Volvo C304 (4x4) Restore and fitout - WR7002
- Thread starter geckoadventure
- Start date
geckoadventure
Geckoadventure
8 February 2016
Chinese new year Holidays
Arrived monday morning to the pleasant sight of the rear cage and all parts painted that I had left the week before.
Brett stuck the engine and gearbox on the forklift and then left for CNY lunch and said you can install and oh yeah learn to drive the forklift lol.
2 hours later I had it all installed but need new gearbox mount bushes.
Then started on the 18,500lb winch install. Success again took me about 2 hours plus searching and cleaning up parts areas to get stuff out.
Chinese new year Holidays
Arrived monday morning to the pleasant sight of the rear cage and all parts painted that I had left the week before.
Brett stuck the engine and gearbox on the forklift and then left for CNY lunch and said you can install and oh yeah learn to drive the forklift lol.
2 hours later I had it all installed but need new gearbox mount bushes.
Then started on the 18,500lb winch install. Success again took me about 2 hours plus searching and cleaning up parts areas to get stuff out.
geckoadventure
Geckoadventure
9 February
Had assistance from the builder all day and we managed to get the cage installed and bolted down after installing the WARN 12,000lb winch and tightening the 18,00 bolts down correctly.
Then dinner time for both of us and we packed up at 5pm after getting the fuel tank reinstalled yet again and the gear change installed and bolted it. A whole pile of parts washed and a list of parts needed to buy.
Had assistance from the builder all day and we managed to get the cage installed and bolted down after installing the WARN 12,000lb winch and tightening the 18,00 bolts down correctly.
Then dinner time for both of us and we packed up at 5pm after getting the fuel tank reinstalled yet again and the gear change installed and bolted it. A whole pile of parts washed and a list of parts needed to buy.
geckoadventure
Geckoadventure
10 February
Morning starts with washing the dusty parts and yeah playing with the puppy.
And the finl result is washed parts eventually and a half washed puppy
Lunchtime and I have the radiator and the intercooler bolted down everything is connected except hose clamps it all takes time including cleaning out threads etc.
Then late arvo it's all hands on deck to mount the two rear panels while I have been testing that all the front panels are fitting and doing final trimming and I take the second hand 80 Series muffler out for a scrub
At the end of the day what do we have well it's starting to look pretty good. It's time to head off to my chinese mums place and collect wifey for the longg drive home.
Morning starts with washing the dusty parts and yeah playing with the puppy.
And the finl result is washed parts eventually and a half washed puppy
Lunchtime and I have the radiator and the intercooler bolted down everything is connected except hose clamps it all takes time including cleaning out threads etc.
Then late arvo it's all hands on deck to mount the two rear panels while I have been testing that all the front panels are fitting and doing final trimming and I take the second hand 80 Series muffler out for a scrub
At the end of the day what do we have well it's starting to look pretty good. It's time to head off to my chinese mums place and collect wifey for the longg drive home.
piratexpress1369a
Explorer
Progress is looking good stay at it
geckoadventure
Geckoadventure
19 February 2016
Friday morning dashed up the 190K to the workshop and arrived just after the workshop opened at 8.10am
Idea was to run arround and get parts etc ready for Saturday and Sunday
After much running around and forgetting parts I pulled the wiring loom out after shoving the wire eating pupppy outside we layed it out for the morning.
So a the end of Sunday what do we have apart from my employee ringing me and saying my RED truck as funny noises from the rear after they took it offroad. So we pack up early for the 20k run down the road to check it out then another 175k home. Fark TOW TRUCK back to Kuala Lumpur turns out the rear locker
tore itself apart after it was stripped today (Wednesday).
We have a wiring loom sitting in the truck all cable tied up and a few connections done. Rear taillight has a broken bolt and rsuted insides so I need new ones from sweden first.
All the wires hanging out of it. The cabin is not on as there is still issues with the engine area. The 12 alternator took me a day to get it to fit properly and belts fitted inluding 2 trips to the spare parts shop to get them correct.
Little Joe has some fun with the puppy after spending 2 days stripping paint.
Then we have a pile of parts to paint or electropaint and anodize.
Oh yeah then the 2 weekend helpers the stripper and the wire man.
Friday morning dashed up the 190K to the workshop and arrived just after the workshop opened at 8.10am
Idea was to run arround and get parts etc ready for Saturday and Sunday
After much running around and forgetting parts I pulled the wiring loom out after shoving the wire eating pupppy outside we layed it out for the morning.
