Builds The Volvo C304 restoration.

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My guess is it's all about the inspection.
Or it will be easy enough to cut some windows into the panels...?

What is the purpose behind this/these vehicle, tours, or?


First its to keep its 12 seat rating then its to allow me to take out the top side panels they unbolt in about 10 mins and use it for transporting people if I have too.

Then its for camping and corporate promotions etc. Then ts for movie shoots. THen its for charity trips to the jungle to carry a lot of kit or 6 people with the side panels removed.
 
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29 December 2018

After a frustrating period of off road charity work and broken annual leave getting called back to the office twice when less than 100k from the lake with your boat on the back is no fun).
A jungle fishing trip in THailand which resulted in a trip to the hospital for 5 days
Tossing the timing belt on my new 80 Series Landcruiser hence causing massive damage and many other incidents its been a frustrating non-holiday.
Volvo work has slowed till they sort out the pesky PINZ which is still causing huge manpower issues 3 times the transfer case has been removed and replaced and now it needs to come out again as they cannot find the errant bearing - ME I think it's a bearing in the rear DIFF in the PINZ SPINE.

So back to the Volvo we have stripped the power steering off the Volvo so we can do the inspection, Saturday morning was spent getting the remaining seats for the Volvo. The distances in KL aare causing huge logistics issues rounding up components. THen off to the local hydraulic shop to get hose made to go from power steering pump back into resivoir. He saw me coming and charged me more than double the IPOH costs for a hydraulic hose.

Calculations for the power steering pump and the steering column unit and the hydarulic ram are also being done to see where the issue is. I have already found the washers on the banjo bolt are .6mm too thick resulting in lost throughput on the hose.

Seat belts were fitted. Remaining 2 steats fitted then I realised I had bought 4 narrow and 4 wide seats and the wide ones are also taller - oops.

A test run still has the gear change issues - we think the bend put in the linklage is causing some issues - further investigation is required.
Also the issue of HI/LO from the same gear lever (R/1/2/3/4/HI/LO on the gear lever) and leaving the truck in LO is still being investigated we think the BENT linkage is the issue. I'm looking at a electric servo arm to go HI/NEUTRAL/LO and eliminate the gear lever change. We are also going to explore CABLE linkage change and dispense with the linkage arm.

I also need to find out why it looses a small amount of coolant from the radiator each week.

We have the HORN and Brake issue to fix then it can now go for inspection.

Then it was time for the Volvo to earn it's keep as a stepladder.
20181229_170255.jpg


Seatbelt connection.
20181229_174841.jpg
seatbelts

Rear seats all fitted but now I need to do some moving and matching.
20181229_180953.jpg
seats

The cabin is a mess while I wait for the now late gear lever cover.
20181229_182041.jpg


A short video of the VOlvo moving back into its kennel.
http://https://youtu.be/Keb3sFjzSGE

[youtube]Keb3sFjzSGE[/youtube]
 

Pacer

Keystone Cruiser
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29 December 2018

After a frustrating period of off road charity work and broken annual leave getting called back to the office twice when less than 100k from the lake with your boat on the back is no fun).
A jungle fishing trip in THailand which resulted in a trip to the hospital for 5 days
Tossing the timing belt on my new 80 Series Landcruiser hence causing massive damage and many other incidents its been a frustrating non-holiday.
Volvo work has slowed till they sort out the pesky PINZ which is still causing huge manpower issues 3 times the transfer case has been removed and replaced and now it needs to come out again as they cannot find the errant bearing - ME I think it's a bearing in the rear DIFF in the PINZ SPINE.

So back to the Volvo we have stripped the power steering off the Volvo so we can do the inspection, Saturday morning was spent getting the remaining seats for the Volvo. The distances in KL aare causing huge logistics issues rounding up components. THen off to the local hydraulic shop to get hose made to go from power steering pump back into resivoir. He saw me coming and charged me more than double the IPOH costs for a hydraulic hose.

Calculations for the power steering pump and the steering column unit and the hydarulic ram are also being done to see where the issue is. I have already found the washers on the banjo bolt are .6mm too thick resulting in lost throughput on the hose.

Seat belts were fitted. Remaining 2 steats fitted then I realised I had bought 4 narrow and 4 wide seats and the wide ones are also taller - oops.

A test run still has the gear change issues - we think the bend put in the linklage is causing some issues - further investigation is required.
Also the issue of HI/LO from the same gear lever (R/1/2/3/4/HI/LO on the gear lever) and leaving the truck in LO is still being investigated we think the BENT linkage is the issue. I'm looking at a electric servo arm to go HI/NEUTRAL/LO and eliminate the gear lever change. We are also going to explore CABLE linkage change and dispense with the linkage arm.

