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Sooty72’s AU-powered XH Ute Build Thread. 

 

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 Post subject: Re: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Wed Jul 28, 2010 1:34 pm 
Getting Side Ways
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Ride: XH Ute / AU3 V8 Wagon

Location: Bris-Vegas
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I picked up my new clutch yesterday, along with a new spigot bearing, and the freshly machined flywheel.
Attachment:
New clutch and flywheel for T5 conversion.jpg

Looks good, doesnt it? 8-)
Everything is pretty much ready to go now, just waiting on my firewall reinforcement plate, but it should be finished today or tomorow, pics will be forthcoming. Then all set for sunday. I'm starting to feel like a little kid before christmas! :D

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Wed Jul 28, 2010 1:38 pm 
Getting Side Ways
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Ride: EB1 Fairmont Ghia T5 Wagon

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I hope all goes well for you on Sunday.

Remember, don't rush. Take you time and do things the right way the first time.

Are you going to put a new welsch plug in the back of the engine while you can? Oh, and a new rear main seal? Cheap, easy insurance.

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: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Wed Jul 28, 2010 1:44 pm 
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BenJ wrote:
I hope all goes well for you on Sunday.

Thanks mate, I'm sure everything will be OK. Only think I'm a bit nervous about is the electrical side of things. I'm hoping it's all "plug & play", so fingers crossed there.

BenJ wrote:
Remember, don't rush. Take you time and do things the right way the first time.

Never do, patience is not always my forte, but I do make sure things are done properly the first time.

BenJ wrote:
Are you going to put a new welsch plug in the back of the engine while you can?

Yep! 8-)
BenJ wrote:
Oh, and a new rear main seal?

And Yep! 8-)
BenJ wrote:
Cheap, easy insurance.

I agree, you would be mad not to, with everything so close. :?

I am also writing a tech doco for this swap, I should have it finished in a couple of weeks.
Cheers guys,
Grant.

 

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Fri Jul 30, 2010 6:03 pm 
Getting Side Ways
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OK, so I looked around at all the different versions of the Firewall reinforcing plate, and decided to have a go at one of my own. I drew up a few ideas, and spoke to our machine shop about making it for me. They threw my idea in the bin and went and got this.
Attachment:
Aluminium Firewall Reinforcing plate - before.jpg


After a bit of time on the computer, and even less time on the CNC mill, we had this.
Attachment:
100_4138.jpg

Attachment:
100_4137.jpg


How cool is that? 8-)

I will fit it up on sunday, and show some pics of it fitted and working. :D
Cheers. 8-)

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

Last edited by sooty72 on Sat Jul 31, 2010 12:31 pm, edited 1 time in total.

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 Post subject: Re: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Sat Jul 31, 2010 12:31 pm 
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Thanks man. I can't take the credit for it, the guys at work made it for me. We have three 5-axis CNC mills there, mainly for doing cylinder head work and the like. They make all sorts of cool stuff, and this was a simple little "foreign" that they knocked out for me.

If anyone wants one, let me know, I may make them available........ 8-)

 

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Thu Aug 05, 2010 1:00 pm 
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Update: Well, the T5 is all in and working fine. Sunday was a HUGE day, but it was worth it. 8-)
I started about 8.30am, ripped out the radiator and thermos, then I removed the master cylinder and booster, so I could get to the firewall, to fit my reinforcing plate. Heres what I started with.
Attachment:
XH ute firewall - standard.jpg

Due to a misunderstanding / communications breakdown, call it what you will, the back of the cnc'd alloy plate wasnt machined to clear the existing clutch cable mount. After a bit of discussion, we figured the plate would be heaps strong enough without the original bit, so I chopped it off. That left me with this.
Attachment:
XH ute firewall - step 1.jpg

I then primed the bare metal bits, then sprayed it with a bit of black to seal it, then drilled the holes and fitted the plate.
Attachment:
XH ute firewall - step 3.jpg

Attachment:
XH ute firewall - step 4.jpg

It cleared the booster fine, so it all went back together again.
Attachment:
XH ute firewall - top view 1.jpg


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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Thu Aug 05, 2010 1:06 pm 
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Then all the fun stuff started. Everything went together really easily. The wiring was a simple plug, like I hoped, the exhaust and tailshaft fitted fine, the ECU went in and it started first go.
Attachment:
XH ute - T5 fitted!.jpg

The manual boot fitted into my original console, so the interior looks great. I cleaned it really well on monday.
Attachment:
Grant's XH ute interior - manual.jpg


I also cleaned the windows, and gave the wheels a really good clean.
Attachment:
Grant's XH ute 7.jpg


And that's it for now. I have been away all week, back to work next week.
The ute goes like a train now, pulls a lot harder, sounds heaps better, and is a lot more fun. 8-)

Cheers to everyone who gave advice and encouragement. Much appreciated. 8-)

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Thu Aug 05, 2010 2:12 pm 
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Hey Sooty.

