Volvo C304 (4x4) Restore and fitout - WR7002
- Thread starter geckoadventure
- Start date
geckoadventure
Geckoadventure
I am going to line the whole interior with soundproofing materiaal. Then cover the rear with the same alloy laminate pnels and the remaining expoed roof also. All the panels to be fitted with flat button bolts to rivnuts to give it that mechanical look. The consoles all to be powdercoated in matt black.
The engine area to be covered in a canvas which will clip on.
The floor areas will have a removeable alloy tray added over the soundproofing for boots/mud/water etc.
I will probably paint the alloy composite also same colour as the truck.
Also toying with recovering the seats in leather.
The rear cabin will get a layer of light sound proofing/insulation material as the roof is 3mm alloy sheet. Then a composite alloy later will be used to cover the inside frame same as the front.
The engine area to be covered in a canvas which will clip on.
The floor areas will have a removeable alloy tray added over the soundproofing for boots/mud/water etc.
I will probably paint the alloy composite also same colour as the truck.
Also toying with recovering the seats in leather.
The rear cabin will get a layer of light sound proofing/insulation material as the roof is 3mm alloy sheet. Then a composite alloy later will be used to cover the inside frame same as the front.
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geckoadventure
Geckoadventure
Um at present no. Rear for the exhaust and heat potential. Roof for rain and heat. Same for front
D
Deleted member 9101
Guest
My grandpa bought one new in 1976 and it was in our family until a few years ago. The little thing always started up and ran great... got a bit rusty though...lol.
geckoadventure
Geckoadventure
26 March 2016
First task connect the Powersteering inspection reveals the banjo bolt is missing hmmmmmmmmmm I
know just the shop. A quick run down to the parts street gets me the parts I need 8mm 12mm and
10mm hoses and connectors etc
Then the task of fitting the turbo water inlet. Since we had to chop the top of the thermostat
housing off which contained the turbo cooling inlet and outlet taps. We have a donor location
from the left side of the engine unfortunately. Worked it all out another trip to the hydraulic
shop and the same assistant lol.
On the way back I drop into a chop shop collect 12 military boxes and 6 special ones. Reveal on
these later and also pickup a diesel filter and housing as this was missing from the engine
when I bought it.
More puppy damage a new scraper destroyed before I even used it.
Then the arduous task of removing the broken sump bolt. Drill it out then try and find the
eaziouts I bought in the morning. Searched for ages could not find. In frustration I climb the
office stairs and then spy a pile of rubbish near the Landrover and investigate yes the eazi
out packaging destroyed along with the plastic case.
Recover the eazi outs and finally have the errant bolt out. Victory finally. Now sump can have
the oil temp sender fitted and fit it back.
Turbo cooling hoses connected. The turbo shielding needs work. Will install this one and build
another fancier one out of alloy in coming weeks as this one has transport damage.
The left side of the engine almost completed change al of the vacccum hoses to new blue silicon
until I ran out more needed. Only 2 pipes need sorting out still. Power teering pump hoses all
connected - mounts to cabin but that may change soon as engine needs to drop out as a complete
unit from the cabin.
Hometime 7.15pm and long horrid drive home ensures in the dark. The brakes stink by the time I
get to the restaurant in KL by 9pm from the heavy braking from 150-170kph constantly.
First task connect the Powersteering inspection reveals the banjo bolt is missing hmmmmmmmmmm I
know just the shop. A quick run down to the parts street gets me the parts I need 8mm 12mm and
10mm hoses and connectors etc
Then the task of fitting the turbo water inlet. Since we had to chop the top of the thermostat
housing off which contained the turbo cooling inlet and outlet taps. We have a donor location
from the left side of the engine unfortunately. Worked it all out another trip to the hydraulic
shop and the same assistant lol.
On the way back I drop into a chop shop collect 12 military boxes and 6 special ones. Reveal on
these later and also pickup a diesel filter and housing as this was missing from the engine
when I bought it.
More puppy damage a new scraper destroyed before I even used it.
Then the arduous task of removing the broken sump bolt. Drill it out then try and find the
eaziouts I bought in the morning. Searched for ages could not find. In frustration I climb the
office stairs and then spy a pile of rubbish near the Landrover and investigate yes the eazi
out packaging destroyed along with the plastic case.
