BUGA Community
General Category => Members Rides => Topic started by: yoeddynz on May 19, 2012, 07:20:25 AM
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Hiya,
After having posted up on here a while ago about the CF i was starting work on I have been meaning to start a thread for the Bedford CF project Im doing at work as a contractor. Its been quite an interesting and fun job so far and when finished the owner is going to have one very unique van.
The customer has been given this van to him by his dad. His dad has owned it since new and the customer used to get taken to school in it when little. It holds quite strong memories for him and he wants to get it back on the road and built to last so he can hand it on to his kids when they grow up.
It had been converted to running a older Falcon engine on lpg and auto box many years back. He drove it like that and really didn't like it. My boss has done many different conversions over the years using the later falcon running gear so it was decided to go down this route. The idea is that it will be future proof, better handling, better brakes with Abs, modern equipment icluding air conditioning, faster and easier coping with towing boats etc. Plus it will be a bloody cool talking point and a one off van.
Starting off I stripped the donor car that was bought as a complete runner with some rear accident damage- it cost $1000 which for all he is getting from it is cheap as.
Everything and anything that would be or could be used in the conversion was removed by me and I labeled all the wires where needed etc as the whole loom is to go into the CF. The air conditioning is to hopefully go in too and the dash complete is going in so after a lot of stripping I ended up with one very empty Falcon shell.
(http://img843.imageshack.us/img843/5024/010320121303.jpg)
(http://img42.imageshack.us/img42/575/290220121293.jpg)
The plasma cutter got lots of use. Whats scary is how much rust I found hidden away on the Falcon! The guys at work said the rust is very common on all the Falcons they have stripped for these conversions. Not impressed with that..
The Bedford was sent to the sand blasters and came back much cleaner underneath. This made things a heck of a lot easier. I finished stripping the rest of the van out. It does have a fair few rust issues but luckily the chassis and underneath is still very solid. And I was happy to discover no rust when I took out the windscreen- always a bonus..
The engine was sat in a corner while I continued on with carefully chopping the whole front end out of the Falcon. Then after loads of measuring I chopped out the Bedford floor and slowly whittled both van and Falcon until I could lower the van over the Falcon till they became one. Forklift came in handy.
(http://img545.imageshack.us/img545/6712/99764530.jpg)
Loads more measuring took place. I wanted to get it as straight as possible and most importantly get the castor angle set up as close as possible to the falcon specs. This took time but once set and tacked in place I could start joining them together.
Don Hoff, the certifier, came along and had a look around this point and was happy. I could continue. Some pretty hefty sheet steel and many awkward shapes, folds, bends later and it started to look more factory. All the time through out the work I have been having to think many steps ahead. There were loads of things that would be made much easier later on with a little forethought at this stage. Overall though it was really, still is, just a case of piece it together- making it up as I go along. Luckily the other fellas at work have built some pretty awesome machines. They often pop over and point things out that could be done easier or more effectively etc. Here is a grand example of one very intelligent fella- the painter..
(http://img823.imageshack.us/img823/2011/15052012001kq.jpg)
The Falcon dash had to be fitted quite early on so I could get an idea of where things would fit in. Much deeper than the CF dash, it had to be chopped down quite a bit while still keeping the main steel structure inside it so I could mount it. I extended the main bar out width ways and made brackets so it can be bolted in place. This is essential as the dash needs to come in and out quite often.
(http://img442.imageshack.us/img442/5091/290320121385.jpg)
(http://img217.imageshack.us/img217/779/290320121384.jpg)
(http://img692.imageshack.us/img692/8369/290320121386.jpg)
The steering has been a head scratcher! The new seating position and dash layout gives a more carlike position compared to the older CF truck position. The Falcon steering column points forwards to the bumper whereas the steering rack is behind the crossmember. These I had to link..but how? I came up with the idea (quite proud of this..) of using two right angle steering boxes from a Mitsi L300 van. The little units that take the column and sent it back to the rack.
I got a heap bits needed from a wrecker and pieced them together, eyeing things up and then making mounts. One box at the front taking the feed from the column and sending it back along the chassis rail to the next box which then sends it down to the rack. I was worried that there would be slack in the system, what with 2 boxes and 6 universal joints but was pleasantly surprised that there is none! It works a bloody treat. Plus the steering column still has the full range of adjustment - up/down and in/out. Happy with that. The universals and shafts that required welding have been welded by a ticketed welder and will be sent away for crack testing.
