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VZ Hardlid Install

Fu Manchu

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Got a hold of a second hand hard lid. Didn't cost a lot, but needed some work.

This is for a Crewman, normal utes are a bit different.

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First I got a photo of how the lock went together.

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I ripped off all the old carpet underneath and removed the old damaged seals.
It was all full of schmutz and rips.

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I chose to use thicker, heavier duty adhesive seals from Clark Blubber, rather than the seal kits which you can get from Holden (pictured for part number) Glad I did too.

I painted all the edges in black satin after cleaning off all the left over crud with a wire brush on the drill. Then on went the new seals.

Next I took measurements of where all the holes were. There are nutserts in the lid for the various fixings.

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I bought the new stretch carpet from Car Builders in Melbourne. Nice and black. Laid out. Then worked into shape.

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I went with Kwikgrip for the adhesive. I normally use 3M High Strength 90. This was a more rudimentary job so Kwikgrip it was. Brushed it on. Used the whole tin. You'll need a bigger tin for a regular lid. The Crewman lid measures 1600mm x 1600mm.

Then I took a look at the hinges and brackets. These were oxidised and crap looking. Cleaned up and painted in wheel silver. They looked mint.

The big hinges were an issue on mine. They were bent. So I found this guide and bent them up to suit. They seem to be the same as those on AU Falcons.
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I had trial fitted the lid and with bent hinges it wasn't working out.
Fitting was all wrong too. The gas struts were being a problem.
I got new struts.

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When I was painting the hardware, I figured I could add some anchors to them.
I also didn't like the factory bolts. Went with some nice gold anodised high tensile ones.
 

Fu Manchu

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I used a longer lock. The first ones were too short.
A mob in Melbourne did some that were perfect and of higher quality.
Fitted up and next was the fitting again.

I couldn't get this right.
Loosened the end hinges and set them forward a fair bit.
Removed the struts this time.
Fit the lid and wangled it into perfect fit. Tightened the hinges laying in the tray.
Screwed on the struts while I was laying in there. Lifted the lid and clipped on the strut. It was enough to hold the whole lid while I did the other side.

The bracket that fits to the cab, and the strut bracket, are going to get nutserts and a thin seal underneath. I hate having self tappers into the body work.
 

Fu Manchu

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I refitted the build plate. I needed the pick to find the holes.
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I found the holes under the carpet using the measurements I took and feeling.
Then used a soldering iron to melt out the holes.

I've attached the install instructions. I found working this out a tiresome puzzle finding bits here and there.
Then I found the install instructions and found they were vague in regard to fitting it true.

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Finished product. I'm going to use some anchors on the forward hinges too. Might even fit a cargo net under it. Note the position of the forward hinges is not ideal in this photo.

Then LED Light and lock solenoids connected to the door locks. Going to make my own.
 

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Fu Manchu

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How it fits up. (Not my car)
Screen Shot 2019-11-03 at 5.01.36 pm.png
 

ant797

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will your plain sale fit into my normal vy ute i been looking for a red one
 

Fu Manchu

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Not sure what you mean?
The lid is 1.6m x 1.6m
 
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