Recover the eazi outs and finally have the errant bolt out. Victory finally. Now sump can have
the oil temp sender fitted and fit it back.
Turbo cooling hoses connected. The turbo shielding needs work. Will install this one and build
another fancier one out of alloy in coming weeks as this one has transport damage.
The left side of the engine almost completed change al of the vacccum hoses to new blue silicon
until I ran out more needed. Only 2 pipes need sorting out still. Power teering pump hoses all
connected - mounts to cabin but that may change soon as engine needs to drop out as a complete
unit from the cabin.
Hometime 7.15pm and long horrid drive home ensures in the dark. The brakes stink by the time I
get to the restaurant in KL by 9pm from the heavy braking from 150-170kph constantly.
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geckoadventure
Geckoadventure
3 April 2016
Quick trip up Sunday morning to Ipoh 190k whizzes past quite fast.
Today's goal is to finish the soundproofing in the cabin and then move on to whatever is left.
First install the last turbo cooling pipe adapter for the 10mm to 8mm tubes.
My helper today is little Jo.
We both tackle the soundproofing until we realise we are out with 1-2 sheets needed. The little cabin has consumed 8 sheets. So we move onto the doors and remove the door handles ready for powdercoating.
Then the puppy decides he wants lots of attention from Joe
Seats are fixed up after we realise a base is not screwed in corretly.
Then the doorhandles are stripped with the wire wheel.
End of the day we have 90% of the soundproofing done.
Suddenly it's hometime.
Quick trip up Sunday morning to Ipoh 190k whizzes past quite fast.
Today's goal is to finish the soundproofing in the cabin and then move on to whatever is left.
First install the last turbo cooling pipe adapter for the 10mm to 8mm tubes.
My helper today is little Jo.
We both tackle the soundproofing until we realise we are out with 1-2 sheets needed. The little cabin has consumed 8 sheets. So we move onto the doors and remove the door handles ready for powdercoating.
Then the puppy decides he wants lots of attention from Joe
Seats are fixed up after we realise a base is not screwed in corretly.
Then the doorhandles are stripped with the wire wheel.
End of the day we have 90% of the soundproofing done.
Suddenly it's hometime.
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geckoadventure
Geckoadventure
9 April 2016 - Saturday
3 day to IPO starts with a late Friday night trip to Ipoh as it'ss last weekend of Cheng Meng (chinese grave cleaning). Traffic is ****.
Fit the powdercoated left side of the dash but the bolt holes don't line up looks like I gottaa make another an oversight it's 30 mm too low so there is a gap between the dash and the window frame.
Then I fit the centre console for a fit before putting in the fuse box and wiring.
I also need to go get 5mm button bolts we have none in the shop.
Then it's time to put the new power steering together for a dry fit as I try to round up the parts. Takes me a while to figure it out. Then I have 3 parts still to find. Find them when Brett turn up later on Saturday evening in a box I would have not looked in lol. Dry fit completed.
Then I pull out of the parts boxes a much needed bonus a 180degree bend and it fits the turbo bonus.
10 April 2016 - SUnday
Remaking panel time. The errant panel being recut.
Fit the fuse box's and wiring to the centre console.
After lunch its fitted to the cabin
Then I look at the right side of the dash and decide mods are needed fo the warning lights.
Remaking time 20 minutes later I have the rough shape ready.
A few spare minutes gives me time to remove the rest of the body filler from the door to expose the reason for the body filler. Pop rivets from the police screens just body filler over. They will now be drilled out and filled with lead over the coming weeks a home.
11 April 2016 - Monday
By lunchtime I have the air cond blower holes ready and working and the bolt holes drilled to match this time.
Power steering fit test damn the 90deg fittings have to go and be replaced by straight ones.
Then the big mistake - someone left the top panel of the centre console on the floor for a couple of years its ruined with moisture. I have to remake and out of 2mm alloy this time not 1mm.
The truck looks a lot more complete.
Then it's hometime its 6pm.
3 day to IPO starts with a late Friday night trip to Ipoh as it'ss last weekend of Cheng Meng (chinese grave cleaning). Traffic is ****.
Fit the powdercoated left side of the dash but the bolt holes don't line up looks like I gottaa make another an oversight it's 30 mm too low so there is a gap between the dash and the window frame.