Luckily the customer is the same height as me at 6' 2” so I need to set up the lot comfortable for me and he is happy. He has been popping in often to check progress and loves it. I chopped the seat base down 3” and the position is really good.
The Falcon brake servo and master fit in neatly where the old CF one was. They line up well with the CF pedal box. The brake pedal only needs be moved 100mm back to suit the new dash position.
I have mounted the Falcon rear axle. Luckily the Falcon was not an IRS model. The axle sts in well and the track is pretty close but the stock (ugly) Falcon wheels have sod all offset and tuck in too far front and rear. But thats cool as he wants different wheels. Plenty of choice with the new stud pattern too. The wheels are also about 15mm smaller in diameter but again thats cool as the van needs taller profile tyres for the expected gravel roads and general abuse expected.
The Falcon front struts were going to come up too high into the foot wells so coilovers are now being used. This is good though as I can fine tune the height later on. Luckily there was a set of Spax coilovers on a 1940's hearse that is currently getting the same Falcon engine conversion along with loads of body work. I pinched the coilovers and built towers to suit them allowing for future adjustment of the top pivot position in the future- just in case. These, along with the whole build so far, have been overbuilt so its all nice and solid. ;)
I have now almost finished building a new floor on the drivers side and started on the first of many many rust repairs to be undertaken. Loads of work yet and it'll certainly keep me out of trouble for a while yet.
Its gonna be so cool firing this van up for the first time- looking forwards to that and the first drive! 8)
(http://img221.imageshack.us/img221/3246/18052012001n.jpg)
(http://img268.imageshack.us/img268/2479/18052012002.jpg)
(http://img804.imageshack.us/img804/9742/18052012003.jpg)
(http://img69.imageshack.us/img69/881/18052012005.jpg)
(http://img710.imageshack.us/img710/1820/18052012006.jpg)
(http://img252.imageshack.us/img252/5416/18052012004.jpg)
(http://img546.imageshack.us/img546/2404/18052012o.jpg)
I'll add more photos as I take them and if I can get some off the work computer I'll add them in. I hope you enjoyed the rather lengthy read... ;D
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Outstanding work, look forward to more postings. ;) alot of work for a FORD don't you think...... :D
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All I can say is WOW Im def into this I shudder to think how much this is gunna cost I dont know how you sleep at night your brain must be going a 1000 miles an hour thinking whats next Keep them photos cumming LUV IT Cheers Reid
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awesome!!!!!!!
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Well done ...Thats the sort of thing that inspirers me ;D ;D ;D Great work and i will be following this thread with great interest. ::) ::)
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Fantastic! I'll be really interested to see if you can fit the air-con in behind the dash seeing as you have chopped so much out of it. I was trying to fit an EB dash into mine but gave it up as I was going to have to chop too much out of it to make it fit.
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wow, awsome work,
its going to be a great van when finnished.
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Cheers guys.
Yeah lots of ford in it. Apparantly really great motor though but yeah if it were my van I'd be using maybe a GM V6. Actually I would put in a modern diesel as I've always found they just mix so well. But this one should go well and will certainly have some smooth grunt to tow with.
I'm glad you lot like it- what with me hacking a beddie about like this.. The owner loves this van but just couldnt get along with the position or way it drove. I think he'll love it so much when it's all done.
Rogue trooper- hopefully the air con unit will fit in on passenger side. It's fairly chunky but as the seats are going back a bit there should be plenty of room up under dash on that side. Time will tell......
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great work mate..
i,m hoping to do something similar with a wb 1 tonner chassis swap.
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Great work buddy you are very skilled and I love how well you have done everything. Just wondering what you have in mind for keeping it cool? I am guessing you will use the twin au thermo's because there one of the best but ford straight six's are renowned for getting hot and blowing head gaskets so I was just wondering how you think it will go in the beddy as in temp wise?
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Had you considered cutting the body off the falcon just leaving the floor pan then cut the floor pan out of the Beddie then drop the Beddie body on the falcon floor pan and weld them together?
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Awesome work mate. Looking forward to the continuing progress reports and the final outcome. Keep us posted and keep up the great work.
Garry.
