piratexpress1369a
Explorer
Awesome work... enjoy your holiday
Sent from my SM-G903W using Tapatalk
Sent from my SM-G903W using Tapatalk
Volvo C304 (4x4) Restore and fitout - WR7002
- Thread starter geckoadventure
- Start date
geckoadventure
Geckoadventure
29 October 2016
Extended Holiday over, workshop has reopened afer the owner was away for an operation, time to work on the Volvo. I have no idea what to do I make a list in the first hour.
1. Fit the intercooler and bolt it down
2. Fit the rear panel
3. Fit the rear tailight and bracket
4. Fit the fuel tank panel.
5. Flush the engine block
Oh no it's a public holiday nothing is open so cannot get anything from the part shops.
So first simple stuff
Fit the rear panel with finger tight stainless steel bolts
Fit the bottom rear taillights and bracket with RIVUTS
Pop the fuel tank cover onto a stand and put it in place
By evening with a few mods I have it ready to bolt in
And finally it's finished bolted in
Extended Holiday over, workshop has reopened afer the owner was away for an operation, time to work on the Volvo. I have no idea what to do I make a list in the first hour.
1. Fit the intercooler and bolt it down
2. Fit the rear panel
3. Fit the rear tailight and bracket
4. Fit the fuel tank panel.
5. Flush the engine block
Oh no it's a public holiday nothing is open so cannot get anything from the part shops.
So first simple stuff
Fit the rear panel with finger tight stainless steel bolts
Fit the bottom rear taillights and bracket with RIVUTS
Pop the fuel tank cover onto a stand and put it in place
By evening with a few mods I have it ready to bolt in
And finally it's finished bolted in
geckoadventure
Geckoadventure
30 October 2016
Remount the gas stuts they are all the wrong way round - oops
The cheap labour is working on the bolting in the intercooler and air cond condenser. Brackets are wire brushed and painted
Meantime I work on the air tank and wire brush it and undercoat it
Then the owner turns up and we connect up the compressors and amp test them. Hmmmm 46 amps drawn from each. Not good on 100 amp wires so 2 new wires are laid 100 amps each direct to the batteries.
Finally the intercooler is finished all I need is 1 new silicon hose and a few clamps
Remount the gas stuts they are all the wrong way round - oops
The cheap labour is working on the bolting in the intercooler and air cond condenser. Brackets are wire brushed and painted
Meantime I work on the air tank and wire brush it and undercoat it
Then the owner turns up and we connect up the compressors and amp test them. Hmmmm 46 amps drawn from each. Not good on 100 amp wires so 2 new wires are laid 100 amps each direct to the batteries.
Finally the intercooler is finished all I need is 1 new silicon hose and a few clamps
geckoadventure
Geckoadventure
6 November 2016
Tow the boat up to the workshop the trailer needs surgery its flexing like mad the old boat weighed a mighty 70kg lol. This one is more like 700kg.
One day on the Volvo yesterday was attend a sultans birthday in KL so I worked on Volvo 2 instead.
Felt really sick so the owner and me work on the stuff underneath o the floor can be bolted in for final time.
We relayed the Winch cables into nice neat rows. Set batteries in new location an recrimped the ends and started on the T-Max winch cables. A new Cable holder was made (left bottom) and one more to be made.
Then I decided HOME. I was getting worse not better
The trailer left in the workshop for surgery
Tow the boat up to the workshop the trailer needs surgery its flexing like mad the old boat weighed a mighty 70kg lol. This one is more like 700kg.
One day on the Volvo yesterday was attend a sultans birthday in KL so I worked on Volvo 2 instead.
Felt really sick so the owner and me work on the stuff underneath o the floor can be bolted in for final time.
We relayed the Winch cables into nice neat rows. Set batteries in new location an recrimped the ends and started on the T-Max winch cables. A new Cable holder was made (left bottom) and one more to be made.
Then I decided HOME. I was getting worse not better
The trailer left in the workshop for surgery
piratexpress1369a
Explorer
Nice work....take care and get better
Sent from my SM-G903W using Tapatalk
Sent from my SM-G903W using Tapatalk
geckoadventure
Geckoadventure
12 November 2016
First some pics of my boat holiday
A lone Elephant. My friends first time seeing a wild elephant he was stoked
A remote camp site early in the morning
Kayaking in the same cove
Saturday
Depart KL 6.30am its a cold 26c im shivering lol just floor it and sit on 150k arrive IPOH 8am im time to have a nice breakfast.
