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Post  Jonny James on Sat 18 Jul 2015, 7:50 pm

Hey Guys

Started posting this on another forum and thought I may as well keep you guys updated as well.

One day I will get a start to my van, until then I will be playing with this.

Garrison Grey, EK 1962 special sedan.

Not much of a car really, just another molested EK in need of a lot of work.

What it does have going for it, for me is a good solid base for building something that will have a few of my own touches.

Current motivation comes from a HK 186S, Trimatic.



Week one of picking the car up (February 2014)

'Garry' - EK sedan. Grey%20EK%20001_zpsbwuovgdv

A few weeks later, I pulled a spare grill down to polish, 50 hours of work later had something to put back into a car.

'Garry' - EK sedan. Grill%20001_zpsvr0m2pkx

Original grill from car vs polished grill

'Garry' - EK sedan. Grill%20002_zpsaro3opxf

Another week or so after the grill fit up. Removed the mud flaps, kicked on a set of EK hub caps which I had repainted the centres, lowered the front down a little with a set of Kings lowered springs and flipped a leaf in the rear.

'Garry' - EK sedan. Grey%20EK%20002_zpsehhrna4e

Some time between the last shot and this one at the 2014 Berrima 'Grey Pride' run. Got a set of 5 BF goodrich Silvertown Wide whites fitted to a matched set of correct EK rims, had them blasted and 2 packed in Garrison Grey (can not stand white wheels with white walls, two different shades of white always makes one or the other look dirty). Also fitted up new grill bar badge, new lenses all around and some more general tidying up.

'Garry' - EK sedan. Grey%20EK%20004_zpsjzd6tty3

From there I had a small window to get a few other things done to the car before the 2014 Cowra FB EK nationals. Only have very few photos of the little jobs down to the car.

One of which was this one.
I had plans of just painting up the grill and radiator support bars. Though something which I had always thought looked funny with a bigger radiator is the shape of the radiator support bar vs the shape of the radiator corners. So after sectioning up a support bar into 7 pieces and welding it back together I ended up with this (before paint) Why? Because I can.

'Garry' - EK sedan. Grey%20EK%20006_zpsq2b565vu

Old radiator support bar out of the car next to the one I sectioned up.

'Garry' - EK sedan. Grey%20EK%20009_zps6d5to4oh

Trial fit up to the car

'Garry' - EK sedan. Grey%20EK%20010_zpspczto5cr

Also Had the car at the exhaust shop getting a new tail pipe bent up. Hated the old exhaust tip, location on were it exited and old tail pipe wasn't high enough over the diff (use to bottom out)... bloody Exhausting job!

'Garry' - EK sedan. Grey%20EK%20011_zps1nab9kou



Went to the Cowra FB EK Nationals and had a blast!

Did the 2014 NSW All Holden day, travelled down with Ted Brennan (Green roof chopped two door EK) and Steve Mowat (green EJ Wagon) Had a good weekend and scored a few good parts for the EK at the swapmeet.

'Garry' - EK sedan. 10379779_716060288483357_4649490523643724951_o_zpsosqidk9j

Then I think I don't think I had turned a spanner on the car until this last week!
Got side tracked with a few of the cars (EJ sedan {next to the EK in the picture above} and a 64 Pontiac), also had other big problems with life (boring stuff).
Continued collecting parts for the car along the way for Garry, knowing one day I will get a chance to do somethings to the car.

Thursday however was the day to make some sort of a start.

Got one last photo of the car before it came apart. (worried that it may not go back together again for a long time)

'Garry' - EK sedan. Rust%20001_zpsiux1ne3o

I have known since the week that I had got it that it needed rust repairs to the parcel shelf (went to fit seat belts and realized some metal may need to be replaced to mount them to)

Rear seat came out, what was left of the parcel shelf cover and rear window out.
This is what I first find

'Garry' - EK sedan. Rust%20002_zpsyosj1cyo

After some time scrapping with a screw driver and paint scraper I decided to get the wire wheel on the grinder out... After and hour this is where I got to for the night.

'Garry' - EK sedan. Rust%20003_zpst9jfnj22

'Garry' - EK sedan. Rust%20004_zpsl9ym3fzt

Couple of holes!

Picked this up close to 12 months ago also for this job

'Garry' - EK sedan. Rust%20005_zpsimd4shxj

So Friday was not a very productive day.

Woke up to this!

'Garry' - EK sedan. Snow%20002_zpspjm4ezxv

Left the rear window out of the grey car out side Thursday night

'Garry' - EK sedan. Snow%20001_zpsbqai8wi5

Anyhow, after having a family snow fight and a good thaw out in front of the heater. I made a start on prepping the replacement panel.

