Jump to content
Panko

Panko's XF Ghia wagon - the resto and rebuild

Recommended Posts

ok dokie, i went back out after the storm finished and fitted the driver's headlight. plugged them all in, and everything works :D 

 

tomorrow, the front bumper is going on to see how everything lines up. 

 

almost ready to fit the rear bumper, but im going to leave that until last because ill be still working around the back of the car cleaning and installing the interior parts 

Share this post


Link to post
Share on other sites

did you swap the ball sockets on the reflectors? the aftermarket ones are soft and the balls slightly larger on MOST of the aftermarket ones i had. = reflector falls off when trying to aim them. 

 

i haven't seen good headlights for XF/XG for ages now. pity the reflectors cost so much to have re done. @SPArKy_Dave was going to "look into" the stuff needed to redo them.. that was 2yrs ago, so should be all set up by now ;) 

Share this post


Link to post
Share on other sites
8 hours ago, deankdx said:

did you swap the ball sockets on the reflectors? the aftermarket ones are soft and the balls slightly larger on MOST of the aftermarket ones i had. = reflector falls off when trying to aim them. 

 

i haven't seen good headlights for XF/XG for ages now. pity the reflectors cost so much to have re done. @SPArKy_Dave was going to "look into" the stuff needed to redo them.. that was 2yrs ago, so should be all set up by now ;) 

 

Ah shit. I didnt change the ball sockets no, and its funny you say that i noticed they seemed a little easier to push into the Ford housing. Fingers crossed they hold, otherwise it will be headlight out job again :( 

Share this post


Link to post
Share on other sites

if they do hold, it will probably be until you are driving in the dark ..then you'll be like Doh!

 

just a heads up.. some of the ford ones are riveted, so will need careful drilling, some are screwed on.
most of the screwed on aftermarket ones have bigger headed screws.. so may need the heads ground down or new (computer?) screws used on the ford sockets to keep room for the ball..

 

i've played mixy maxy junk resto before.. hence i got the originals redone in mine..

Share this post


Link to post
Share on other sites

Had another day with good progress. 

Fitted the bumper, fog lights, headlight protectors, number plate. 

 

bumper back on. 

fitted using the rare spares repro bumper mount kit. its the first time i can remember as long as i have had the car, that its had both the front and rear side clips on the front bumper. 

ive never seen my front bumper fit so well :D 

 

pEBOGSt.jpg

 

GOIblLx.jpg

 

HkQ7ceH.jpg

 

I then fitted up my NOS Hella fog lights :D 

 

GaJThhC.jpg

 

And this is where I got up to today. fitted one of my spare pairs of genuine headlight protectors (I have 3 pairs inc the one that got smashed), fitted the number plate, and parked it up for the night. getting close, but still have a long way to go. 

 

HI0cNgW.jpg

 

tomorrow i wont get much done. Have a bit to do away from home. but this does mean i can start on the little things like the trims that need doing. the front of the car is nearly finished  :D 

Share this post


Link to post
Share on other sites

Friday i spent the afternoon pulling out the gauge cluster to fix a number of non working lights in the dash...one of my most hated tasks on this car :( 

 

nXUdxLe.jpg

 

then glued the base of the bonnet emblem back together 

 

Fdhdxz6.jpg

 

wEZ7ECQ.jpg

 

this stuff is awesome FYI  :P 

 

niXnqGS.jpg

 

Yesterday i had a couple of mates come round in the heat to help me out. 

 

pulled the carpet out to clean it

 

dzEBAq5.jpg

 

found the build sheet 

 

vNaRh3C.jpg

 

then one of my mates got stuck into cleaning the carpet for me. 

He also did the floor mats and the boot carpet

 

cSPciSu.jpg

 

<<<< clean on the half...not clean on that half >>>>

 

KNoIELS.jpg

 

and this is where we finished up yesterday before i had to go out. 

 

Bonnet protector fitted, power antenna fitted, bonnet emblem fitted. 