Arrive workshop 9am and everyone (hey wait a minute) is present working on the Volvo wow 4 people working on it. Battery box being changed to accommodate the 4 batteries in a line. 2 150 AMp and 2 DEEP CYCLE 150 amps for the 12V. Wiring is getting plugs attached.
First job join the 2 parts of the cabin together. Find the bolts damn 4 3/8th bolts missing we search the
shop and find 0. Why does Volvo mix imperial and metric bolts on the same part? I go to the bolt shop and get what we need and get 2 thread types to be sure. 1 hour later return - DAMN! they don't fit. Brett finds 3 and we are missing one. Finally we apply the glue and the sealant and lower the top to the base. Bolt it down. Yahoo done.
Lunchtime workers go home and then we start on getting everything under the floor ready so we can bolt down the floor.
First the lockers I have the wrong solenoids from ARB. Crap down to the hydraulic shop for new ones. Since I have to be back in KL to give a 6pm charity event I go to the hydraulic sop then head forr home however 1 hour in the hydraulix shop leaves me frusrated 2 sets pleas come out with etc . 50 feet of soft hose comes back with 6mm joints fark!!!!!!!!. Homeward bound yes of course it raains heavily turning the road to a ice skating rink. Arrive at the presentation 5 mins late give the presentation and I get participants joining up. Now I have 10 kids from the home to teach how to kayak and paddle for 8+ hours per day for 8 days.
13 November 016
Sunday
Up early no im not 1am I take cough medicine and its the sleepy one by mistake. 7.31am wake up fark!!!!! Floor the car even harder poor little Isuzu doesn't see the slow side of 160k much, arrive IPOH 9.08am.
First job run through the mods to the boat trailer.
Reinforced no longer the massive flex it had. he general view was it would have folded in half or snapped soon if it was not noticed. Discussion on batteries and fridge and hammock racks conttinues.
Then its onto the Volvo
I have the wrong solenoids after all that effort yesterday sigh!
Sweep up everything around the Volvo takes me an hour to cleanup.
Discussion on the 12V and wiring changes and the 12v battery management takes another hour by then its lunchtime.
So the afternoon is spent finishing the compressor take installation. Paint trim paint fit test fit fit ec. Then it's done just one little paint touch up to go later. It's not perfect but its practical and removeable.
Battery boxes realigned and more cable brackets have been installed. The 12v electric cart battery's are huge.
The 12v battery monitor is to be obtained next week
The cabin joined. Now I need to paint it again.
Since i'm at a cleanpoint I decide its home time I will go work on Volvo 2.
Next weeks tasks:
Lockers finish install
T-Max winch finish cables
Start clutch slave cylinder install
Finish PTO and 4x4 Vaccum and breather hose installation
Finish rear panel install and window install
Hell drive home pouring rain - I just cruise Bruce Springsteen then Blondie on the stereo
8pm i'm sitting in a little restaurant 500 metres from the KL workshop watching a motor bike accident happen
9pm i'm in the workshop working on Volvo 2.
First some pics of my boat holiday
A lone Elephant. My friends first time seeing a wild elephant he was stoked
A remote camp site early in the morning
Kayaking in the same cove
Saturday
Depart KL 6.30am its a cold 26c im shivering lol just floor it and sit on 150k arrive IPOH 8am im time to have a nice breakfast.
Arrive workshop 9am and everyone (hey wait a minute) is present working on the Volvo wow 4 people working on it. Battery box being changed to accommodate the 4 batteries in a line. 2 150 AMp and 2 DEEP CYCLE 150 amps for the 12V. Wiring is getting plugs attached.
First job join the 2 parts of the cabin together. Find the bolts damn 4 3/8th bolts missing we search the
shop and find 0. Why does Volvo mix imperial and metric bolts on the same part? I go to the bolt shop and get what we need and get 2 thread types to be sure. 1 hour later return - DAMN! they don't fit. Brett finds 3 and we are missing one. Finally we apply the glue and the sealant and lower the top to the base. Bolt it down. Yahoo done.
Lunchtime workers go home and then we start on getting everything under the floor ready so we can bolt down the floor.