'Garry' - EK sedan. Rust%20006_zps0oa7d8vb

Cut over sized

'Garry' - EK sedan. Rust%200062_zpsldygnz3g

'Garry' - EK sedan. Rust%20007_zpstwx0mzpj

I had then taken to it with my new toy

'Garry' - EK sedan. Rust%20008_zpsah0vozpa

Result is a nice clean panel to work with.

'Garry' - EK sedan. Rust%20009_zpsd1dnn9zr

'Garry' - EK sedan. Rust%20010_zps756ewdnf

Did not get much else done after this as visitors had turned up.



Got a little more done today.

Started off by fixing some holes in the window channel

'Garry' - EK sedan. Rust%20011_zpsk6hiwa0f

'Garry' - EK sedan. Rust%20012_zps1boxr2sq

Then moved onto the large Swiss cheese part. I cut the badly affected area out and placed the roughly cut to size/shape repair section in with a few tacks to do a final in place cut to make sure for a good fit.

'Garry' - EK sedan. Rust%20013_zpsbk8swwuw

Then after the trimming cut the section back out ready for some rust proofing before I fully weld in tomorrow... Hopefully

'Garry' - EK sedan. Rust%20014_zpsmjah1dzu

Cheers for now
Jon  Cool


Last edited by Jonny James on Fri 24 Jul 2015, 4:39 pm; edited 1 time in total
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Post  sinbin on Sat 18 Jul 2015, 9:47 pm

'Garry' - EK sedan. Innuendo_remnants_zps6zgzfi1j

Here's a picture when Garry was visiting Innuendo.

Regards, Smooth Cool
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Post  Jonny James on Sun 19 Jul 2015, 4:33 pm

Got one side of the rear window area rust repairs finished up today.

Started off by using some butt weld clamps to get thing into position.

'Garry' - EK sedan. Rust%20015_zps7juc5mik

'Garry' - EK sedan. Rust%20016_zpsoic9zkof

About half way through welding I needed to pull the panel down to the boot hinge bracket, a couple of self drilling screws used.

'Garry' - EK sedan. Rust%20017_zpsrix8b6jj

Welding all but finished.

'Garry' - EK sedan. Rust%20019_zps59xd5zug

Quick grind up. First time I've really tried to metal finish a repair panel with out seeing the welds once ground.

'Garry' - EK sedan. Rust%20020_zpsdowzhtxv

Then for a little cold gal paint until I'm ready to seal it up properly.

'Garry' - EK sedan. Rust%20018_zpsviqtbuta

That is enough for one weekend, hope to get the other side finished after work during the week.
Cheers Jon  Cool


Last edited by Jonny James on Fri 24 Jul 2015, 4:40 pm; edited 1 time in total
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Post  wizard1 on Sun 19 Jul 2015, 8:03 pm

excellent job very talented thanx wizard

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Post  Jonny James on Sun 26 Jul 2015, 10:30 pm

A little more done today.

All metal work repairs done in the rear window channel areas.

'Garry' - EK sedan. Rust%20021_zpsqeyomxff

'Garry' - EK sedan. Rust%20022_zpsjsiukaou

'Garry' - EK sedan. Rust%20024_zpsi0nlwlhf

'Garry' - EK sedan. Rust%20023_zpsjxh8vlej

Next up rear seat belt fit up.

Plan is to recess reels down 40mm.

'Garry' - EK sedan. Rust%20025_zps6hgdrnwe

Until Next time
Jon Cool
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Post  VAN005 on Mon 27 Jul 2015, 7:24 pm

never seen those butt weld clamps before there awsome will have to get some, great work your doing
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Post  HQVAN on Mon 27 Jul 2015, 9:56 pm

Nice work Jon!
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Post  Jonny James on Sat 01 Aug 2015, 4:49 pm

Well another week down, no where near as much done as I would like but got some good hours in never the less.

started off by folding up some seat belt recess boxes.

'Garry' - EK sedan. Seat%20belts%20004_zpsqkzcnsni

'Garry' - EK sedan. Seat%20belts%20003_zpswtoor32g

Once that was done, marked out where they had to go in the car and cut a good chunk of the metal I had just replaced in the car.

Note boot hinge support bar in the road.

'Garry' - EK sedan. Seat%20belts%20005_zpstbbzlmmz

Cut the bar out to drop the new box in.

'Garry' - EK sedan. Seat%20belts%20006_zpset0xhyw3

Seat belt sitting in there to make sure I was on the right track.