Then I fit the centre console for a fit before putting in the fuse box and wiring.
I also need to go get 5mm button bolts we have none in the shop.
Then it's time to put the new power steering together for a dry fit as I try to round up the parts. Takes me a while to figure it out. Then I have 3 parts still to find. Find them when Brett turn up later on Saturday evening in a box I would have not looked in lol. Dry fit completed.
Then I pull out of the parts boxes a much needed bonus a 180degree bend and it fits the turbo bonus.
10 April 2016 - SUnday
Remaking panel time. The errant panel being recut.
Fit the fuse box's and wiring to the centre console.
After lunch its fitted to the cabin
Then I look at the right side of the dash and decide mods are needed fo the warning lights.
Remaking time 20 minutes later I have the rough shape ready.
A few spare minutes gives me time to remove the rest of the body filler from the door to expose the reason for the body filler. Pop rivets from the police screens just body filler over. They will now be drilled out and filled with lead over the coming weeks a home.
11 April 2016 - Monday
By lunchtime I have the air cond blower holes ready and working and the bolt holes drilled to match this time.
Power steering fit test damn the 90deg fittings have to go and be replaced by straight ones.
Then the big mistake - someone left the top panel of the centre console on the floor for a couple of years its ruined with moisture. I have to remake and out of 2mm alloy this time not 1mm.
The truck looks a lot more complete.
Then it's hometime its 6pm.
geckoadventure
Geckoadventure
16 April 2016 - Saturday
Everything goes bad wake up late, on road late by 75 min and hit the 7am traffic 2.5 hours later one frustrated KIWI with a ISUZU with hot brakes pulls up at the workshop with a happy puppy delighted to see me. Oh yeah and the wife came along to visit her mum in IPOH also ************** the whole way about my driving.
After the morning Mum greetings etc. Down to the worksop. First parts collection go fix the power steering hoses and swap the elbow bends for straights and get them relamped and purchase gasket glue for fitting the sump. Then the air conditioning hose needs to be found and purchased that turns into nightmare 2 shops dissappear into dead ends with WAZE and then I fluke a 4x4/air cond shop however since my car is not being serviced by them the service guy starts yelling at the shop lady in cantonese and I stand there lisening to strings of cantonese being rattled off like a machine gun. Eventually she rings someone I assume the shop owner and I get 8 feet for an outrageous price. Then need bolts over to the bolt shop for a minor success. it's now 1pm when I arrive at workshop again so straight to lunch instead. Actually it's LUNCH from FRIDAY and DINNER and SATURDAYS breakfast. Yeah yesterday was a ***** in the office.
First job create a J bracket to hold the blower as curently it HANGS by 2 brackets. Yeah
someone did not finish the blower stuff off properly. Takes me all arvo to create this as I not want to drill a hole in the front of the CABIN as that was the easy way to create a rust hole later. So it take 4 hours of stuffing around just after 5pm I have a nasty bracket made up ready to paint.
Painted and drill 2 holes up under the dash mount the 2 RIVNUTs and then it all bolts together and the blower hoses also fit however we will need to put the window wiper arms in there is no room. So I will have to make up 2 Y joints for the drivers side to provide more space for the wiper kit. The blower doen't shake so the design holds up.
The hoses in place ready for the air conditioning contractor to finish off.
The clutchmaster cylinder and the master brake booster etc have also been fitted and still needs a little finishing.
6pm time fed the puppy etc now to find a hotel and food. Now that's a bad idea 4 beers and a nice chinese later I literaly stagger upstairs for a well eaned proper sleep. Wife went home in the train.
Tomorrow is the air conditioning condenser fit.
17 April 2016 - Sunday
Morning no breakfast woke up too late. Faactory is opened for me 8.30am 9.00am I come back from breakfast to start.
Todays task make these 4 pieces into one joined unit and bolted to the service hatch. Intercooler, Air cond condenser and the shroud and the fan.
The fan has nothing its bare. So 10 brackets (and 10 round down bolts made up) need to be made and fit the shroud to the air cond condenser and the condenser to the intercooler.
I finish about 5pm and bolting it down the FAN Breaks damn, falling off a few months back and hitting Pete on the head then the floor cracked it. Now I gotta order a new one.
