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 BF Powered XF Race Car

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Joshy351
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PostSubject: BF Powered XF Race Car   Mon Nov 28, 2016 6:09 am

So I have been keen on getting onto the Barra conversion bandwagon!  Me and Mel have had the plans to build a race car for years out a XF we dragged out of a scrap heap.  Because of family matters we couldn't get the project finished.  Several years down the track and we are glad we waited because everything happens for a reason.  Those in between years I just focused on the XD and done a full rebuild and raced it hard for the last 2 year but its time to put her to rest before anything bad happens because I was pushing it hard in the end.  The last thing I want to do is put my DJR signature XD into a wall or something.  With Mel getting more and more interested in racing also wants a car to race but refuses to race my XD because of sentimental reasons behind the car.  So finding a XF in the scrap heap all those years ago is a god send for a pure racer project.  I found a excellent condition 2007 BF Falcon conversion for $750.  Parts include:

190 Engine with 130,000 ks on the clock with papers and proof of the cars services
Full wiring loom including relay box
The whole cooling system including radiator and fan
Spanish Oak Computer
Starter Motor
Power steering pump and lines, air-con pump
Throttle pedal
BF Dashboard cluster
Air Box and piping
Exhaust engine pipe with cat and a muffler
Labor to pull it all from the car.  I didn't do a thing!
and if there is anything else I need of the car I'm welcome to go back and get whatever I need for no extra.

I have also purchased:

X-Series Roll cage - $200
XG ute sway bar $25
Xg ute power steering lines - $20 (with mini cooler)

Next on the list:

XG ute engine mounts ($20)
XG ute power steering box (I may have one yet)
Au Falcon T5 Gearbox and Bellhouseing + BA Clutch and Flywheel - all together $440
XF Dashboard cluster
Get wiring loom modified to Stand alone loom $800

Stuff I have!

XF T5 gearbox and mounts
XF pedal box
EL Diff and modified tail shaft
EL Fuel pump and loads of other EL stuff

Here are the pics so far!

The donor car!









This car didn't make its 166000 ks service which was due this month.  It was pranged in July.

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PostSubject: Re: BF Powered XF Race Car   Mon Nov 28, 2016 6:19 am

The Engine is out ready for pic up!











Mel was very excited to get her new motor,  Just the glare was in her face lol





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PostSubject: Re: BF Powered XF Race Car   Mon Nov 28, 2016 6:43 am

The roll cage.  I have started to give the pipe work a quick polish just to brighten it up a bit!







And unloading the Barra.  We were playing funny buggers telling everyone we caught a Barra so big we had to get it fork-lifted into the Colorado lol





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PostSubject: Re: BF Powered XF Race Car   Mon Nov 28, 2016 8:02 am

One of the things that had me sold on this conversion was how good the oil is in the engine.  Its so clean and dead on the full mark.  (the oil ran back up the dip stick a little bit when taking the pic.)  I had to have this engine.  I will do a full oil and filter change on it before start up.





Its just so tidy and clean!



Some of the other stuff!



A T5 that came out of a XF (had it for years) could be useful for some things like rear mount and clutch cable mounts.  It has a modified EL tail-shaft hanging out of it which was spare for the XD.



More parts!



XG Swaybar



XG power steering lines and cooler!   That was a cool score!



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PostSubject: Re: BF Powered XF Race Car   Mon Nov 28, 2016 8:19 am

Ok so going back in time about 2011ish.  We pulled this XF from the scrap heap.  Some people may remember our old original Thread on X-Falcon about our xf racer we called Drift-XF.  I may still use it for a drift session or 2 once we turbo it in the future but for now to concentrate on just sprints and track days.

So we are going to use the XF Body kit I have for it.  Minus the bonnet scoop.







I drove it up to the shed to kick out some crap!





Mels turn!



