Volvo C304 (4x4) Restore and fitout - WR7002
- Thread starter geckoadventure
- Start date
geckoadventure
Geckoadventure
29 January 2017
14/15 January was a charity trip into the jungle to deliver food to the Orang Asli after the monsoon rains
Then the factory was unavailable the next weekend.
So 29 January was second day of Chinese New year so I'm back on the Volvo. Ihave the mighty RED Landcruiser after fixing the aircond and a few other items to make life comfortable for the wife on our Journey to IPOH for Chinese New Year.
It's decided after measuring the pedal travel and position etc that the pedal axle needs to be 30mm lower to give 40mm of travel and match up to the lower position of the fulcrum needed.
We are working on the pedals when we hear a mewing noise a close investigation reveals 4 kittens in the guillotine and one angry mamma cat.
She runs leaving me to sort out a box and warmth for the kittens - they are cold and wet and Mr Brown is locked away he will kill the kittens.
We finish the brake pedal off and its mounted in the bracket. It all fits in the proper place. I make a bracket for the clutch arm. It does not fit well however there is a 20mm height difference. We need to remake the clutch cylinder bracket.
The clutch needs a spacer bush made its a bit loose.
That obstacle means I can work on the accelerator pedal.
30 January 2017
Work on the pedal continues and it's mounted in place it looks like it will work . I mount the steering column to make sure niothing is in the way.
Home time - wifey decides its CNY we have dinner with Mum before leaving. 9.30pm we leave Ipoh for the 200k drive home. Yup you guessed it CNY traffix was so bad atfer 2 hours I had travelled 9k on the highway. 6.5 hours later at 4am in the morning I arrive home exhausted. I keep the wife awake the whole way as punishment for making us leave late lol.
14/15 January was a charity trip into the jungle to deliver food to the Orang Asli after the monsoon rains
Then the factory was unavailable the next weekend.
So 29 January was second day of Chinese New year so I'm back on the Volvo. Ihave the mighty RED Landcruiser after fixing the aircond and a few other items to make life comfortable for the wife on our Journey to IPOH for Chinese New Year.
It's decided after measuring the pedal travel and position etc that the pedal axle needs to be 30mm lower to give 40mm of travel and match up to the lower position of the fulcrum needed.
We are working on the pedals when we hear a mewing noise a close investigation reveals 4 kittens in the guillotine and one angry mamma cat.
She runs leaving me to sort out a box and warmth for the kittens - they are cold and wet and Mr Brown is locked away he will kill the kittens.
We finish the brake pedal off and its mounted in the bracket. It all fits in the proper place. I make a bracket for the clutch arm. It does not fit well however there is a 20mm height difference. We need to remake the clutch cylinder bracket.
The clutch needs a spacer bush made its a bit loose.
That obstacle means I can work on the accelerator pedal.
30 January 2017
Work on the pedal continues and it's mounted in place it looks like it will work . I mount the steering column to make sure niothing is in the way.
Home time - wifey decides its CNY we have dinner with Mum before leaving. 9.30pm we leave Ipoh for the 200k drive home. Yup you guessed it CNY traffix was so bad atfer 2 hours I had travelled 9k on the highway. 6.5 hours later at 4am in the morning I arrive home exhausted. I keep the wife awake the whole way as punishment for making us leave late lol.
geckoadventure
Geckoadventure
2 February 2017
Public holiday in KL train up arrive IPOH 1.00am - Tired I collect the trusty Isuzu from the workshop 8.30am
Back to KL in the evening
4 February 2017
I'm starting to hate this drive I just sit on 150K for the 190k just keep outta my way.
First job finish the accelerator pedal off a few mods it will be finished. Like heck, I decide to add a clamp to stop the cable top moving and causing issues a few more hours are lost making sure itsLate in the arvo down to the bolt shop - hey it's open I get 4 imperial UNC 1/4 inch bolts. They don't fit damn.
The go faster pedal is slowly getting completed.
5 February 2017
Mr. Brown smells cat and eventually finds mama cat upstairs and a 2 hour watch and wait game. Mama cat proves she is cunning and eventually slinks away unscathed.
