1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

The Volvo C304 restoration.

Discussion in 'Volvo Trucks' started by cicak, Aug 1, 2011.

  1. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.

    [​IMG]

    [​IMG]

    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.

    [​IMG]
    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.
     
  2. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
    [​IMG]

    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.
    [​IMG]

    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.
    [​IMG]

    7 February 2017

    Another holiday - take joe from the home with me. We work on brackets for the seat bottoms etc.
    [​IMG]
     
  3. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
    [​IMG]

    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.
    [​IMG]

    The completed go faster pedal.
    [​IMG]

    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.
    [​IMG]
     
  4. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
    [​IMG]

    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.
    [​IMG]

    Cut out the 2 sidelights fill panels as the new sidelights from Volvo are much bigger and need new mounting
    points created.
    [​IMG]

    [​IMG]
     
  5. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
    [​IMG]
     
  6. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
    [​IMG]

    [​IMG]

    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.

    [​IMG]

    [​IMG]

    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.
    [​IMG]
     
  7. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
     
  8. cicak

    cicak

    Messages:
    1,063
    Likes Received:
    29
    Joined:
    Oct 15, 2005
    Location:
    Malaysia, Kuala Lumpur
    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.
    [​IMG]

    Steering arm has been shorted 40mm resulting in reduction of steering turns from 2.25 to 1.5 making it nicer to drive.
    [​IMG]

    Rear electrics panel is almost completed.
    [​IMG]

    [​IMG]

    I finish the rear piping and all the way to the front and sheath the piping under the dash.
    [​IMG]

    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.
    [​IMG]

    Right rear mudflap mount
    [​IMG]

    and left
    [​IMG]

    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.
    [​IMG]

    The hydraulic shops beginnings was for the tin mining industry in IPOH.
    [​IMG]

    The brake and clutch piping all protected, holding brackets will be made next weekend
    [​IMG]

    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.
     
  9. scrapdaddy

    scrapdaddy Standing on the corner SILVER Star

    Messages:
    6,053
    Likes Received:
    1,693
    Joined:
    Aug 21, 2011
    Location:
    Dittmer, Mo.
    Some good progress! Going to be one heck of a truck, keep it going.