Great job mate.

I know the effort is worth it, and I am glad you think so too.

Cheers
BenJ

 

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BenJ's EB GL Sedan - Previous Ride
My respect and thanks go to - snap0964, Paulmac, SWC and MRE-50L

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Sat Aug 07, 2010 6:31 pm 
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Yep, I am very happy with the results. We spent this week at the Gold Coast, and went for drives everyday. Even made a trip back home on Thursday "to check things out", but mainly just to drive it more. 8-) Even the Mrs likes the new sounds and the acceleration of it.

I cant believe how much the BTR was strangling the poor thing! It idles nicer, sounds heaps better, revs much quicker, is much more responsive, and s**t loads more fun. I will be recommending this conversion to everyone with an E-series.

Next job is to fit the auto into the donor ute, refit the pedal box and dash and get it driving again. Then we will fix a few things, and sell it off as a running driving XH ute, with auto and LPG. I need to get a minimum of $1200.00 for it. Shouldnt be too hard. :?

 

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Sat Aug 07, 2010 11:02 pm 
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A BBM conversion is another mandatory mod for the XH's (non XR's that is) . . . .IMO.

 

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Sun Aug 08, 2010 5:11 pm 
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The BBM conversion is on my to do list, but not for a while.
I really do need a new exhaust, from the extractors back at least. I also need new carpet, and fit some carpet over the back of the cabin.

I would also like to mod and fit an EL console, with cup holders, to finish the interior.

My next purchase though will probably be an after market shifter for the T5. I'm thinking I will get the Hurst Billet/Plus unit. When I can afford it.... 8-)

 

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Sun Aug 08, 2010 5:44 pm 
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sooty72 wrote:
Thanks man. I can't take the credit for it, the guys at work made it for me. We have three 5-axis CNC mills there, mainly for doing cylinder head work and the like. They make all sorts of cool stuff, and this was a simple little "foreign" that they knocked out for me.

If anyone wants one, let me know, I may make them available........ 8-)


Are you guys able to mill billet LCA's? drawing provided?

 

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Sun Aug 08, 2010 8:53 pm 
Getting Side Ways
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I take it you mean Lower Control Arms?
I dunno, but anything is possible. The material would have to be supplied, and it would be expensive. Why would you want a cnc'd alloy suspension arm? the factory ones ar OK for a street car, and a simple steel plate welded on the bottom would make them s**t loads stronger, if you needed it. Aluminium arms seem like a waste of money.......

I will ask tomorow and let you know.

 

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Yes, I own a Ute. No, I won't help you move!

EL Wagon Build Thread http://www.fordmods.com/the-garage-f53/sooty72-s-ef-futura-wagon-long-term-project-t90025.html
XH Ute Thread http://www.fordmods.com/post1138970.html#p1138970

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 Post subject: Re: Sooty72’s XH Utes thread. T5 done & dusted!
Posted: Sun Aug 08, 2010 11:34 pm 
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sooty72 wrote:
I take it you mean Lower Control Arms?
I dunno, but anything is possible. The material would have to be supplied, and it would be expensive. Why would you want a cnc'd alloy suspension arm? the factory ones ar OK for a street car, and a simple steel plate welded on the bottom would make them s**t loads stronger, if you needed it. Aluminium arms seem like a waste of money.......

I will ask tomorow and let you know.


Yes, Lower Control Arms. The arms are to fit AU uprights into an E-Series, so nothing is available to do this, hence the CNC'd arms.

 

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ILL60 - EF XR8, Sunroof, Ticky Kit, 19x8.5/19x11 TE37's, 347, AFr185's, TFS BoxRcustom converter, Hurst Quarterstick, huge billet cam.

51TER - DL LTD. Stock.

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 Post subject: Re: Sooty72’s XH Utes thread. T5 getting even closer now!
Posted: Mon Aug 09, 2010 8:18 pm 
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[quote="sooty72"]
Attachment:
Aluminium Firewall Reinforcing plate - before.jpg

Attachment:
100_4138.jpg

Attachment:
100_4137.jpg

/quote]


that is way too fancy for fordmods...what happened to evenyone making the ones from tech doco, with the 3mm plate and the pipe with all the dodgy welds :P

 

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