First job finish the accelerator pedal off a few mods it will be finished. Like heck I decide to add a clamp to stop the cable top moving and causing issues.
It's all ready in the arvo and finally looks better. Then the 4 bolts for the door stop will not screw in.
Late in the arvo down to the bolt shop - hey its open I get 4 imperial 1/4 inch bolts. They don't fit damn.
The go faster pedal is slowly getting completed.
7 February 2017
Another holiday - take joe from the home with me. We work on brackets for the seat bottoms etc.
Public holiday in KL train up arrive IPOH 1.00am - Tired I collect the trusty Isuzu from the workshop 8.30am
Back to KL in the evening
4 February 2017
I'm starting to hate this drive I just sit on 150K for the 190k just keep outta my way.
First job finish the accelerator pedal off a few mods it will be finished. Like heck, I decide to add a clamp to stop the cable top moving and causing issues a few more hours are lost making sure itsLate in the arvo down to the bolt shop - hey it's open I get 4 imperial UNC 1/4 inch bolts. They don't fit damn.
The go faster pedal is slowly getting completed.
5 February 2017
Mr. Brown smells cat and eventually finds mama cat upstairs and a 2 hour watch and wait game. Mama cat proves she is cunning and eventually slinks away unscathed.
First job finish the accelerator pedal off a few mods it will be finished. Like heck I decide to add a clamp to stop the cable top moving and causing issues.
It's all ready in the arvo and finally looks better. Then the 4 bolts for the door stop will not screw in.
Late in the arvo down to the bolt shop - hey its open I get 4 imperial 1/4 inch bolts. They don't fit damn.
The go faster pedal is slowly getting completed.
7 February 2017
Another holiday - take joe from the home with me. We work on brackets for the seat bottoms etc.
geckoadventure
Geckoadventure
9 February 2017
Another Public holiday the drive to IPOH is easy less than 90 minutes still on 150k.
First job finish the accelerator pedal off a few mods it will be finished. Like heck I decide to add a clamp to stop the cable top moving and causing issues.
We take the clutch pedal miles away to a engineering shop they are also open. They specialize in GEAR cutting. More on this later as they can make PORTAL gears hmmmmmmmmmmm.They will have the nylon bush ready
Saturday. The day cruises by working slowly to finish the bracket.
The go faster pedal is slowly getting completed.
10 February 2017
Bolt shop take a pic of the thread with me. Crossed thread and a UNC tap and I run around all 4 bolts on the right door then the left door and all the bolts now fit. Now the bracket bolts in and the go faster pedal all works. The inspector gives it the thumbs up. Then it's painted.
Mr Brown excited to see me as usual.
The completed go faster pedal.
Then only thing left commence the brake line fitting. We prepare the Volvo to move across the workshop. By 4.30pm it's across the shop and on the hoist with a lot of effort its sitting on wooden planks on the hoist.
6pm hometime.
Another Public holiday the drive to IPOH is easy less than 90 minutes still on 150k.
First job finish the accelerator pedal off a few mods it will be finished. Like heck I decide to add a clamp to stop the cable top moving and causing issues.
We take the clutch pedal miles away to a engineering shop they are also open. They specialize in GEAR cutting. More on this later as they can make PORTAL gears hmmmmmmmmmmm.They will have the nylon bush ready
Saturday. The day cruises by working slowly to finish the bracket.
The go faster pedal is slowly getting completed.
10 February 2017
Bolt shop take a pic of the thread with me. Crossed thread and a UNC tap and I run around all 4 bolts on the right door then the left door and all the bolts now fit. Now the bracket bolts in and the go faster pedal all works. The inspector gives it the thumbs up. Then it's painted.
Mr Brown excited to see me as usual.
The completed go faster pedal.
Then only thing left commence the brake line fitting. We prepare the Volvo to move across the workshop. By 4.30pm it's across the shop and on the hoist with a lot of effort its sitting on wooden planks on the hoist.
6pm hometime.
geckoadventure
Geckoadventure
11 February 2017
Strip the volvo brake lines out then down to the parts shop for Toyota and Volvo hoses and the hydarulic shop for new pipe and fittings. $550rm is emptied from my wallet.