First the lockers I have the wrong solenoids from ARB. Crap down to the hydraulic shop for new ones. Since I have to be back in KL to give a 6pm charity event I go to the hydraulic sop then head forr home however 1 hour in the hydraulix shop leaves me frusrated 2 sets pleas come out with etc . 50 feet of soft hose comes back with 6mm joints fark!!!!!!!!. Homeward bound yes of course it raains heavily turning the road to a ice skating rink. Arrive at the presentation 5 mins late give the presentation and I get participants joining up. Now I have 10 kids from the home to teach how to kayak and paddle for 8+ hours per day for 8 days.
13 November 016
Sunday
Up early no im not 1am I take cough medicine and its the sleepy one by mistake. 7.31am wake up fark!!!!! Floor the car even harder poor little Isuzu doesn't see the slow side of 160k much, arrive IPOH 9.08am.
First job run through the mods to the boat trailer.
Reinforced no longer the massive flex it had. he general view was it would have folded in half or snapped soon if it was not noticed. Discussion on batteries and fridge and hammock racks conttinues.
Then its onto the Volvo
I have the wrong solenoids after all that effort yesterday sigh!
Sweep up everything around the Volvo takes me an hour to cleanup.
Discussion on the 12V and wiring changes and the 12v battery management takes another hour by then its lunchtime.
So the afternoon is spent finishing the compressor take installation. Paint trim paint fit test fit fit ec. Then it's done just one little paint touch up to go later. It's not perfect but its practical and removeable.
Battery boxes realigned and more cable brackets have been installed. The 12v electric cart battery's are huge.
The 12v battery monitor is to be obtained next week
The cabin joined. Now I need to paint it again.
Since i'm at a cleanpoint I decide its home time I will go work on Volvo 2.
Next weeks tasks:
Lockers finish install
T-Max winch finish cables
Start clutch slave cylinder install
Finish PTO and 4x4 Vaccum and breather hose installation
Finish rear panel install and window install
Hell drive home pouring rain - I just cruise Bruce Springsteen then Blondie on the stereo
8pm i'm sitting in a little restaurant 500 metres from the KL workshop watching a motor bike accident happen
9pm i'm in the workshop working on Volvo 2.
geckoadventure
Geckoadventure
19 November 2016
Got the locker mechanisms changed so now they are installed correctly.
Couple of bolts missing from the rear panel and it's all ready.
20 November 2016
Sunday time for the t-max to be wired up. Have to start from stripping the solenoid to see how to connect the winch wiring up. Took all day to get it finished and have nice lengthed cables. Only the remotes to wire in now.
The drive home is horrendous it pours most of the way home and it a 3 hour journey sigh
Got the locker mechanisms changed so now they are installed correctly.
Couple of bolts missing from the rear panel and it's all ready.
20 November 2016
Sunday time for the t-max to be wired up. Have to start from stripping the solenoid to see how to connect the winch wiring up. Took all day to get it finished and have nice lengthed cables. Only the remotes to wire in now.
The drive home is horrendous it pours most of the way home and it a 3 hour journey sigh
geckoadventure
Geckoadventure
26 November 2016
Wake up late then have to go collect the trusty Isuzu from the workshop using the spare keys after it's had
the gearbox out to replace a main seal and yet another oil change I believe no. 8 for the year so 40,000k
has whizzed past.
Floor it for the 190k to Ipoh and arrive at 9:06 and wow all hands on deck again working on the battery box expansion and wiring up the rear tail lights and startin to plug up the front wiring so it can be removed if we lift the cabin off.
24v batteries connected
27 November 2016
Spent the morning putting the front prop shaft in.
My lunch view every weekend out over the limestone temples and hills.
Made a bracket to hold the accelerator cable a quick tidy up needed next weekend and it's ready.
The front prop shaft in. Apparently it's the wrong way round sigh.
The trip home again is horrendous 3 hours 45 mins. I'm really starting to hate the Sunday nite home drive
Wake up late then have to go collect the trusty Isuzu from the workshop using the spare keys after it's had
the gearbox out to replace a main seal and yet another oil change I believe no. 8 for the year so 40,000k
has whizzed past.
Floor it for the 190k to Ipoh and arrive at 9:06 and wow all hands on deck again working on the battery box expansion and wiring up the rear tail lights and startin to plug up the front wiring so it can be removed if we lift the cabin off.
24v batteries connected
27 November 2016
Spent the morning putting the front prop shaft in.
My lunch view every weekend out over the limestone temples and hills.
Made a bracket to hold the accelerator cable a quick tidy up needed next weekend and it's ready.