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Yep - using the existing falcon radiator with the twin fans is what I'll be using. The fans seem like a good design with a decent cowling to help them pull air through. Lots of room around engine too so hot air will have no resistance from escaping out underneth the van. :)
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Excellent work, do you have any pics of the van sitting on the ford chassis. Would love to do something similar but alas that to great a task for me right now. Keen for more updates on the progress. Did the ford need to be lengthened or does it sit perfect with wheels lining up and so on.
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Brendeni the Ford doesn't have a chassis it's a monoque consturction which will have to have plenty of bracing for tortional strength, hard task but not impossible
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Cheers Petrolhead:) i like the thought of adding new running gear to an old body.
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Little update fellas.
It runs! :)
My second to last day working on the van before I take off overseas for two months so it was a goal to get it all sorted and running. Started it up this morning just after smoke break. Whipped up a make shift fuel tank for the start. Only had a cat fitted so pretty loud but very smooth, sweet and lush sounding 8) started easy peesy and idled well. Got up to temp then found a small leak on back of power steer pump- a suspect seal that I had already replaced but apparantly always give troubles so will convert to older fitting when back.
Fitted modified prop shaft today as well- now two peice due to length. Looks all good.
The certifier Don Hoff was up from chch to check over another car at work so he had a good look over van, checked steering etc and gave big thumbs up. When back the end will be weighed so we can order some suitable rate springs. I will fit brake lines and finish wiring to rear lights etc then we can test drive it.
It's been quite a busy time with wiring and pipe work- very tight in places and when I first started laying out the falcon wiring loom I really wondered if it might actuall fit in place. Easy when moving a loom from one car to another but into a van is different- everything is in a different place and much tighter around the bay. But I got there in the end and it looks pretty neat and tidy too :)
Very happy. Hannah popped by work at end of the day so was cool to be able to turn the key and start it up.
I will add a short video in next day or so.
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You might be able to get the engine to sit a fair bit lower if you fit an FG sump and oil pickup. The FG is a rear sump.
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Hiya- sorry for late reply. Progress has been nice and steady on the van. Its almost ready for the first test drive. I have to weight the front in order to get the right springs ordered. And the body is still riddled with rust holes but that is to be done once I know all else is OK. Its a pretty solid van anyhow so removing the rot shouldnt be too much of a a drama.
I'll post some pics in next few days once its back down on its (currently horrible stock falcon wheels) and get it out in the sunshine.
I have put up a wanted advert but will repeat here- Im after a pair of complete taillight units and lenses- cf1. Its issing them and had some tiny yucky replacements fitted.
cheers
alex
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If no one here has "spares", think i spotted some on ebay.co.uk the other day. Shipping may be a bastard tho!
Al
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The owner/ has managed to source not one but two pairs of lights :) so that's all good. Now we need a decent bonnet....
Been back on this at work after getting back from two months away. Last friday we took it for the first test drive. I took a small vid on my phone...
Bedford CF on Ford Falcon chassis (http://www.youtube.com/watch?v=2myyJ38nKXA#ws)
Very happy with how it drives. Very smooth ride and not too loud considering it has no insulation, no exhaust, no sound deadening etc. brakes are fantastic, steering good. in fact its like driving an AU falcon...
I'm now busy removing rust.. of which there is quite a lot but luckily the underside is very very solid making the repairs so much easier.
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Very nice mate, well done. Tell me though, how die you get the steering to connect up?
I'm planing on installing an AU engine in my van also. No going to as much trouble as you though. Have thought about using the steering column but theres no way it will connect up without some kind of gearbox arrangement.
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Bevel box is used
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Check out Ben's bonnets I think they are the dux nuts
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Awesome job guys, cant wait to see it done. One thing though, although you know your van building, the camera work is well, lets say it maybe a good idea to get someone else to do the camera while you guys stick to custom vans. Maybe a longer video,i never get sick of seeing a beddy on film.
george
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Hiya,
The steering is done with two opposed bevel boxes from mitsi or Toymota vans. Worked out well but took some measuring and looking for bits to suit because we can't weld any steering components for certification.
The camera work.. Well I didn't think we would be driving it that day so it's all taken on my old Nokia n95 phone. But then when I edited it on Imovie it compressed it heaps for you tube. But hey you get the idea. :).
When the van is more complete I'll take better vids.