I also need to find out why it looses a small amount of coolant from the radiator each week.

We have the HORN and Brake issue to fix then it can now go for inspection.

Then it was time for the Volvo to earn it's keep as a stepladder.
20181229_170255.jpg


Seatbelt connection.
20181229_174841.jpg
seatbelts

Rear seats all fitted but now I need to do some moving and matching.
20181229_180953.jpg
seats

The cabin is a mess while I wait for the now late gear lever cover.
20181229_182041.jpg


A short video of the VOlvo moving back into its kennel.
http://https://youtu.be/Keb3sFjzSGE

[youtube]Keb3sFjzSGE[/youtube]
Nice update, rough month.
RE: 80series, what motor is in there, 1hdt?
Happy New year, it's gonna be a better one.
 
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First its to keep its 12 seat rating then its to allow me to take out the top side panels they unbolt in about 10 mins and use it for transporting people if I have too.

We found out news a few weeks ago I have to keep it to under 12 seats else if I go to some other asian countries it's considered a BUS and a whole pile of issues arise at the customs entry. So its going to be amended to 8 seats on the inspecton.
 
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1 February 2019

We have been beavering away on the Volvo as much as one can in a open air workshop when it's 34 celcius. I have all the rear seats now bolted down properly and the final 2 different seat bases adjusted to fit.

The carpet for the cabin floor has been done with the passenger seat floor complete. The driver side needs a mistake corrected but will be installed on 1st Feb 2019.

The brakes have been an issue and finally after rebleeding the brakes awith my trusty new assistant which necessitated the removal of each wheel to reach the bleed nipple sigh. Then the retest and still we had no brakes.

Last weekend we took all the wheels off and ran the Volvo on jacks,, that was scary. Hmmmmmmmmmmm problem found. The vaccum was not working it's shared with the PTO and the 4x4 via 3 T-joints so we direct connected it to the brakes and we had brakes. But it still will not lock the wheels up so further attention is being paid this coming weekend.

We looked at the HOrn and tried to connect the wiring to the steering wheel with no success. A separate dash switch is being setup this weekend.

Once these 2 items are completed we can attempt the dreaded re-registration inspection.

Today is a public holiday so I'm working on the templates for the rest of the carpeting in the transmission tunnel and footwells etc.

Giving the new sidekick the wheel nuts to undo. At 44kg the tire is heavier than her lol.
20190112_175429.jpg


Last row of seats bolted dpown properly.
20190113_175707.jpg


Working on the carpet templates to take to the cushion shop.
20190113_193823.jpg


Zing clinging to me in a 2 hour thunderstorm he hates thunder.
20190121_162402.jpg


Preparing the floor for the velcro to be glued down
20190121_174717.jpg


The front row of seats almost ready for the last seat to be bolted in until I cut the wrong lugs off and had to reweld them in lol. Felt such an idiot.
20190121_180018.jpg


The passenger seat with the floor carpet fitted
20190122_190820.jpg


The passenger seat with the floor carpet fitted
20190122_190921.jpg


Just to prove the lights work.
20190127_192334.jpg


20190127_192506.jpg


Today's goal is to get the tacho working via the page instruction guide and the carpet templates to the cushion shop.
 
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3 February 2019

Well 2 more days on the Volvo has brought success and total frustration. Weve had FRI/SAT/SUN this week on it.

So to start off on a healthy manner I had breakfast a waffle and ice cream at our health shop near the workshop lol.
20190201_140203.jpg


My electrics whiz buddy turns up and we install the HORN button. Wahoo only BRAKES left for the inspection.

Then we try and get the TACHO connected. Cannot reach the tach wire from the fuel pump - oh crap. Go to use the "P" of the alternator only to find its a PETROL alternator and no PINS are available. Order a TOYOTA DIESEL Alternator from a friendly mechanic - delivery after 11 Feb. Then onto the SPEEDO. The halls effect unit is already installed on the driveshaft. However we find one of the l;ocking nuts has vibrated out. More issues to solve cannot get a nut bolt shops are all closed until the 11th.

A rebleed of the brakes made no difference so we elected to just pump a lot of fluid out of the brake lines, OOps suddenly black fluid came out oops so we decded off come the front callipers for a full rebuild even though the brakes were contracted out to be rebuilt a few months ago.