The front prop shaft in. Apparently it's the wrong way round sigh.
The trip home again is horrendous 3 hours 45 mins. I'm really starting to hate the Sunday nite home drive
geckoadventure
Geckoadventure
5 December 2016
One week on the Volvo coming first we move the cabin ready for a trial fit sometime this week. The whole crew is available to work on the Volvo all week. So I'm calling it the big rush week.
All hands on deck to install the ceiling.
Poor Yap trying to figue out how to do the front ceiling.
Mr Brown jumps up to assist and supervise
End of Day 1 of the big rush we have the roof done
Evening I end up 90k away at the closing ceremony of the 2016 RFC with 2 other friends who decided in a drinking session in Chang Mai in Thailand on Saurday night to fly to Malaysia lol and several other friends also came at last minute.
One week on the Volvo coming first we move the cabin ready for a trial fit sometime this week. The whole crew is available to work on the Volvo all week. So I'm calling it the big rush week.
All hands on deck to install the ceiling.
Poor Yap trying to figue out how to do the front ceiling.
Mr Brown jumps up to assist and supervise
End of Day 1 of the big rush we have the roof done
Evening I end up 90k away at the closing ceremony of the 2016 RFC with 2 other friends who decided in a drinking session in Chang Mai in Thailand on Saurday night to fly to Malaysia lol and several other friends also came at last minute.
Last edited:
geckoadventure
Geckoadventure
6 December 2016
Picked up the kiwi video crew from their RFC 2016 hotel took them to see the Volvo in IPOH did a video interview for OFFOAD EXPRESS NZ and then back to Kuala Lumpur and out for dinner with the others.
7 December 2016
Slow morning after the long 190k drive backup to IPOH i managed to fly up early in the morning rather quickly lol
By the middle of the afernoon all the top removeable panels are completed except one which is being remade in the morning
I work on the front cabin panels getting them all to be removeable correctly for easy access.
Picked up the kiwi video crew from their RFC 2016 hotel took them to see the Volvo in IPOH did a video interview for OFFOAD EXPRESS NZ and then back to Kuala Lumpur and out for dinner with the others.
7 December 2016
Slow morning after the long 190k drive backup to IPOH i managed to fly up early in the morning rather quickly lol
By the middle of the afernoon all the top removeable panels are completed except one which is being remade in the morning
I work on the front cabin panels getting them all to be removeable correctly for easy access.
geckoadventure
Geckoadventure
8 December 2016
I'm out getting window rubber and bolts then have to go out again whhen we realise the window rubber is incorrect an we cannot get the reversing camera to work and until it works we cannot glue down the roof so out I go again to find EPILSON reversing camera's a quick call to the importer from the box gives me the local IPOh supplier. Buy a new one and we replace the cable on the roof retest tomorrow
Then it's time to assist with the bottom panel gluing session 5.01pm we start have to finish by 6pm. 4 of us get it done withh 15 minutes to spare.
Tomorrow we will know if its all looking good.
Initial impression is the truck now looks clean and simple inside
I'm out getting window rubber and bolts then have to go out again whhen we realise the window rubber is incorrect an we cannot get the reversing camera to work and until it works we cannot glue down the roof so out I go again to find EPILSON reversing camera's a quick call to the importer from the box gives me the local IPOh supplier. Buy a new one and we replace the cable on the roof retest tomorrow
Then it's time to assist with the bottom panel gluing session 5.01pm we start have to finish by 6pm. 4 of us get it done withh 15 minutes to spare.
Tomorrow we will know if its all looking good.
Initial impression is the truck now looks clean and simple inside
geckoadventure
Geckoadventure
9 December 2016
The end result of last nights gluing session is shade awesome, but oh and we need new gas stuts damn the 400M one's are not strong enough I need 600N the doors start to drop down a little.
So a 45 square foot jungle workshop is what it looks like now.
We retest the reverse camera after laying the new wires and yup it fails again so afer much stuffing around it finally works and the Battery Monitor turns up from the UK. Fit next week.
Next is the windows I fit the 2 side windows and give them a clean they come out smick.
Now the locks. Yap starts to modify the locks to accommodate the central locking while I clean out the holes for the locks to fit in.
Next week this will be ready to install and test out wow a 36 year old truck with Cental locking lol. The welded up keyhole is getting something special made up to hide the welded up hole.