Then it's time to fit the sump after sitting on the shop floor for 3 years. I can fill it with oil next trip.
Next trip is on 7th May. I have charity work next weekend and then 4x4 driver training the May long weekend. I take the doors home with me for leading at home.
Parts ordered for clutch slave cylinder and copper piping to connect it all up. I will also start the brakes and next trip finish the gearbox mounts and all the small things needing to be done. Next round of Tanaka parts will have been ordered and shipped.Oh yeah the fan is ordered and ready to pickup.
Centre console will be ready and as also will the speaker brackets along with the service hatch panels all of the above being lazer cut.
7pm hometime its a crawl 3 hours home.
Everything goes bad wake up late, on road late by 75 min and hit the 7am traffic 2.5 hours later one frustrated KIWI with a ISUZU with hot brakes pulls up at the workshop with a happy puppy delighted to see me. Oh yeah and the wife came along to visit her mum in IPOH also ************** the whole way about my driving.
After the morning Mum greetings etc. Down to the worksop. First parts collection go fix the power steering hoses and swap the elbow bends for straights and get them relamped and purchase gasket glue for fitting the sump. Then the air conditioning hose needs to be found and purchased that turns into nightmare 2 shops dissappear into dead ends with WAZE and then I fluke a 4x4/air cond shop however since my car is not being serviced by them the service guy starts yelling at the shop lady in cantonese and I stand there lisening to strings of cantonese being rattled off like a machine gun. Eventually she rings someone I assume the shop owner and I get 8 feet for an outrageous price. Then need bolts over to the bolt shop for a minor success. it's now 1pm when I arrive at workshop again so straight to lunch instead. Actually it's LUNCH from FRIDAY and DINNER and SATURDAYS breakfast. Yeah yesterday was a ***** in the office.
First job create a J bracket to hold the blower as curently it HANGS by 2 brackets. Yeah
someone did not finish the blower stuff off properly. Takes me all arvo to create this as I not want to drill a hole in the front of the CABIN as that was the easy way to create a rust hole later. So it take 4 hours of stuffing around just after 5pm I have a nasty bracket made up ready to paint.
Painted and drill 2 holes up under the dash mount the 2 RIVNUTs and then it all bolts together and the blower hoses also fit however we will need to put the window wiper arms in there is no room. So I will have to make up 2 Y joints for the drivers side to provide more space for the wiper kit. The blower doen't shake so the design holds up.
The hoses in place ready for the air conditioning contractor to finish off.
The clutchmaster cylinder and the master brake booster etc have also been fitted and still needs a little finishing.
6pm time fed the puppy etc now to find a hotel and food. Now that's a bad idea 4 beers and a nice chinese later I literaly stagger upstairs for a well eaned proper sleep. Wife went home in the train.
Tomorrow is the air conditioning condenser fit.
17 April 2016 - Sunday
Morning no breakfast woke up too late. Faactory is opened for me 8.30am 9.00am I come back from breakfast to start.
Todays task make these 4 pieces into one joined unit and bolted to the service hatch. Intercooler, Air cond condenser and the shroud and the fan.
The fan has nothing its bare. So 10 brackets (and 10 round down bolts made up) need to be made and fit the shroud to the air cond condenser and the condenser to the intercooler.
I finish about 5pm and bolting it down the FAN Breaks damn, falling off a few months back and hitting Pete on the head then the floor cracked it. Now I gotta order a new one.
Then it's time to fit the sump after sitting on the shop floor for 3 years. I can fill it with oil next trip.
Next trip is on 7th May. I have charity work next weekend and then 4x4 driver training the May long weekend. I take the doors home with me for leading at home.
Parts ordered for clutch slave cylinder and copper piping to connect it all up. I will also start the brakes and next trip finish the gearbox mounts and all the small things needing to be done. Next round of Tanaka parts will have been ordered and shipped.Oh yeah the fan is ordered and ready to pickup.
Centre console will be ready and as also will the speaker brackets along with the service hatch panels all of the above being lazer cut.
7pm hometime its a crawl 3 hours home.
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geckoadventure
Geckoadventure
17 May 016
Not much to report
Attended a medical mission in the jungle so lost a weekend.
Then took a bunch of kids from the orphanage for May day weekend to the beach for camping so lost a weekend but the kids are more important.