The end result was some very sick looking callipers with 6 of the 8 pistons not moving and all the holes blocked up.
20190201_154126.jpg


Meantime Andrew had completely stripped the Pesky Pinzgauer rear tandem axles completely apart to find the mystery whine only to find a single diff bearing gone!. It's CNY he also cannot get any parts until the 11 Feb.
20190201_164445.jpg


Meantime the second calliper is in the 12v battery charger and baking soda cleaner and enormous amounts of crap come out.
20190202_134321.jpg


The callipers are installed after we get the rebuild kit and special order of isuzu truck window washer nozzles are obtained after they close for the CNY celebrations until the 11th February and reassemble the callipers.
20190202_162303.jpg


Meantime I have most of the carpet templates cutout mainly because the Volvo will not fit under the Kussen/Cussen/Cushion/Upholstery workshop everythng has to be done remotely. Only a few remain for my assistant to help with tomorrow.
20190202_194524.jpg


A last minute brake test run of the VOlvo is a failure it takes 2.5 street lights to stop over the normal 1 and a bit and then the engine starts dying - no fuel. We realise the electric pretank pump is no longer clicking but its working slowly. Strip it out and find its 24volts. Damn they forgot to change n the 12v conversion it's browned out.

Sunday

My trusty assistant turns up so she gets the carpet templates to complete. We have to finish Volvo 1 before we can recomence work on Volvo 2 and Volvo 3 (is going to be started side by sde also).
20190203_154947.jpg


She is kinda tiny and flexible and works unconventially lol.
20190203_162753.jpg


20190203_165735.jpg


However, by 6pm she has all but one carpet template completed ready to see if the cushion shop might be open Saturday since they are not chinese owned lol.
20190203_183044.jpg


While she did that I got the window washers roughly connected and tested successfully in several test positions as we are trying to avoid drilling holes in the cabin.

The end of a frustrating 3 days.

Tuesday and Wednesday is CNY. So I will be back on the Volvo on Wednesday, wife has told me to keep working on it to get it finished.
 
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7 April 2019

Got my little sidekick to help out but since he is recovering from his motorbike accident he slept all arvo instead
20190406_164319.jpg


Then the arvo thunderstorm rains started and we all headed for the treehouse and talked s*** for 3 hours and drank tea.
20190406_182557.jpg


Pulled the window washer and checked for leaks.
20190406_191039.jpg


The carpet is slowly being installed.
20190406_191726.jpg


Drivers side is a mess while we fix up the brakes issue
20190406_192226.jpg


Slowly the carpet is installed.
20190407_190128.jpg


Rubber Door seals installed.
20190407_190257.jpg
 
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1 May 2019

There's not been a lot of real activity on the Volvo 6 weeks of weddings, birthdays a sick friend the passing of my 15 year Rawang Toyota Professor Mechanic. Collected the Landcruiser finally from IPOH 200k away then more issues with the Landcruiser breaking down several times since causing the loss of 2 Saturdays. Then the breakdown of the RED jungle truck and trailering it 70k from town since I no longer have my Toyota professor he did however before he passed recommend a new mechanic 70k from town.

Now back to the Volvo's

We have progressed in the brakes issue to purchasing a 80 Series Landcruiser twin diaphram booster and master cylinder and now im waiting for Andrew to mount it remotely. However the pesky PINZ still torments us and only on the 1st did they get the pesky PINZ back together with all new bearings in the transfer case and the rear differentials and wheel bearings etc then upon testing late on 1st it was still making a whining noise leaving work on the Volvo's stopped.

The window washer was removed as we thought it was leaking it's not now we are finding a new location for it as the 80 series booster is going in that location.

The carpet is slowly being installed.

I have made a bracket for the radiator overflow and mounted the overflow bottle.

We have worked on fitting the doors correctly and straitening a hinge out has sorted out the passenger door bottom. The top is having screw issues preventing the door being bolted down flush.

All the front door seals have been fitted and removed.

We lost the 3 batteries when they suddenly dropped to 2 volts overnight. They are now in a battery revival shop.
 
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Any updates?

Yeah slowly getting there pics later.

The poor Volvo is/was in the workshop queue the pesky PINZ is on its 3rd or 4th xfer case and now its behind the urgent JEEP repaint and soundproof and rekit job.

They are almost finished fitting the new Landcruiser 80 series master cylinder after saving 2inches on the pedal bracket and have about 1/4" more to save to make it fit. Then we have to change the fulcrum point on the brake pedal to give 3/4" more travel to the piston then it might be ready for testing.