Last edited by Joshy351 on Mon Dec 05, 2016 7:04 am; edited 1 time in total
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PostSubject: Re: BF Powered XF Race Car   Mon Nov 28, 2016 8:31 am

so we got it sprayed in high fill and this is about where things came to a halt on this project back somewhere 2011-2012.  We are going to pick up the car and bring it home to Rockhampton in less then 2 weeks so we are getting real excited!  We may have to strip it completely back and re-undercoat but that shouldn't be to big of an issue.  The paint doesn't have to be summernats quality, just tidy enough for passing scrutineer at the track days.  We have a paint scheme sorted but we will revel that at the end

I have all the side skirts and the other parts of the body kit stored away.









Big hole that has to get fixed!  Not looking forward to that bit!

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PostSubject: Re: BF Powered XF Race Car   Mon Nov 28, 2016 1:05 pm

The floor in this thing is awesome!  Hope its still the same!





She was originally gold but someone went crazy with the red paint!

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PostSubject: Re: BF Powered XF Race Car   Wed Nov 30, 2016 6:31 am

Just a quick update!  I got all the wiring out and got it ready to send to JB Automotive Electrical.  Should have it back in about 3 weeks which is perfect.  We are picking up the XF in a week and a half time.  I should be able to get the Crossflow and auto out and get the engine bay painted.

This is the engine bay wiring loom (needed) and the alternator wires. The relay box wiring loom and computer Jb doesn't need, the throttle peddle is there too.



This one is getting sent



Now to get the engine wiring off the motor!  Man that was a tricky job.  Hope I remember how it all goes back on.



and its off.  Wow that was a mission.  I had to remove the aircon pump to get one wire out.



And this is whats getting sent away.



all packaged up and ready to go to JB Automotive Electrical.

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PostSubject: Re: BF Powered XF Race Car   Tue Dec 20, 2016 5:40 am

Ok so here is a huge update!  A week and a half ago we ventured down to Maryborough where our race car shell was located and picked it up.  We took the XE (The Sheriff) down to get it stored away safely while we build the race car.  Otherwise we would have to many cars at the one place.  I really need a massive shed lol.


Off to Mary Land we go!



Storing the Sheriff







Drag out the race car shell!







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PostSubject: Re: BF Powered XF Race Car   Tue Dec 20, 2016 5:49 am

Getting some air in the tires!



Ripped out an EL Diff from an old wreck.





Mel and Dad collecting up some parts!





Me and dad getting the old crossflow to go so we can load it on the Tilta Trailer.





Got it going!  But it had a sticky needle and seat.  Now bolt on a bonnet

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PostSubject: Re: BF Powered XF Race Car   Tue Dec 20, 2016 6:12 am

Strap her down and time to head home to Rockhampton.







We stopped in at Hervey Bay to see more family and to collect more parts including my XF Body kit!  Its going to look tough as hell!!





Back home in Rockhampton after 3 days of cars and partying with family and friends for an early Christmas because I have to work the whole Christmas period.









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PostSubject: Re: BF Powered XF Race Car   Tue Dec 20, 2016 6:21 am

And into its hidy hole lol. Im use this tarp untill my new roof Im getting made arrives. Its going to repel hail its going to be that strong hehe.





Unloading the EL Diff.







Playing around with the body kit and deciding how we want it to look.





Christmas has come early with some wheel dolly's, a car cover and some new sidewalls for the temp shed.



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PostSubject: Re: BF Powered XF Race Car   Tue Dec 20, 2016 6:27 am

The wiring harness is on its way back to me frome JB Automotive Electrical.



I done some research on the XF and this is how it would have looked like out of the factory.



And my new roof arrived that repels hail. This meterial is so strong it should out last the metal frame! lol

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PostSubject: Re: BF Powered XF Race Car   Wed Dec 28, 2016 7:37 am

Hi everyone time for a quick update.  So this morning I picked up the T5 gearbox from the wreckers.  This box came from an AU xr6 ute.  I also have the clutch, flywheel and sandwich plate.  I also got a clutch from a BA xr6 ute and noticed that there are a few differences.

