Build The Volvo C304 restoration.

[cicak]

25 June 2016



Bad Day lunchtime wedding in IPOH to attend with wife. Unpack the new upright toolkit and load tools and parts in it and get to work. No sooner start work on Volvo realise I time to get ready for the wedding.

Return 5pm with 1 hour left before lockup - remove the injectors and that's it for the day - Wasted day

26 June 2016

Have help this morning and we start with the service hatch panels mounting.

This side takes us 2 hours sand the edges down from the lazer cutting drill the holes properly remove the door frame drill the hole in the frame remount etc. The lazer cut out pieces are being recut so I can weld them in next weekend. Then will sand and undercoat ready for the top coat

The other side the two panels don't fit so well the top half needs trimming and the bottom well start again. No pics they are so bad.

Then it's a quick look at the air cond condensor, intercooler and fan setup. Damn more issues for the workshop to correct before I mount them.

Then I try and mount the overhead console which is a bust it's 8mm too long I cut the 8mm out but we run out of time and I do not have the 4mm hex impact driver to drive in the RIVNUTS damn curses.

The new gear change tierod setup is left for them to engineer a new bar so I can use Toyota parts which are plentiful here and oh cheap.

Home time bye bye to the workshop puppy - there is always next weekend.

 

[cicak]

2 JUly 2016

That drive the 5.45am waking up on a Satuday morning and the 190K drive to the workshop in Ipoh is getting to me I just floor it the poor little Isuzu just soaks it up.

First work on the engine sort out this smoking thing iv'e been told to run it till it stops smoking - it's running and smoking for about 4 minutes and then it revs up and DIES. A mekanic is organised for Monday morning from the factory behind.

Then I look at the fuel tank leak its gotten worse since last week more parts neded from the hydraulic shop to fix it.

Next job try and install the speaker panels. Make a template for the ends and cut the shapes out. Then a fitup it ain't right. I realise it's 30mm missing in height. Next I get the angry hammer out and flatten the top bend out then realise the top is where the bend should be sigh 30mm is missing.

Then it fits. The panel will be retuned to Rob's Sunday night to fix the measurements and be cut at the new lazer cutting shop sometime in the next 2 weeks.

The overhead console is next it' to heavy for me to handle like this and it won't fit well so I trim 13mm off the front and reshape the angle then it starts to fit. However, I need to cut it in 2 its just heavy for me to manage by myself. I select the cutzone and slice it in 2.

I fit all the RIVNUTZ to the roof recycling old holes drilled for something before and the 4mm RIVNUTz eventually are all fitted. Time for workshop close and go collect my SUnday helper. A pleasant night at hawker stalls drinkin beer and ordering chinese food from the food stalls is a welcome relief from the travelling.

3 July 2016


First fit the speaker panel and pose for a pic

We start on the overhead console and get it to fit bolt the rear half in
and take a pictue later in the day

Then we work on the left passenger dash panel Joy's job is to make sure it all bolts in clean and bolt down the centre console properly.

We cut the centre console top into 3 pieces as it's realised the panel cannot be removed once the front windows are in and drill out new RIVNUTz

Then the wanna be apprentice I say make a template for the exhaust heat shield. Why not cut it out now he asks why need a template. "Perfection/Quality" is the response.

It will be cut from stainless steel next week and install on the 16th weekend.

The workshop owner turns up and we decide I will stay Monday and get the engine worked on as he is away for 3 weeks from Tuesday morning.

We fit the centre console panel but I forget to take a pic until monday night.

6pm home time floor it to Kuala Lumpur there is no traffic its all heading north for the coming holiday and we visit the lazer cutting contact with the overhead console and the speaker panels and now the exhaust shield.

The console will be cut from alloy and welded up for me by a local expert alloy welder.

Then I turn around head home collect clothes say hello and goodbye tot he wife and the cats and head back to IPOH and find a cheap hotel close to the workshop.

4 July 2016

Cleanup the truck and put everything not needed on the workbench and my new mobile toolkit and reprime the fuel lines.

The workshop guy turns up about 11am and he looks over it all inspecting vaccum hoses and my home made ignition etc Then he ses start it up. It coughs and splutters and then it idles away slowly no smoke nothing huh what the hell its working fine. I offer the mekanic compensation he sees I love diesels too no need to pay me and heads back to his workshop behind ours. I let it run checking cooling hoses

etc it's all fine. We suspect the injector pump was slightly stuck.

Progress finally it runs properly.

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[video]

So next tasks alternator plugs to be obtained

I work on the undercoating the new welded on parts with primer then top coat using a brush - rough but it turns out ok.