3pm back in the workshop after 4 hours/away I get the Rear brake lines done but I have to go steel pipe brake to brake as the flexible hoses are not the right length so we will get more monday and fix up the issue. Meantime I finish the piping to the master cylinder for the rear brakes and will sort out a longer flexi hose next week.
12 February 2017 - Sunday
Fit the clutch slave cylinder and lay the piping out till I run out of pipe as I cannot find the 2 spare 5 foot lengths I saw in the workshop Friday.
Cut the panel under the passenger seat in the wheel well to give access to the injector pump etc.
Fit the drivers floor.
Cut out the 2 sidelights fill panels as the new sidelights from Volvo are much bigger and need new mounting
points created.
Strip the volvo brake lines out then down to the parts shop for Toyota and Volvo hoses and the hydarulic shop for new pipe and fittings. $550rm is emptied from my wallet.
3pm back in the workshop after 4 hours/away I get the Rear brake lines done but I have to go steel pipe brake to brake as the flexible hoses are not the right length so we will get more monday and fix up the issue. Meantime I finish the piping to the master cylinder for the rear brakes and will sort out a longer flexi hose next week.
12 February 2017 - Sunday
Fit the clutch slave cylinder and lay the piping out till I run out of pipe as I cannot find the 2 spare 5 foot lengths I saw in the workshop Friday.
Cut the panel under the passenger seat in the wheel well to give access to the injector pump etc.
Fit the drivers floor.
Cut out the 2 sidelights fill panels as the new sidelights from Volvo are much bigger and need new mounting
points created.
geckoadventure
Geckoadventure
16 February 2017
Work on the steering disassemble and reassemble the steering column parts so the worm screw works properly.
Rebolt it all in and the brahe booster yet again.. Chasing parts etc and the day is gone.
17 February 2017
Work on the steering again bolt in the top half of the steering and it all fits nicely.
Work on the steering disassemble and reassemble the steering column parts so the worm screw works properly.
Rebolt it all in and the brahe booster yet again.. Chasing parts etc and the day is gone.
17 February 2017
Work on the steering again bolt in the top half of the steering and it all fits nicely.
geckoadventure
Geckoadventure
3 March 2017
Drop into friends workshop to get the alloy watertank remade into stainless steel. There is his immactulately finished PINZ. In the shop is my friends PINZ all the light grey panels are new and designed in-house. They look so factory that he has more pinz's lined up after to have the same operation done.
4 March 2017
Day Trip to the Volvo I was going to drive quietly since the Isuzu'as rear tires started sliding out during the week in the rain. However, it's dry so I sit on 140k instead. Work continues on brake lines they are getting so close to being finished. We order the new hydraulic cylinder for the power assist steering. 2 weeks and can collect. Then it's an emergency run down to the tire shop for 2 new rear tires for the trusty ISUZU.
Back to Kuala Lumpur in the evening as tomorrow it's my birthday and I have 4x4 driver training to run. It's a much safer 190k run back home with the new Michellin sneakers on it.
Mr Brown throws a sad when I leave.
Drop into friends workshop to get the alloy watertank remade into stainless steel. There is his immactulately finished PINZ. In the shop is my friends PINZ all the light grey panels are new and designed in-house. They look so factory that he has more pinz's lined up after to have the same operation done.
4 March 2017
Day Trip to the Volvo I was going to drive quietly since the Isuzu'as rear tires started sliding out during the week in the rain. However, it's dry so I sit on 140k instead. Work continues on brake lines they are getting so close to being finished. We order the new hydraulic cylinder for the power assist steering. 2 weeks and can collect. Then it's an emergency run down to the tire shop for 2 new rear tires for the trusty ISUZU.
Back to Kuala Lumpur in the evening as tomorrow it's my birthday and I have 4x4 driver training to run. It's a much safer 190k run back home with the new Michellin sneakers on it.