I'm now having a much waited for break over Xmas and keeping busy fitting a quad cam Mazda v6 into my hb viva.... ::)
Alex
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Long overdue update :P
I have been working away on the beddie but not full time and also I have had time off working on my Vauxhall Viva HB which is now fitted with engine type number four.
The Bedford is not far from going for a wof test. Once it has been tested and hopefully only failed on the lack of certification it will then get inspected by the engineer who has been following it through since I started it. Hopefully it should all be good and get a cert :)
Then its off with all the paint and many layers of filler that is weighing it down. There are many big dents and the roof is caved in on one area and filled with bog. It looks like the van at some point was driven under something that was a bit 'lower' than the van... plus we found out that the van was rolled onto its side many moons ago and hence the back is all a bit un-square...
The rear end has had a big makeover I think since last time I posted. Instead of having side opening doors it now has a custom made top hinged door- ala Japanese vans. This was the owners choice and it works really well- he now has a lovely cover for camping when its raining. The plan is that at a later date a set of sides can be made out of canvas and turn it into a nice little sheltered area :-)
The old front seats, we think were possibly Torana items, have gone and instead I have fitted captains chairs with a swivel base on the passenger side.
The back 'stressed' seats have been fitted with the appropriate mounting points to suit the cert requirements. These are all removed now for the final interior steel fabrication jobs to be finished.
A set of 15" steel Falcon rims have been sent away to get widened out to 7.5" They will be fitted shiny hubcaps and with decent modern tyres once back. The idea is that it will look nice and stock/period.
(http://i57.photobucket.com/albums/g226/yoeddynz/020820132321_zpsfdbe01f5.jpg)
Here is a another cool CF on the oldschool.co.nz forum for your viewing...
http://oldschool.co.nz/2011/forum/index.php?/topic/39698-1979-cf-bedford-bey-thats-mean-as-van/ (http://oldschool.co.nz/2011/forum/index.php?/topic/39698-1979-cf-bedford-bey-thats-mean-as-van/)
Here's my own ongoing, constantly evolving Viva project..latest engine...
(http://i57.photobucket.com/albums/g226/yoeddynz/P1080649_zpsf73d9ff9.jpg)
If you're interested in the Viva then you can read about it here...
http://oldschool.co.nz/2011/forum/index.php?/topic/28896-yoeddynzs-1968-viva-now-has-a-mazda-v6-lurking-in-engine-bay/ (http://oldschool.co.nz/2011/forum/index.php?/topic/28896-yoeddynzs-1968-viva-now-has-a-mazda-v6-lurking-in-engine-bay/)
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Sweet, cheers for the update, any pics of the rear hatch thingy you mentioned?
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Hi just checked out your house truck thred Now that's what I call a motorhome AWESOME Beautiful work & love your cats That looks like a great life you's live Love the v6 viva too love that sort of work wish I were 20 years younger Cheers Reid
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Hello all. I have not updated this in a while but here we go...
So Van has just come back from upholsterers and is looking pretty sweet inside. They have down a very neat job. I think it would be sweet if the seats were re-covered in leather but at least they match the scheme quite well. So a just the rear door to paint,some wiring/stereo to finish, under seal the underside and then its going up to Auckland to get the Cert committee to say yay or nay to the steering arrangement. Hopefully it'll be fine- It should be..because it is.. but if not I have worked out an alternative arrangement if not.
Photos I grabbed yesterday when I had popped into old work and saw it...
(http://s25.postimg.org/r0z2wr5pr/20150116_145545.jpg) (http://postimage.org/)
(http://s25.postimg.org/7x5rgesvj/20150116_145932.jpg) (http://postimage.org/)
(http://s25.postimg.org/gtgjkcjhr/20150116_150742.jpg) (http://postimage.org/)
(http://s25.postimg.org/6xfgkpdpr/20150116_150750.jpg) (http://postimage.org/)
(http://s25.postimg.org/xjrx9ohwv/20150116_150825.jpg) (http://postimage.org/)
Cheers all,
alex
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Wow,
nice van u got there.
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Looks Great! Very nice work. 8)
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Its looking great eh! Drives really nice too. It will be heading up to Auckland to go through an extensive cert check because of the steering system.
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Good luck ,
Im sure it will pass.
No holding you back then. :D
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Brilliant! Thanks for the update and photo's. Awesome .....top job!
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Keen for an update 😃😃