Then I got sick turns out is the heart again (however this time I could not feel the irregular beat) so I have lost 2 weekends working on the truck however spending 3 days in hospital and then a week off work gave me time to work on stuff
doodled the fridge and campin kitchen slideouts all I need is a couple of dimensions to finish it and get it lazer cut and then construct it.
Then I managed to purchase the first batch of switches I need for the switch panel.
The doodled slide out panels plan. Test bearings etc have been obtained so I can test measurements and bolt/nut configurattions.
If i'm OK this weekend and the heart stops beating as irratically this week then I will go work on the truck. Else I will be doodling a final plan for the slide out drawers.
Not much to report
Attended a medical mission in the jungle so lost a weekend.
Then took a bunch of kids from the orphanage for May day weekend to the beach for camping so lost a weekend but the kids are more important.
Then I got sick turns out is the heart again (however this time I could not feel the irregular beat) so I have lost 2 weekends working on the truck however spending 3 days in hospital and then a week off work gave me time to work on stuff
doodled the fridge and campin kitchen slideouts all I need is a couple of dimensions to finish it and get it lazer cut and then construct it.
Then I managed to purchase the first batch of switches I need for the switch panel.
The doodled slide out panels plan. Test bearings etc have been obtained so I can test measurements and bolt/nut configurattions.
If i'm OK this weekend and the heart stops beating as irratically this week then I will go work on the truck. Else I will be doodling a final plan for the slide out drawers.
piratexpress1369a
Explorer
Keep your health up and get better. ..slide outs will be cool to see
geckoadventure
Geckoadventure
21 May 2016
After 2 weeks rest 3 days in hospital 6 days off work resting my heart and new medication i'm back in action.
First the sad news while I was typing in the last report I head a noise outside at 7am and thought thats a window smashing then I heard a car wheel spinning away I go to go to work and I see my ISUZU window lying on the road. new toll tag, GPS and card camera gonefark.
Late start up to IPoh 190K away and the 7am traffic is bad yeah I left an hour late and hit the idiot traffic. 9am arrive workshop to be greated by the ever growing happy puppy.
I work on mounting the diesel filter to a new location on the motor with a new alloy bracket and then fix up the hoses to the fuel pump, breather hose and fuel return connect the sender unit and we hunt down batteries to collect Monday.
For the last hour I pull the doors and start sanding them down and seeing how to pull the windows out and fill the engine with oil and top up the radiator.
22 May 2016
First job of the morning for my assistant is to fit the gas struts for the doors while I work on stripping the windows out of the doors and preparing the central locking bolt threads etc from the galvanising. Everyhing has to be drilled and retapped.
I spy a water leak in the radiator it needs to be removed and repaired next week. The engine is hand turned and seems to be ok.
Doors can finally stay open unassisted.
I lead filled 2 holes and still have about 8-10 more from the old riot squad grills on each door to fix.
My assistant getting lessons on how to wire wheel fine rust away. 400 grit and hen 600 and then 1000 grit sandpaper is next before painting.
The doors working by themselves. Now I gotta go get a new set of gas struts all with rose joints in them.
Then we put in the new gearbox rubber mounts.
Then its time to take the 1 day assistant back to KL and return.
23 May 2016
Monday first job run off to the battery shop and hydraulic shop. Come back 2pm witht he stuff I need and then realise I forgot battery terminals. The day is wasted when I return at 4.30pm only time to setup a a small amount of the work needed to get the engine started before the 6pm cutoff.
All I got done was to tighten the fuel tank fittings up and then get the batteries into place and started to connect them up. Now I gotta make square rubber gaskets for the fuel tank covers
Batteries connected except the posative wire.
So what was done. Doors attacked yet again, Fuel tank ready to go just fuel pump to weld in brackets and connect up. Gearbox mounts. Doors holding up by themselves.
After 2 weeks rest 3 days in hospital 6 days off work resting my heart and new medication i'm back in action.
First the sad news while I was typing in the last report I head a noise outside at 7am and thought thats a window smashing then I heard a car wheel spinning away I go to go to work and I see my ISUZU window lying on the road. new toll tag, GPS and card camera gonefark.
Late start up to IPoh 190K away and the 7am traffic is bad yeah I left an hour late and hit the idiot traffic. 9am arrive workshop to be greated by the ever growing happy puppy.