Mr Brown throws a sad when I leave.
geckoadventure
Geckoadventure
10 March 2017
Get to Ipoh and realise no Fone however, the workshop is opened for me. Work on the brakes and clutch piping all finished except I miss getting the last pipe correctd as they have moved the mounting brackets 30mm and there is no more strech left as the hydraulic shop closed 5 minutes ago sob.
11 March 2017
The workshop is locked cannot get in. Damn the wrong message was conveyed to the workers and I cannot ring them. So I head home to KL a days work lost.
Get to Ipoh and realise no Fone however, the workshop is opened for me. Work on the brakes and clutch piping all finished except I miss getting the last pipe correctd as they have moved the mounting brackets 30mm and there is no more strech left as the hydraulic shop closed 5 minutes ago sob.
11 March 2017
The workshop is locked cannot get in. Damn the wrong message was conveyed to the workers and I cannot ring them. So I head home to KL a days work lost.
geckoadventure
Geckoadventure
18 March 2017
My last full weekend on the Volvo until after June as I have 14 kids from the orphanage to teach kayaking on Sundays until their 5 days kayaking adventure with me in June.
Inspection shows
Front mudflaps mounting points bolted on.
Steering arm has been shorted 40mm resulting in reduction of steering turns from 2.25 to 1.5 making it nicer to drive.
Rear electrics panel is almost completed.
I finish the rear piping and all the way to the front and sheath the piping under the dash.
I grind down the front holding nuts 3mm to make the joining nut on the pipe to flexi hose tighten up and the front brakes are then completed and make the firewall to the master cylinder piping up.
Right rear mudflap mount
and left
Power steering assist cylinder collected. Before you ask yes its equal pressure both ways even though it looks single action. It will be mounted to the DIFF next week.
The hydraulic shops beginnings was for the tin mining industry in IPOH.
The brake and clutch piping all protected, holding brackets will be made next weekend
I finish the rear piping and all the way to the front and sheath the piping under the dash.
Clutch pipe is relayed as one piece from slave cylinder to firewall
Wahoo they are all finished and tightened down.
Knock off time
19 March 2017
9:10am damn the gates been locked I cannot get in. I give up and go home at 10.00am. Another day lost.
My last full weekend on the Volvo until after June as I have 14 kids from the orphanage to teach kayaking on Sundays until their 5 days kayaking adventure with me in June.
Inspection shows
Front mudflaps mounting points bolted on.
Steering arm has been shorted 40mm resulting in reduction of steering turns from 2.25 to 1.5 making it nicer to drive.
Rear electrics panel is almost completed.
I finish the rear piping and all the way to the front and sheath the piping under the dash.
I grind down the front holding nuts 3mm to make the joining nut on the pipe to flexi hose tighten up and the front brakes are then completed and make the firewall to the master cylinder piping up.
Right rear mudflap mount
and left
Power steering assist cylinder collected. Before you ask yes its equal pressure both ways even though it looks single action. It will be mounted to the DIFF next week.
The hydraulic shops beginnings was for the tin mining industry in IPOH.
The brake and clutch piping all protected, holding brackets will be made next weekend
I finish the rear piping and all the way to the front and sheath the piping under the dash.
Clutch pipe is relayed as one piece from slave cylinder to firewall
Wahoo they are all finished and tightened down.
Knock off time
19 March 2017
9:10am damn the gates been locked I cannot get in. I give up and go home at 10.00am. Another day lost.
piratexpress1369a
Explorer
Nice progress...
Sent from my SM-G903W using Tapatalk
Sent from my SM-G903W using Tapatalk
OuterLimits
I control the horizontal and the vertical
Amazing build!!!
geckoadventure
Geckoadventure
Sorry little to report.
I been sick caught a stomach bug 1 week diarrohea after every meal then finally on the 10th day a severe headache and bad chest infection which then caused an asthma attack (first in over 5 years) so end of second week ended up with a visit to the hospital and a 11 day stay. 1.5 days out and back for checkup and they kept me in again I was far from right. another 6 days and they let me out and still have 10 days off work till the stomach is right. Diagnosis a severe stomach bug which if not treated would have been the end of me.
Mean time the Volvo has not progressed apart fromn new front windows ordered out of 8.9mm laminated glass. The new stainless steel water tank will be ready this week.