I been trying to fit the door tops with no luck until we managed to find some 5.2mm UNC bolts. So then we decided to fit the door tops from the spare sweden doors. So I stripped 2 and OMG found a large amount of rust in the window runners so now they need careful restoration also sob.

The 3 batteries have been revived to about 90% capacity so I will replace them later.

Meantime huge amounts of work have been done on Volvo 2 with the cabin top almost finished sandblasted and panel beaten and body filled.

Pics later.

It will be several more weeks till anything happens as I have the orphanage KIDS kayaking adventure final recce and event to do in the coming weeks.
 
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backchat;44630064 said:
any updates?

A terrible update

We had the haze no work was done on the Volvo I/2 or 3 just stayed indoors for 4 weeks as the workshop is a open workshop the haze made eyes water etc so I stayed away.

We have rebuilt the brake pedal it's almost finished and we have found the brake issue we had 1cm of master cylinder travel not 3.5cm like we need to apply sufficient pressure.

Volvo 1 has spat its batteries sigh 1 deep cycle battery needs to be replaced as will the other 2.

I have been in hospital due to the haze and ended up with serious bronchitis sigh

I hope to have the brakes in by XMAS as we are off this weekend for days to deliver 200 more kids to the jungle villages sfter the end of the school year. Mission impossible monsoon rain and 12tonnes of food to deliver up to 60k into the jungle. From last weekends guys attempt it's 1 day each way or more. I have 12 hardcore trucks with me to try and achieve this. I am on 3 weeks holiday after this so no updates or work till 21st December. I will do a story on the CSR trip when I get back.

Volvo 2 has no progress apart form the new rear window being made up.

Volvo 3 no progress but I am about to pull the cabin off and get it blasted.

Mr Brown the "guard" dog from the workshop who was my weekend companion for 3 years in IPOH is no more he was badly hurt and passed away in a jungle accident recently leaving everyone upset

I hope to have good news by XMAS..
 
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5 May 2020

Well after 9 weeks of the COVID movement ban which started 12 March we are finally allowed to crawl out of our homes and learn to drive again and interact with people but not leave the state and not the 6 cats in my house. The office has told us to work from home for another 12 months at least. However, life is different parts shops have closed permanently, workshops have gone parts cannot be got no stock etc as the suppliers have not reopened. Cannot have coffee together and the list goes on and on.

My condolences to anyone who has lost friends etc from this virus we have been lucky here in Malaysia we managed to get it contained no thanks to people who spread it from a few larges gatherings despite being told not to have them. However, our lives are changed for a very long time moving forward. Those people on the front line are the hero's of all this.

The errant Landcruiser 80 is off to the workshop 70k away to be cut up and the salvagable parts being installed in the new acquired really cheap Landcruiser.

The mighty Isuzu is getting a new clutch and master brake cylinder and rear brakes after something fell apart in the rear drum destroying the complete insides lol.

Now that we have decided to loan Hotpant the 80 Series for her Africa trip. Elcheapo the Africa bound Landcruiser 80 has the engine and auto out with the engine getting a complete overhaul after being able to blow smoke of every colour out of the exhaust. The 5 speed manual gearbox from the other 80 is being installed. Its also being kitted out for overland with roller drawers etc all being recycled and the 80 gutted inside to cleanup any issues before we start the internal cargo barriers and electrical installation.

The Volvo is still up on jacks and has not been started for 9 weeks.

Bleeding the brakes we find the issues the pads are not moving enough. It's back to stripping everything out of the Volvo again. We pull the portals out callipers and all Pedals out Callipers out and strip and rebuild and refit but I could not get the callipers with PADS to install. Finally we see the problem. The callipers had been pulled and rebuilt previously with new pads installed but they did notice that the old pads had had 3mm trimmed from the middle of the pad so it could clear a portal bolt resulting in the pad not clamping the disc correctly. Fitting the PADS after the calliper bolted in caused the pad to hang on the portal bolt. We fixed that and refitted the pads and checked for correct operation. Still no proper BRAKES. We elect to start building up the brakes to the before 2010 status. We add a vaccum tank and the brakes are better we add another tank and build a rack of 3 tanks and add the cross member vaccum tank back to the setup. More brakes now it stops from 60kph but still will not lockup. Investigation to a bigger master cylinder is continuing.

Pulling the portal and discs and callipers off
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Zing is very happy to have us all back in the shop especially at thunderstorm time he has someone to hug.
20200511_133542.jpg
 

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