I work on mounting the diesel filter to a new location on the motor with a new alloy bracket and then fix up the hoses to the fuel pump, breather hose and fuel return connect the sender unit and we hunt down batteries to collect Monday.
For the last hour I pull the doors and start sanding them down and seeing how to pull the windows out and fill the engine with oil and top up the radiator.
22 May 2016
First job of the morning for my assistant is to fit the gas struts for the doors while I work on stripping the windows out of the doors and preparing the central locking bolt threads etc from the galvanising. Everyhing has to be drilled and retapped.
I spy a water leak in the radiator it needs to be removed and repaired next week. The engine is hand turned and seems to be ok.
Doors can finally stay open unassisted.
I lead filled 2 holes and still have about 8-10 more from the old riot squad grills on each door to fix.
My assistant getting lessons on how to wire wheel fine rust away. 400 grit and hen 600 and then 1000 grit sandpaper is next before painting.
The doors working by themselves. Now I gotta go get a new set of gas struts all with rose joints in them.
Then we put in the new gearbox rubber mounts.
Then its time to take the 1 day assistant back to KL and return.
23 May 2016
Monday first job run off to the battery shop and hydraulic shop. Come back 2pm witht he stuff I need and then realise I forgot battery terminals. The day is wasted when I return at 4.30pm only time to setup a a small amount of the work needed to get the engine started before the 6pm cutoff.
All I got done was to tighten the fuel tank fittings up and then get the batteries into place and started to connect them up. Now I gotta make square rubber gaskets for the fuel tank covers
Batteries connected except the posative wire.
So what was done. Doors attacked yet again, Fuel tank ready to go just fuel pump to weld in brackets and connect up. Gearbox mounts. Doors holding up by themselves.
Last edited:
piratexpress1369a
Explorer
Hope you are feeling fine. .Great work. ..stay at it
geckoadventure
Geckoadventure
28 May 2016
I have an assistant this weekend. We are on time for the 190K drive to IPOH so I stop 40K up for DONUGHTS 40 minutes to go the lasst 45K to the workshop EASY.
**** buying the doughnuts takes forever then on exit from the roadstop TRAFFIC JAM. WAZE states accident 570 metres away 30 minutes wait. NO NO NO NO !
So here is the reason I was 30 minutes late to the workshop. Takes a LOT of skill to hit the bridge and only put both front wheels over the edge. Stupid prick was out with the insense and on his knees praying frantically and rocking back and forth as we crawl by at 9.00am.
So first items trip to the Hydraulic shop for last minute stuff and the 12v battery is purchased. Back to workshop damn its lunchtime so lunch first.
Joy works on the doors sand first and we fill the separation tubes full of WD40 so we can attempt door splitting later today.
Someone sends me pics HEY your on TV with the fishing video
So here it is
[URL="http://www.geckoadventure.net/Images30/5_Tourism_Malaysia_Angling_Paradise.wmv[/URL]
Stupid PLUG for the Injector pump.
We fill the tank with DIESEL. NO NO NO everyone forgot the bottom BUNG which is impossible to see is missing, 10 litres of diesel runs all over the floor and $50rm of KITTY litter needed to soak it up. Another item to get from the hydraulic shop next saturday.
29 May 2016
We work on the doors by 10.15 we have one door split. Its a lot of work. A Bar the right size to slip up inside the tube gentle tapping to push the inside tube up and we have to cut one tube out to get to the inside tube and lots of WD40.
Then I decide I need to cut the panel open to see how much rust is inside the panel. Sure enough my guess is correct. I will make a cover panel up later to replace the cut out panel. Anyone else with a VOlvo should look at doing this also. Rust converter and undercoat etc will be needed on rebuild to prevent a reocccurance.
The cutout panel hmmmmmmm perfect.
We go to lunch and cannot find the puppy to lock him out so leave him in the Factory. Bad move. Return to a bag of 500 cable ties all over the floor. New VOlvo Fan dragged on the floor. My tool box sponge ripped up on the floor. Damn a mess to cleanup.
The rust is revealed the rubber strip between the 2 door halves keeps moisture causing a lot of rust.
And more rust.
The naughty puppy.
The wiring of the fuel tank is completed as is the hose connecctions all ready to go with some minor wire protection needed to be installed next weekend.