All that is left to complete is:
Drive away after testing.
I been sick caught a stomach bug 1 week diarrohea after every meal then finally on the 10th day a severe headache and bad chest infection which then caused an asthma attack (first in over 5 years) so end of second week ended up with a visit to the hospital and a 11 day stay. 1.5 days out and back for checkup and they kept me in again I was far from right. another 6 days and they let me out and still have 10 days off work till the stomach is right. Diagnosis a severe stomach bug which if not treated would have been the end of me.
Mean time the Volvo has not progressed apart fromn new front windows ordered out of 8.9mm laminated glass. The new stainless steel water tank will be ready this week.
All that is left to complete is:
- Air conditioning
- Power steering hydraulic cylinder fit up
- Dash and wiring to the DASH and the switch panel
- Doors re construct and fit
- Wipers find and fit and customise
- Fit the front windows
Drive away after testing.
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geckoadventure
Geckoadventure
22 May 2017
Well it's been 8 weeks at least since I last saw the Volvo. After being off work sick for 6 weeks with a stomach virus from something I ate and now training the orphanage kids for the August Kayak adventure I took a day off work to visit it for progress.
Meantime in the 7 weeks I have obtained new front windows cutoms made and cut for the wonderful price of 40USD a pair for 9.7mm laminated autoglass oh and I left it at home damn curses. I have new LED headlights. The new stainless steel water tank is still being made.
So whats been done.
- Powersteering is almost completed
- Rear 12v power panel is completed no pics as the Volvo is way up on the hoist.
They collected the power steering parts from the engineering shop and I fitted then to the power steering
cylinder. Went down to the hydraulic shop cut the hoses to length and got new ends fitted. Then connected the power steering hoses to the new cylinder. New holding brackets for the left and right hoses made and mounted. Could not fit the top power steering hoses as the Volvo is way up on the hoist. But next visit I will have it done.
Mr Brown was so happy to see me he decided to help me on the workbench while I chopped 10mm off the mounting bolts.
Finally it was all bolted down. We may have to change the design of this does not work.
Discussion on the switch rollcall we have 5 to buy to have them able to complete the front switch panel.
Then it was time to test out the new LED headlights. Ooooh they are cool. Bonus they have sidelights and indicators built into them.
So now we can weld in the inserts I made and touch them up with paint etc.
A few things left to do:
- Air conditioning
- Assemble doors
- Build new Drivers dash panel
- Wipers build and fit
- Connect remaining switch panel wires
- PTO find switchs and refit
- Test everything
Well it's been 8 weeks at least since I last saw the Volvo. After being off work sick for 6 weeks with a stomach virus from something I ate and now training the orphanage kids for the August Kayak adventure I took a day off work to visit it for progress.
Meantime in the 7 weeks I have obtained new front windows cutoms made and cut for the wonderful price of 40USD a pair for 9.7mm laminated autoglass oh and I left it at home damn curses. I have new LED headlights. The new stainless steel water tank is still being made.
So whats been done.
- Powersteering is almost completed
- Rear 12v power panel is completed no pics as the Volvo is way up on the hoist.
They collected the power steering parts from the engineering shop and I fitted then to the power steering
cylinder. Went down to the hydraulic shop cut the hoses to length and got new ends fitted. Then connected the power steering hoses to the new cylinder. New holding brackets for the left and right hoses made and mounted. Could not fit the top power steering hoses as the Volvo is way up on the hoist. But next visit I will have it done.
Mr Brown was so happy to see me he decided to help me on the workbench while I chopped 10mm off the mounting bolts.
Finally it was all bolted down. We may have to change the design of this does not work.
Discussion on the switch rollcall we have 5 to buy to have them able to complete the front switch panel.
Then it was time to test out the new LED headlights. Ooooh they are cool. Bonus they have sidelights and indicators built into them.
So now we can weld in the inserts I made and touch them up with paint etc.
A few things left to do:
- Air conditioning
- Assemble doors
- Build new Drivers dash panel
- Wipers build and fit
- Connect remaining switch panel wires
- PTO find switchs and refit
- Test everything
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