Page 6 of 7

Re: VIN 17005 New Zealand

PostPosted: Wed Aug 02, 2017 11:01 am
by Spudmurphy
Nice one Gary. I can vouch for the "simple method" - it worked a treat.

Hopefully package to you, will be sent out on Thursday :-)

Re: VIN 17005 New Zealand

PostPosted: Wed Aug 09, 2017 2:40 am
by gary290
thanks Spud,
this is my version of repairing the rear roof box.
DSC_1209[1].JPG
DSC_1209[1].JPG (827.84 KiB) Viewed 4714 times

so i made up 4 sets of these
DSC_0019[1].JPG
DSC_0019[1].JPG (2.71 MiB) Viewed 4714 times

DSC_0021[1].JPG
DSC_0021[1].JPG (2.72 MiB) Viewed 4714 times

DSC_0022[1].JPG
DSC_0022[1].JPG (2.7 MiB) Viewed 4714 times

DSC_0024[1].JPG
DSC_0024[1].JPG (2.54 MiB) Viewed 4714 times

DSC_0025[1].JPG
DSC_0025[1].JPG (2.53 MiB) Viewed 4714 times


the t panel sits nice and so does the garnish so i'm quite happy with it,
i think this is not just a repair but one of those things you must do as the original design is a bit rubbish.

Re: VIN 17005 New Zealand

PostPosted: Wed Aug 09, 2017 2:57 am
by gary290
my first attempt at restoring the door cards
DSC_0011[1].JPG
DSC_0011[1].JPG (2.88 MiB) Viewed 4713 times

DSC_0012[1].JPG
DSC_0012[1].JPG (2.7 MiB) Viewed 4713 times

DSC_0014[1].JPG
DSC_0014[1].JPG (3.24 MiB) Viewed 4713 times

DSC_0016[1].JPG
DSC_0016[1].JPG (2.03 MiB) Viewed 4713 times

DSC_0017[1].JPG
DSC_0017[1].JPG (2.02 MiB) Viewed 4713 times

DSC_0018[1].JPG
DSC_0018[1].JPG (2.06 MiB) Viewed 4713 times

Re: VIN 17005 New Zealand

PostPosted: Wed Aug 09, 2017 8:37 am
by Spudmurphy
Love the roof box fix - nice work. I totally agree with you regarding the fixing of the box I think that every D should have it done. It was a no brainer for me as the bond had failed and probably was the contributory factor for the passenger torsion bar failure.
I ditched the Bolts supplied with the roof box kit I bought and used really nice mushroom headed allen bolts. The one thing that makes mine look "not so pretty" was my liberal application of worth bond so the nice "stainless steel goodliness" is all hidden.
One thing I need to fabricate for mine is the roof sealing panel.

Oh, I also fabricated a s steel bracket that holds the wiring loom down in the roof/door channel - - all those little touches that nobody sees .

Loving the leather rework too.

your first attempt reminds me of the first time I put speaker Grill cloth on a Fender Guitar amp - you have to keep the weave straight - uh mine wasn't - 'tis now!

Re: VIN 17005 New Zealand

PostPosted: Sat Oct 07, 2017 11:31 pm
by gary290
Thanks to Spudmurphy I have got on to fixing my rad fans and shroud, for whatever reason the po cut the shroud in half and binned it with one of the fans, so when Spud was about to chuck his broken shroud so i thought i could make it work for me
DSC_1220.JPG
DSC_1220.JPG (1.18 MiB) Viewed 4539 times

DSC_1222.JPG
DSC_1222.JPG (1.19 MiB) Viewed 4539 times

the po did such a crap job they even cut the warning sticker in half!
all the rad brackets were bent out of shape and missing bolts etc...
i bought 2 new fans and had the shroud fixed and glassed together, it's a bit rough but i'm happy with it and it's under the car anyway
DSC_1255.JPG
DSC_1255.JPG (613.19 KiB) Viewed 4539 times

DSC_1256.JPG
DSC_1256.JPG (653.77 KiB) Viewed 4539 times

DSC_1257.JPG
DSC_1257.JPG (745.22 KiB) Viewed 4539 times

DSC_1258.JPG
DSC_1258.JPG (746.25 KiB) Viewed 4539 times

DSC_1263.JPG
DSC_1263.JPG (568.16 KiB) Viewed 4539 times


also the po removed the fan relay and stuffed in a wire with a switch and this is how the fans operate now, so i think the system isn't working properly, any ideas?

thanks again to Spud for helping me get this sorted

Re: VIN 17005 New Zealand

PostPosted: Mon Oct 09, 2017 12:41 pm
by Spudmurphy
Brilliant Brilliant Brilliant!!!
When you asked me for the broken shroud (I was pretty new to posting on the forum then) - I really thought you were pulling my leg.
But well done you - I'm sooooooo glad you were able to make use of it - because it would have been in landfill by now.

Re: VIN 17005 New Zealand

PostPosted: Mon Oct 09, 2017 4:51 pm
by Admin-bloke
Well done for the fix.

Reinstall the fan relay and link the wires together that go to the otterstat/ radiator fan switch located in the rear left hand coolant pipe left hand side near the exhaust/ frame chassis when stood behind the car bonnet looking down on the engine bay.

The fans should run. If they now run then buy a new radiator switch and install but use a cable tie instead of the oem clip.

In preparation for if they don't run, take a photo of the wiring area where the relays are, especially where an orange and black stripe wire nearer the centre console corner of that area.

Re: VIN 17005 New Zealand

PostPosted: Mon Oct 09, 2017 9:56 pm
by gary290
cheers Spud and thanks Admin,
installed the fans last night and they work with the current setup, tonight i will be trying the original system to see if anything happens

Re: VIN 17005 New Zealand

PostPosted: Tue Oct 10, 2017 4:59 am
by gary290
result!! put the relay back in and joined the wires together then the sound of the fans was music to my ears,
so whats going on here please
DSC_1264.JPG
DSC_1264.JPG (583.22 KiB) Viewed 4456 times

DSC_1265.JPG
DSC_1265.JPG (561.58 KiB) Viewed 4456 times

Re: VIN 17005 New Zealand

PostPosted: Tue Oct 10, 2017 7:44 am
by Admin-bloke
That's a common upgrade as the fan fail relay was intermittent in operation and that add the oem fix.

I've never had chance to have a look inside the oem relay, as it was supposed to be made of 2 coils etc to detect if a fan wasn't working and display this as a warning lamp on the dash