So a the end of Sunday what do we have apart from my employee ringing me and saying my RED truck as funny noises from the rear after they took it offroad. So we pack up early for the 20k run down the road to check it out then another 175k home. Fark TOW TRUCK back to Kuala Lumpur turns out the rear locker
tore itself apart after it was stripped today (Wednesday).
We have a wiring loom sitting in the truck all cable tied up and a few connections done. Rear taillight has a broken bolt and rsuted insides so I need new ones from sweden first.
All the wires hanging out of it. The cabin is not on as there is still issues with the engine area. The 12 alternator took me a day to get it to fit properly and belts fitted inluding 2 trips to the spare parts shop to get them correct.
Little Joe has some fun with the puppy after spending 2 days stripping paint.
Then we have a pile of parts to paint or electropaint and anodize.
Oh yeah then the 2 weekend helpers the stripper and the wire man.
piratexpress1369a
Explorer
Was it the bracket for the alternator giving you all the stress
geckoadventure
Geckoadventure
yes the 12V made up alternator bracket.
Yes after they welded it up properly it didn't fit properly then the bolt hols did not line up. Then the belt clipped the backet then it had to be heated and whacked etc and then the holes needed to be driller - al 4 of them etc this went on for afternoon and a morning. sigh.
then i got the wrong belt and had to race back at 3.45pm 15 mins before parts shop closed saturday to get another belt lol
totally wasted day in terms of progress.
4 more parts to fit and I can drrop te cabin on finally.
geckoadventure
Geckoadventure
Sunday 6 March 2016
A quick dash up to IPOH. 1hour 15 mins a new record time and the 190k slides by early in the morning air - go ISUZU.
Finally I have the pesky alternator installed after a couple of days effort
Then it's time to lower the cabin bottom onto the chassis after lunch.
And hey 2 hours later we have it sitting on the chassis
The junior driver Joe
OK so I'm happy is installed
Then we install the service ladder for fun
Monday 7 March 2016
I decide to cleanup the items I have been cleaning up at home and get them painted. Grill, Engine cover, PEdals, Air cleaner, front prop shaft etc
Es gives them a coat of axle undercoat black
Then the cabin had to be removed as the turbo cooling sill not worked out properly and the power steering hoses need to be installed.
I pack the doors to take them back to Kuala Lumpur to work on next weekend. Then it's time or the long haul back to KL.
Sunday 12 March 2016
Doors sitting in the ISUZU at home. I am in 2 minds strip the complete outside of the doors or and and add another coat off paint. I decide strip and reunderccoat and top coats as I don't want 6 layers of paint
Doors ready for stripping
A pair of doors now ready for final sanding and a minor repair and then painting.
Stripping the paint revealed 2 war wounds from it's days as a RIOT squad truck I assume from the grills. They will be further sanded down as part of the character being left on the truck.
I have a growing list of parts to get or deal with. Tomorrow is the dash parts to the powdercoaters.
A quick dash up to IPOH. 1hour 15 mins a new record time and the 190k slides by early in the morning air - go ISUZU.
Finally I have the pesky alternator installed after a couple of days effort
Then it's time to lower the cabin bottom onto the chassis after lunch.
And hey 2 hours later we have it sitting on the chassis
The junior driver Joe
OK so I'm happy is installed
Then we install the service ladder for fun
Monday 7 March 2016
I decide to cleanup the items I have been cleaning up at home and get them painted. Grill, Engine cover, PEdals, Air cleaner, front prop shaft etc
Es gives them a coat of axle undercoat black
Then the cabin had to be removed as the turbo cooling sill not worked out properly and the power steering hoses need to be installed.
I pack the doors to take them back to Kuala Lumpur to work on next weekend. Then it's time or the long haul back to KL.
Sunday 12 March 2016
Doors sitting in the ISUZU at home. I am in 2 minds strip the complete outside of the doors or and and add another coat off paint. I decide strip and reunderccoat and top coats as I don't want 6 layers of paint
Doors ready for stripping
A pair of doors now ready for final sanding and a minor repair and then painting.
Stripping the paint revealed 2 war wounds from it's days as a RIOT squad truck I assume from the grills. They will be further sanded down as part of the character being left on the truck.
I have a growing list of parts to get or deal with. Tomorrow is the dash parts to the powdercoaters.
piratexpress1369a
Explorer
Nice progress stay at it
geckoadventure
Geckoadventure
16 March 2016
Managed to get the dash parts to the powder coaters last night turns out its 26k from work so they will be ready next week. For the princely sum of $25USD I get the 3 parts powdercoated.