 

lbiR8vh.jpg

 

we started painting the rear windscreen trims but ran out of paint  :( and I had to work all day today, so tomorrow i have a day off so back into. hopefully by tomorrow night ill be able to mount the rear number plate, the wipers, wiper grill and rear window trims 

Share this post


Link to post
Share on other sites
8 minutes ago, deankdx said:

that carpet is amazing!

 

making good progress in this heat, it's written Me off 

im not going to lie, we were sweating from pretty much every part of our bodies imaginable haha 🤢 but the heat didnt stop us lol

Share this post


Link to post
Share on other sites

Today i spent most of my time to work on the car, replacing the inner door belts, which are stapled to the door cards...this was not fun. and i only got 2 done so far.

 

using a dremel tool with a 1.5" cutting disc i carefully cut all the staples away, then pull the door belt off, then pull whats left of the staples out the other side of the door card skin.

 

RgPQFsY.jpg

 

this is what happens to the old belts. they are shagged after removing them. if i had to reuse them, i couldve been a lot more careful, but they were already sun fucked as it was

 

NYyHYeq.jpg

 

the new ones have to be riveted on, because 3 upholsterers i spoke with said nobody has those big staples and staple presses anymore, and they would only rivet them on also, which means carefully drilling new holes also. 

so here it is sitting clamped ready to have holes drilled. 

 

UQyEZrQ.jpg

 

thankfully you dont see the rivets, or how there are a couple of rogue ones where i drilled the holes out of whack :D 

 

8anT5K8.jpg

 

RHR one done. yes it is a little wavey, and thats because they are so soft, they are sensitive to the pull of the pop rivets. but test fitting it on the car proved the glass will straighten it out. 

 

8aknVnb.jpg

 

and driver's door card done. 

 

Hr4ztBH.jpg

 

wMdPF3u.jpg

 

last thing i did was finish spraying the rear windscreen trims for the tail gate, fitted them, and gave them a polish and wax once fitted. 

 

DM2nqFo.jpg

Share this post


Link to post
Share on other sites

did well, the first one i did of those belts i swapped them from xf trims(back in the olden days before they were all stuffed) onto XE trims.. i dug out the old rivets and drilled fine holes in the new(used) belts and refitted the staples. the next one i did similar tied them on with tie wire.. then found out about the rivets. simples but had to bend the door in a couple of spots on a few cars to clear the big rivets i used. 

 

 

Share this post


Link to post
Share on other sites
2 minutes ago, deankdx said:

did well, the first one i did of those belts i swapped them from xf trims(back in the olden days before they were all stuffed) onto XE trims.. i dug out the old rivets and drilled fine holes in the new(used) belts and refitted the staples. the next one i did similar tied them on with tie wire.. then found out about the rivets. simples but had to bend the door in a couple of spots on a few cars to clear the big rivets i used. 

 

 

 

yeah i did the first few rivets on the RHR door card then went and tried it on the car. it seemed to go on ok, so i hope they all do haha

Share this post


Link to post
Share on other sites
2 minutes ago, ESPSIX said:

Get a black texta and colour the rivets, or you see them with the window down.

 

ha shoot. thankfully i havent fitted them yet so i can do that before i fit them i guess. 

Share this post


Link to post
Share on other sites

Dave it was probably more the equipment. Id imagine its a staple press thats needed to get the staples through a layer lf rubber, steel, velour, and fibreglass. Apparently its old tech and nobody uses it now. 

Im sure if i called around 100s of places I might find someone with the right gear, but i dont have the time. 

 

I saw that Bear, i wish that were true lol 

Share this post


Link to post
Share on other sites

The black texta idea is definitely the go for the rivets, I just had a mate point mine out last week and said the same thing.

 I guess I’ll get onto it next time I’m fighting with the door locks haha.

 

Awesome progress mate, looking forward to seeing it.

Share this post


Link to post
Share on other sites
32 minutes ago, user272 said:

The black texta idea is definitely the go for the rivets, I just had a mate point mine out last week and said the same thing.