'Garry' - EK sedan. Seat%20belts%20007_zpss5g62g7g

'Garry' - EK sedan. Seat%20belts%20008_zpssncdkgre

'Garry' - EK sedan. Seat%20belts%20009_zpssu5irxvl

Had a read of the relivent VSB

Note sizes required

'Garry' - EK sedan. Seat%20belts%20001_zps03zibros

Cut the reinforcing plates out of 3mm plate, they ended up being bigger than required (80mm x 60mm). Also installed some locating 5mm screws to stop it spinning.

'Garry' - EK sedan. Seat%20belts%20011_zpsz7zf6mfa

'Garry' - EK sedan. Seat%20belts%20010_zpskeoaktep

Note the bevel on the edge and also the radiused corners as per the rules.

'Garry' - EK sedan. Seat%20belts%20012_zps5umesbnd

Reinforcing plate will be held up with some nyloc nuts (not tightened up to tight)

'Garry' - EK sedan. Seat%20belts%20013_zpskimdnwyt

I then cut the other side into the car

'Garry' - EK sedan. Seat%20belts%20014_zpsup0rus3f

Tacked the corners into place

'Garry' - EK sedan. Seat%20belts%20016_zps4msr9ad9

Then cut the wings off (originally thought I may need them... plans changed along the way)

'Garry' - EK sedan. Seat%20belts%20015_zpsvaputwzv

Ground the edge of the box flush with the parcel shelf one side at a time

'Garry' - EK sedan. Seat%20belts%20017_zpsagrn5erx

Ran a 1mm cutting wheel up between the to edges to be welded

'Garry' - EK sedan. Seat%20belts%20018_zpsxwdyszya

Welded one side and then moved onto the next

'Garry' - EK sedan. Seat%20belts%20019_zpsf2zt2bke

Ground smooth

'Garry' - EK sedan. Seat%20belts%20020_zpsccnatpzr

Welded the boot hinge support bar to the box from under neath

'Garry' - EK sedan. Seat%20belts%20021_zps5tjuocnz

These are the instructions from the seat belts that I'm fitting

'Garry' - EK sedan. Seat%20belts%20002_zpsqbw50gkw

The supplied washer that spaces the seat belt reel up (refereed to as ''trim spacer'') this will space the reel above the locating screws.

'Garry' - EK sedan. Seat%20belts%20022_zpsvvt93mvl

Now back out to the shed to finish the other side
Cheers Jon Cool
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Post  Rohan on Sun 02 Aug 2015, 10:55 pm

This is a great post (and sure puts my work to shame)....
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Post  Jonny James on Mon 03 Aug 2015, 4:16 pm

Rohan wrote:This is a great post (and sure puts my work to shame)....

Thanks Rohan Cool
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Post  fc59 on Wed 05 Aug 2015, 9:41 pm

Very tidy work
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Post  Jonny James on Sun 23 Aug 2015, 9:33 pm

Hey Guys,

Small update on some slow progress.

Started off Saturday morning with intentions of working on getting the gaps better around the boot lid.

'Garry' - EK sedan. Boot%20001_zpsnkuyyfs4

Thought it was a good idea to strip the paint off to do so around the edges to give me the best idea on what areas need work.

'Garry' - EK sedan. Boot%20002_zpst4cn3dtz

Then got to the point where i said to myself I've gone this far why not keep going!

'Garry' - EK sedan. Boot%20003_zpsmhtsp1yj

Plan is to have no badging on the boot lid.

Beaver panel is surprisingly good rust wise. Does have the almost factory bumper section join dents in the beaver though.

'Garry' - EK sedan. Boot%20005_zps0furwbos

Worst of the rust on the drivers corner.

'Garry' - EK sedan. Boot%20004_zpsb7cv0d89

Saturday afternoon I went for a drive to Woodstock to pick up a panel cut for an idea that'has been kicking around in my head.

Plan is to recess the fuel filler like on the utes, vans and wagons. Small custom touch that should look factory when finished.

'Garry' - EK sedan. Boot%20006_zpsgpghk97s

After a quick blast this morning.

'Garry' - EK sedan. Boot%20007_zpsehvchmnf

Also knocked most of the dents out of the beaver this morning.

This week I should hopefully get to fixing the rust, make a start on getting the fuel filler recess into shape and position

Until next time
Jon  Cool
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Post  Rusty62TransAm on Mon 24 Aug 2015, 12:56 pm

A great Write Up and Great Work Jon. vg1

An enjoyable read. Thank you for sharing.


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