Have a friend who will cad design the service doors covers for me so we are looking at a cool design for that then it can be laser cut and powder coated at another little engineering shop I had recommended to me from a friend.
Have got some rust kill converter for the two issues I found on the front doors then I can final sand and undercoat the doors.
Managed to get the dash parts to the powder coaters last night turns out its 26k from work so they will be ready next week. For the princely sum of $25USD I get the 3 parts powdercoated.
Have a friend who will cad design the service doors covers for me so we are looking at a cool design for that then it can be laser cut and powder coated at another little engineering shop I had recommended to me from a friend.
Have got some rust kill converter for the two issues I found on the front doors then I can final sand and undercoat the doors.
Last edited:
piratexpress1369a
Explorer
Nice price on the powder coating
geckoadventure
Geckoadventure
19 March 2016
Saturday morning finds me and an assistant Rob at the workshop before 8am collect the keys
greet the happy puppy an then go have breakfast and discuss the plan as Rob has to be back in
KL by 4pm.
Rob preparing the dimensions for the cutting out of the service hatch panels and the
surprise. They are to be laser cut and prepare in the coming weeks.
By lunchtime I have quite a bit of the soundproofing done in the cabin.
It's too hot for the workshop puppy he just lies around stealing stuff and breaking it. 39c
is very hot lol.
Then it's time to take Rob back to KL and then dinner refuel and the nite drive back up. End
of the day 570k travelled.
20 March 016 (Sunday)
I also apply paint stripper to the one door I have to work on and commence to get rid of the
body filler. The black is the rust converter.
More soundproofing work continued.
I gotta get rid of these holes. ooks like the welder has to come out and I have one more to
fix and the roof needs a repaint we found a istake which needs fixing.
Even the front of the window is being soundproofed.
The dogs collection of damaged kit.
Then I mounted the doors and checked alignment - opps some bending required.
Then I install the front windows again and try and find the seal rubbers cannot.
21 March 2016 Monday
The overhead instrument console is layed out getting it ready to take to Rob to get measured
up to get laser cut.
Then it's time to do the console instrument layout check with the new steering wheel. The
console will be remade its not right.
I move onto the overhead console and lay it out until im happy with it. It's also to be
laser cut.
Then the afternoons progress is slowed by the arrival of Nazir who has come to collect the
Volvo's old engine for his C303 restore project. Happy restoring Nazir I will come and visit
you in Taiping soon. That is a cool old Chev pickup he has.
Then the final task for the day is to swap the sneakers and empty more junk from the
workshop wow 7 pieces removed in one day.
Saturday morning finds me and an assistant Rob at the workshop before 8am collect the keys
greet the happy puppy an then go have breakfast and discuss the plan as Rob has to be back in
KL by 4pm.
Rob preparing the dimensions for the cutting out of the service hatch panels and the
surprise. They are to be laser cut and prepare in the coming weeks.
By lunchtime I have quite a bit of the soundproofing done in the cabin.
It's too hot for the workshop puppy he just lies around stealing stuff and breaking it. 39c
is very hot lol.
Then it's time to take Rob back to KL and then dinner refuel and the nite drive back up. End
of the day 570k travelled.
20 March 016 (Sunday)
I also apply paint stripper to the one door I have to work on and commence to get rid of the
body filler. The black is the rust converter.
More soundproofing work continued.
I gotta get rid of these holes. ooks like the welder has to come out and I have one more to
fix and the roof needs a repaint we found a istake which needs fixing.
Even the front of the window is being soundproofed.
The dogs collection of damaged kit.
Then I mounted the doors and checked alignment - opps some bending required.
Then I install the front windows again and try and find the seal rubbers cannot.
21 March 2016 Monday
The overhead instrument console is layed out getting it ready to take to Rob to get measured
up to get laser cut.
Then it's time to do the console instrument layout check with the new steering wheel. The
console will be remade its not right.
I move onto the overhead console and lay it out until im happy with it. It's also to be
laser cut.
Then the afternoons progress is slowed by the arrival of Nazir who has come to collect the
Volvo's old engine for his C303 restore project. Happy restoring Nazir I will come and visit
you in Taiping soon. That is a cool old Chev pickup he has.
Then the final task for the day is to swap the sneakers and empty more junk from the
workshop wow 7 pieces removed in one day.
piratexpress1369a
Explorer
Progress is looking good. ..are you going to sound proof the doors
