, 2012 7:17 pm 
Tyre Shredder
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Joined: 20th Apr 2011

Ride: 1991 eb1 fairmont

Location: townsville
QLD, Australia

i'll be watching this one.
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 Post subject: Re: 4.0 Conversion
Posted: Sat Oct 20, 2012 12:39 pm 
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Location: Darwin
NT, Australia

I had seen many 302 windsor conversions into the 3 different Zephyrs that were offered in Australia and even a few Xflows but never a SOHC so i purchased a smashed XH with a T5 and ripped her apart.
I chose a shop with a good reputation to do the conversion for me as i had fractured my back and hip and didnt want to be crawling around a car and they said i would be supplied with an engineers for the work.
Well the shop Custom Fabrications in Palmerston went bust and neglected to tell me and did a 1/3 of the work they promised, i paid upfront for the work and seeing as though they are bankrupt i have been told by the cops and the legal people at my work i have fat chance of getting my money back.
I have since started finishing the welding they did not complete (i was told by the owner that they ran out of gas and had no money to buy more) at least they did the engine mounts and T5 mounts.
I chose another shop in Adelaide to do the brake conversion consisting of MK3 hubs late model falcon rotors commodore calipers and comodore struts using mostly MK3 front end as well as XY-XF tie rods, lucky i didnt use the shop up here as they said they couls do this work as well.

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2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Sat Oct 20, 2012 12:55 pm 
Stock as a Rock
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Age: 40

Posts: 196

Joined: 9th Jul 2005

Location: Darwin
NT, Australia

The engine is from an XH2 that came with extracors and is the same as EL hybrid, i purchased a EL XR6 ecu 5TAA (i also have the 5DAC if any1 is interested) a BBM for a conversion, AU injectors, a wade cam , had the head reconditioned as i couldnt find a XR6 head up here, the only wrecker here wanted more than it was worth (on the phone) and i stood at the counter for 20 mins with no service so i didnt buy it.
I also purchased an XR LSD rear for the XH diff which was supposed to be converted at Custom Fabrications but was never done.
I plan to fit an MSD 6A, any1 got a diagram for this?

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 Post subject: Re: 4.0 Conversion
Posted: Sat Oct 20, 2012 12:58 pm 
Stock as a Rock
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Age: 40

Posts: 196

Joined: 9th Jul 2005

Location: Darwin
NT, Australia

My other project.

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 Post subject: Re: 4.0 Conversion
Posted: Sat Oct 27, 2012 9:22 pm 
Stock as a Rock
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Age: 40

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Location: Darwin
NT, Australia

This weeks progress.
Engine removed so i can properly put the sump in place and machine the flywheel as well as fit a new clutch.
Engine bay is being seam welded as well as prepped for painting.

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2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Sat Oct 27, 2012 11:41 pm 
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Age: 40

Posts: 2327

Joined: 6th Oct 2005

Ride: 93EB Fairmont / BA Falcon XR6T

Location: Western Sydney
NSW, Australia

Nice project. 8-)

 

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93 EB II Fairmon8 with 17' EL GT's / Clear indicators / H.I.Ds / Sports exhaust / Lowered 2' / K&N / XR6 ECU.
2004 BA MKI XR6T in Lightning Strike paint / K&N / XR8 bonnet / BF lights and a few tweaks.

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 Post subject: Re: 4.0 Conversion
Posted: Sun Oct 28, 2012 10:01 am 
Tyre Shredder
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Posts: 333

Joined: 20th Apr 2011

Ride: 1991 eb1 fairmont

Location: townsville
QLD, Australia

will you be retaining the hydraulic clutch for the vehicle or going to cable to suit the gearbox?
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 Post subject: Re: 4.0 Conversion
Posted: Sun Oct 28, 2012 7:07 pm 
Getting Side Ways
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Posts: 5582

Joined: 20th May 2005

Gallery: 11 images

Ride: EB1 Fairmont Ghia T5 Wagon

Location: Seven Hills, Sydney
NSW, Australia

Sweet conversion.

Really looking forward to seeing this come together.

Cheers
BenJ

 

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My respect and thanks go to - snap0964, Paulmac, SWC and MRE-50L

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 Post subject: Re: 4.0 Conversion
Posted: Thu Nov 22, 2012 10:01 pm 
Stock as a Rock
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Age: 40

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Joined: 9th Jul 2005

Location: Darwin
NT, Australia

OK, i have been busy with work and family etc etc, so progress has been a little slower than i would like.
Here are som pics of the wireing going into the car, i know its a little messy at the moment but it will be neatened up.
I could have hidden the relays etc but i could see myself in the middle of nowhere trying to reach a relay or fuse so i went for convience.

Rustyeb1991 i will be using the cable clutch from the XH.

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2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Sun Nov 25, 2012 10:13 pm 
Stock as a Rock
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Age: 40

Posts: 196

Joined: 9th Jul 2005

Location: Darwin
NT, Australia

Engine is back in the car, wireing is going well and have started on the interior wireing.
Steering column is cable tied in place just for placement so next thing to fit will be the pedal essembly and booster/master cylinder.
I think i have hidden most of the wiring, i used bakeing trays to cover the relays fuses etc, when there painted to match i think they will blend in and still leave the relays and fuses easily accessible.

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2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Mon Nov 26, 2012 1:10 pm 
Getting Side Ways
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Joined: 27th Feb 2005

Ride: Supercharged EF Fairmont

Location: T.I. Performance HQ
VIC, Australia

Looking good! Fair bit of work to the firewall and rad support to fit the longer donk!

Let us know if you need a J3 Chip to disable Smartlock :)

Cheers,
Jason
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 Post subject: Re: 4.0 Conversion
Posted: Mon Nov 26, 2012 8:53 pm 
Stock as a Rock
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Age: 40

Posts: 196

Joined: 9th Jul 2005

Location: Darwin
NT, Australia

Galapogos01 as i am using the complete loom and gauges i will be retaining smartlock, however i will need a J3 for the cam and a few other mods, but thats after i get her started.

I picked up a complete turbo kit from a BF so i will be looking for a turbo manifold soon.

 

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Mk2 Zephyr
2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Mon Nov 26, 2012 9:05 pm 
Stock as a Rock
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Age: 40

Posts: 196

Joined: 9th Jul 2005

Location: Darwin
NT, Australia

Bf kit.

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Mk2 Zephyr
2011 XR6 Special edition

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 Post subject: Re: 4.0 Conversion
Posted: Mon Nov 26, 2012 9:08 pm 
Stock as a Rock
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Age: 40

Posts: 196

Joined: 9th Jul 2005

Location: Darwin
NT, Australia

If anyone is interested in DOHC parts i cant use let me know.
The parts are in Melbourne and i will be in Melb late Nov to early Jan.

 

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2011 XR6 Special edition

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