We wanted to finish the roof by gluing down the top but alas we run out of time. It will be done first thing Monday morning.
So the end of the week we have thrown some 268 hours at it but missed the big goal of putting the cabin on.
10 December 2016 (Saturday)
Worked on the front panels went out to get some dome bolts for the ceiling as the roofing screws are going to cut my head and they look ugly.
Came back and had one panel almost finished and then the guillotine chopped to much off trying to trim 1mm off SOB. Down tools and we go to lunch and then I head back to Kuala Lumpur for a couple of days.
The end result of last nights gluing session is shade awesome, but oh and we need new gas stuts damn the 400M one's are not strong enough I need 600N the doors start to drop down a little.
So a 45 square foot jungle workshop is what it looks like now.
We retest the reverse camera after laying the new wires and yup it fails again so afer much stuffing around it finally works and the Battery Monitor turns up from the UK. Fit next week.
Next is the windows I fit the 2 side windows and give them a clean they come out smick.
Now the locks. Yap starts to modify the locks to accommodate the central locking while I clean out the holes for the locks to fit in.
Next week this will be ready to install and test out wow a 36 year old truck with Cental locking lol. The welded up keyhole is getting something special made up to hide the welded up hole.
We wanted to finish the roof by gluing down the top but alas we run out of time. It will be done first thing Monday morning.
So the end of the week we have thrown some 268 hours at it but missed the big goal of putting the cabin on.
10 December 2016 (Saturday)
Worked on the front panels went out to get some dome bolts for the ceiling as the roofing screws are going to cut my head and they look ugly.
Came back and had one panel almost finished and then the guillotine chopped to much off trying to trim 1mm off SOB. Down tools and we go to lunch and then I head back to Kuala Lumpur for a couple of days.
Last edited:
piratexpress1369a
Explorer
Awesome job... looking forward to seeing you getting close to putting the cab om
Sent from my SM-G903W using Tapatalk
Sent from my SM-G903W using Tapatalk
geckoadventure
Geckoadventure
12 December 2016 (Monday)
Charity Day took People from Light up Borneo and potential donors to the scheme to a remote Orang Ali
village to do a Mini Hydro recce. 11 4x4's and 37 people. Took my mighty Red truck for a stroll in the
Jungle.
The girls from the group looked after the village kids while the other went to do the hydro meauring. Me I
just relaxed for once.
However I want one of these little jungle dogs a Telemonian climbs steps loyal, kills snakes, hunts
squirrels.
The mighty Red on its new Trepadors which I found to be quite harsh.
Arrive home 11pm exhausted.
Charity Day took People from Light up Borneo and potential donors to the scheme to a remote Orang Ali
village to do a Mini Hydro recce. 11 4x4's and 37 people. Took my mighty Red truck for a stroll in the
Jungle.
The girls from the group looked after the village kids while the other went to do the hydro meauring. Me I
just relaxed for once.
However I want one of these little jungle dogs a Telemonian climbs steps loyal, kills snakes, hunts
squirrels.
The mighty Red on its new Trepadors which I found to be quite harsh.
Arrive home 11pm exhausted.
geckoadventure
Geckoadventure
13 December 2016
Day 6 of the big rush and im in Kuala Lumpur sorting out collecting my new passport then into thhe office to
sort out the paperwork for the work permit.
14 December 2016
Day 7 of the big rush and I'm picking up parts for the Volvo from the laser cutters. I have to wait for one
part to be cut out as they do not wanna bend it. It's ok we will bend it you just cut it. I wait 1 hour.
Then sorting out my work permit yet again. Eventually I arrive at Ipoh 1.30pm.
The door locks are now fited
Cental locking also ready for wiring.
The exhaust heat shield and the turbo sheild waiting to be installed.
Mr Brown getting a Subway cookie.
Day 6 of the big rush and im in Kuala Lumpur sorting out collecting my new passport then into thhe office to
sort out the paperwork for the work permit.
14 December 2016
Day 7 of the big rush and I'm picking up parts for the Volvo from the laser cutters. I have to wait for one
part to be cut out as they do not wanna bend it. It's ok we will bend it you just cut it. I wait 1 hour.
Then sorting out my work permit yet again. Eventually I arrive at Ipoh 1.30pm.
The door locks are now fited
Cental locking also ready for wiring.
The exhaust heat shield and the turbo sheild waiting to be installed.
Mr Brown getting a Subway cookie.