Then time to connect the front 12v battery up
Then back to the final door and we have to cut the panel out to enable splitting of the door.
Wow it works the second door is soon apart and I give the bare metal a quite galvanise underccoat to protect it. However I had to also cut the outside tube out to accomplish the door split.
Then we worked on laying the 2 sets of winch cables from the rear winches to the batteries. Winch controller (Albrights) will be connected next weekend.
The intercooler is finally now connected - only the fan is left to connect next weekend.
Due next week. Centre top console. Speaker panels. Brackets for the intercooler and air cond condensor. Panels for the service hatch doors. The test panel looks awesome.
Injector Pump plug
Reconnect the repaired radiator.
Test startup
replace the engine water with coolant
Bolt the fuel tank down
4 hours home in the traffic it was a CRAP drive.
And the heart well Monday was checkup day all perfect again heart was happily sitting on 65BPM and regular again.
I have an assistant this weekend. We are on time for the 190K drive to IPOH so I stop 40K up for DONUGHTS 40 minutes to go the lasst 45K to the workshop EASY.
**** buying the doughnuts takes forever then on exit from the roadstop TRAFFIC JAM. WAZE states accident 570 metres away 30 minutes wait. NO NO NO NO !
So here is the reason I was 30 minutes late to the workshop. Takes a LOT of skill to hit the bridge and only put both front wheels over the edge. Stupid prick was out with the insense and on his knees praying frantically and rocking back and forth as we crawl by at 9.00am.
So first items trip to the Hydraulic shop for last minute stuff and the 12v battery is purchased. Back to workshop damn its lunchtime so lunch first.
Joy works on the doors sand first and we fill the separation tubes full of WD40 so we can attempt door splitting later today.
Someone sends me pics HEY your on TV with the fishing video
So here it is
[URL="http://www.geckoadventure.net/Images30/5_Tourism_Malaysia_Angling_Paradise.wmv[/URL]
Stupid PLUG for the Injector pump.
We fill the tank with DIESEL. NO NO NO everyone forgot the bottom BUNG which is impossible to see is missing, 10 litres of diesel runs all over the floor and $50rm of KITTY litter needed to soak it up. Another item to get from the hydraulic shop next saturday.
29 May 2016
We work on the doors by 10.15 we have one door split. Its a lot of work. A Bar the right size to slip up inside the tube gentle tapping to push the inside tube up and we have to cut one tube out to get to the inside tube and lots of WD40.
Then I decide I need to cut the panel open to see how much rust is inside the panel. Sure enough my guess is correct. I will make a cover panel up later to replace the cut out panel. Anyone else with a VOlvo should look at doing this also. Rust converter and undercoat etc will be needed on rebuild to prevent a reocccurance.
The cutout panel hmmmmmmm perfect.
We go to lunch and cannot find the puppy to lock him out so leave him in the Factory. Bad move. Return to a bag of 500 cable ties all over the floor. New VOlvo Fan dragged on the floor. My tool box sponge ripped up on the floor. Damn a mess to cleanup.
The rust is revealed the rubber strip between the 2 door halves keeps moisture causing a lot of rust.
And more rust.
The naughty puppy.
The wiring of the fuel tank is completed as is the hose connecctions all ready to go with some minor wire protection needed to be installed next weekend.
Then time to connect the front 12v battery up
Then back to the final door and we have to cut the panel out to enable splitting of the door.
Wow it works the second door is soon apart and I give the bare metal a quite galvanise underccoat to protect it. However I had to also cut the outside tube out to accomplish the door split.
Then we worked on laying the 2 sets of winch cables from the rear winches to the batteries. Winch controller (Albrights) will be connected next weekend.
The intercooler is finally now connected - only the fan is left to connect next weekend.
Due next week. Centre top console. Speaker panels. Brackets for the intercooler and air cond condensor. Panels for the service hatch doors. The test panel looks awesome.
Injector Pump plug
Reconnect the repaired radiator.
Test startup
replace the engine water with coolant
Bolt the fuel tank down
4 hours home in the traffic it was a CRAP drive.
And the heart well Monday was checkup day all perfect again heart was happily sitting on 65BPM and regular again.
Last edited:
piratexpress1369a
Explorer
Nice progress