Here is the new AU XR6 T5 Gearbox







Here is the AU clutch and flywheel



And the BA clutch and flywheel



Both together



The first thing I noticed was that the thickness of the flywheels look different.  And the stud pattern between the Au and the BA are different as well.



I hope this doesn't hinder the fitment of the AU box too much.  Im hoping to run the BA flywheel and get a clutch plate to suit the au box.  I will still need a pilot bearing and a clutch cable.
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PostSubject: Re: BF Powered XF Race Car   Thu Dec 29, 2016 6:01 am

Ok so this morning I was mucking around in the shed and I really needed to know if this AU clutch and flywheel was going to work for me.  Yesterday when I was at the wreckers picking up the box and clutch I was compareing the flywheels from AU to BA and the seamed to be different stud patterns.  So I thought I would try and bolt the AU Flywheel onto the barra anyway just to be sure.  And guess what it bolted on no problem.  I figured out that the way I was comparing the flywheels back to back one hole would never line up Rolling Eyes lol.  So I dummy fitted the clutch and gearbox to see how it all fits.  Looks mad can't wait to get it into the XF.







Looks awesome!



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PostSubject: Re: BF Powered XF Race Car   Thu Dec 29, 2016 6:10 am

Oht OH!  No hole for the clutch cable.  Going to have to do some drilling by the looks of it.!







The whole drive train.  I had this EL tailshaft cut down for the XD but we cut it to short.  But I think it will work perfect for the XF setup.



Looks the goods!

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PostSubject: Re: BF Powered XF Race Car   Thu Jan 05, 2017 8:30 am

Ok just before I left for my new years eve holidays I had my stand alone wiring harness turn up at my door step!  Lucky I noticed it there other wise it would have sat there for 3 days lol.  









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PostSubject: Re: BF Powered XF Race Car   Thu Jan 05, 2017 8:39 am

So yesterday and today I done the tedious job of sorting out what plug goes where.  Wow what a mission.  A lesson learned here make sure you mark and number your plugs before taking them off lol.

This one is not an injector plug.








And its all connected.





Bugger I broke a the cam sensor clips!  Any suggestions on how I could fix them?
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PostSubject: Re: BF Powered XF Race Car   Thu Jan 05, 2017 8:44 am

I also put together my wheel dollies.  I was giving the missus heaps and said I was building car stuff on our expensive rug hahah.



I also removed all the heater hoses.  It made the wiring easier to put on and plus being a race car we wont be needing a heater.  So I'm going to block off these hole with a welsh plug.


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PostSubject: Re: BF Powered XF Race Car   Mon Jan 09, 2017 3:25 am

And so if begins!!

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PostSubject: Re: BF Powered XF Race Car   Mon Jan 09, 2017 7:36 am

And it has been plucked from the bay!

Some serious angle on the lift lol





Tranny fluid went everywhere but hey its out!

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PostSubject: Re: BF Powered XF Race Car   Tue Jan 10, 2017 9:49 am

So I completely strip out the engine bay today!





Ripped out all the heater box and aircon.



Im going to mount the computer up in here.



And mount all the relays along those flat bits.  Should look awesome!

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PostSubject: Re: BF Powered XF Race Car   Thu Jan 12, 2017 8:07 am

I went on a little parts mission this morning!

Picked up the BF fuel pump,  Got the flywheel machined and picked up the flywheel bolts from Ford.



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PostSubject: Re: BF Powered XF Race Car   Mon Jan 23, 2017 3:28 pm

Time for a quick update for you guys!

I kick out the back windscreen.  It came out just as quick as I can type this lol





started to sand down the engine bay!



sanded off all the scaly paint!







Fixed the dent in the back door.



and cleaned up all the rust holes.  I'm getting a quote tomorrow to see how much it is to fix them.





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PostSubject: Re: BF Powered XF Race Car   Mon Jan 23, 2017 3:33 pm

Me and Mel dummy fitted the roll cage this afternoon as well.







She also cleaned off all the old insulation off the roof.

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