 I guess I’ll get onto it next time I’m fighting with the door locks haha.

 

Awesome progress mate, looking forward to seeing it.

 

dont get me started on door locks. i spent a day last week with dad helping me trying to figure out why the central locking was going bezerk. Farkin LHF key barrel lock switch was playing up sending the system into a meltdown. all sorted now...i just cant use the passenger door to unlock or lock the car with the key. 

 

as bad as it is, work is super quiet at the moment, which is the only reason ive been able to make good progress on the car. this week i only have saturday off, and I dont start until 1pm today. 
so next week will be a bit of a mad rush, and heavy push to get it finished. 

Share this post


Link to post
Share on other sites

only had a small time to get some bits done this morning. started with installing the new race seat :D 

 

rNlBoRf.jpg

 

thankfully it was only temporary, while i moved the car so i had enough room to re-install the carpet. 
the carpet came up mint for original carpet :D 

 

UVncbh2.jpg

 

driver's seat back in. 

 

5lfXAV1.jpg

Share this post


Link to post
Share on other sites

Oh in other news, I have got the car reinsured with Shannons insurance, along with the Escort and my LR Discovery. 

 

I was worried they wanted to inspect, or see photos, or have a signed letter from the repairer to prove its fixed to prior standard. but no. all the guy on the phone wanted was a detailed description from me as to what was done. 

 

He was more than happy to reinsure the car, knowing it was previously a "total loss". 

Share this post


Link to post
Share on other sites

Even though I was working long hours each day this week, getting home at around 7-730pm, the routine was to eat dinner, then straight into the garage for an hour to get some more done on the car. 

this week i spent each night fitting new exterior door handles...

 

The workshop supervisor wasnt much help though :D  

 

XdPOdEW.jpg

 

today was the last day I had before All Ford Day, where id have my mates available to help me get the stuff done that I wouldnt be able to do on my own. 

 

started with the fuel spill tray...

this is the only one..

 

jhZPWGz.jpg

 

2Un5HDV.jpg

 

this is the new one...

 

Y0gEpDd.jpg

 

mRIoPZR.jpg

 

Then the rear seat. 

 

since the accident, the LH latch for the seat back wouldnt lock in anymore, so tonight after fitting the seat back, i tried adjusting the latch, but no good. turns out the catch on the car must have gotten bent from the impact of the accident, so gave it a few whacks with a steel mallet, and it came good, in fact its a tighter fit than it ever was. the seat used to rattle a bit...not anymore :D 

 

bqqFHwz.jpg

 

and finished off the night with the visor. 

 

kJoW19B.jpg

 

so all the hard shit is done. 

whats left to do? 

- passenger seat

- all the interior plastics

- badges

- rear bumper

- exterior door bash strips

- centre console

- wiper arms

- plenum cover (paint and fit) 

- number plate garnish (paint and fit) 

- rear quarter glass trims need the black section painted ( :( ) 

 

so i still have a bit to do, but its not unachievable 

Share this post


Link to post
Share on other sites

i don't like those spill trays, but My XF wagon had an ugly fuel stain under it because it didn't have one. 

 

doing well with the structured car time. keep that up for as long as possible and you'll be miles ahead in the project game

Share this post


Link to post
Share on other sites

Only had the second half of today to work on the car. 

 

finished off all the painting on the car....

 

Wiper/plenum grille done 

 

the other trim bit is the piece that goes under the rear bumper...

 

uzhLWNZ.jpg

 

fitted, and the bottom windscreen trim fitted also   :D 

 

TiJ7HzS.jpg

 

number plate garnish, mine that i repaired. painted and fitted. 

 

IrzKe62.jpg

 

dcBsqy5.jpg

 

number plate fitted. all the lights are working, so technically i could drive it tomorrow  :D which i might do just around the block

 

xT55jr6.jpg

 

 

the plan for tomorrow is to finish the exterior. so badges on, is really the last thing of the exterior i can do for now. im leaving the rear bar off until i have finished putting the inside together. 

 

 

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

×