Try and fit the air filter. Won't fit I cannot work out why even looking up old pics until we realise we added a 45 degree brace to the frame just before we sandblasted it. I need to find a new location for the filter.

Rear cabin panel can now go on I will get a rubber seal next friday. The cabin install gets closer and closer.

The air compressor tank gets a location for me to install it.

The battery box will be redesigned to allow the smaller batteries to fit side by side.

Fuel tank cap organised I need get a PROTON one and cut it down.

I take the drivers dash and look at how to make it removeable as the clutch and brake fluid

containers are in it.

Next weekends list is ready
- Alternators wire up the batteries.
- Rear tail lights fit
- T-MAX winch sort out the wiring
- Fit the air filter
- Fit the air conditioning condensor and refit the
- Blank out the air cond blower 3rd hose
- Make a y pipe up for the air cond ducting
- Finish the air compressor bolt lockdown
- Fit the air cond tank
- Fit the rubber seal to the rear window panel

6PM home time

 

[cicak]

9 July 2016

We head off the night before for the long 190K drive to IPOH as it's holiday week and the traffic could be rubbish. We arrive 1am on schedule in IPOH however, we cannot find a spare hotel room everything Is full. 2.30am sick of searching we decide sleep outside the workshop. The puppy goes ballistic with glee as he hears the Isuzu pull up. Bad move we get no sleep mosquito's plague us and the guard dogs from down the road keep running up to the truck barking.

Workshop unlocked after 9.30am as two tired people work on the truck. Little Joe from the orphanage is my assistant this weekend.

First job for Joe is to undercoat the galvanised fuel tank cover with galvanising primer paint.

His second job while I tackle the 4 holes in the roof which turns to 5 when a pin hole hole is revealed. Joe takes stock off the wiring loom ends to count the wires at each end point so I can purchase the necessary waterproof plug sets.

The roof welding is ready for cleanup next weekend.

Then it's time for a visit to the hydraulic shop to convert the fire extinguisher into a air tank.

We burn 4 hours while explaining to the hydraulic shop what I want they look sceptical but tell us to come back in 60 minutes. Lunch at KFC. Then off to the paint shop to order more paint. The girl behind the counter looks at the tin and says for Brett's shop - yes - Ok come back Monday this colour takes a while to make up. Ok next Saturday then. Joe says that girl is HOT - I laugh yes she is lol.

Then we run off and get some clues for finding a good wiring shop for alternator plugs. We find it The guy says what are you building shows me pic's of his 1950's cadillacs and chryslers. The pic's of the Volvo make him happy . We show him pic of the unknown Nissan Alternator. Ah Nissan Sentra I have the plug. Then the 14B-T - I have the plug. Wiring and connections for the alternator cables is organised we are set. Back to the hydraulic shop to collect the tank.

We get back to the shop 4.30pm however a successful day.

We wind up work 6pm and go buy Joe some clothes and a decent meal we are both dog tired and then to my mother in laws to stay for the night.

Sunday 10 July 2016

9.15am we roll into the workshop. Joe's first job start the truck show him how to jump start a Diesel. Let it run no leaks etc. all perfect and fix the air leak from the injectors.

He is given the job of making the wiring loom for the reversing camera and spare wires and 2 earth wires right through to the front of the truck. Takes him to lunchtime and we fit it after lunch.

Then we clean the truck out and install the floor so we can work on the roof wiring and then work on the air filters new home and finally finish the intercooler and air cond condensor bolt down.

The intercooler has an issue the bottom bolts do not line up quite a bit of force to the right is needed to make them line up not good. will take time next weekend to fix. I fit the new air condensor fan since the last fan fell off landed on Peters head then the floor and broke sigh. Cut allen bolts to fit the fan to the air cond condensor and that is almost ready for painting have 6 little holes to TIG up first and make a bottom bracket to hold the fan etc next weekend.

Then the air filter needs a new home. Location is found and it will be a next weekend job also.

We have spare time so we get out the plastic dip kit and Joe prepares the door handles with the polisher.

They look ace - top part to be done next weekend.

6pm Lockup time - dinner before we head into the Holiday traffic - good job as it's 4 hours home.

 

[cicak]

16 July 2016

Quiet drive up to IPOH

First fix the intercooler as only 3 bolts fit easily the 4th needs pressure to make it fit. I spend all day running up and down fitting and drilling the intercooler holes and lowly make headway.

Start working on making a bracket for the Air Compressor

Then it was hometime again as the 6.30pm lockup time arrived.

Then monday night going to dinner we collect this little treasure off the road a little injured and a little sick. It's name is now Rocket.

I collect the doors from the panel shop they are really well done. Very little body filler will be needed.

 

[cicak]

24 July 2016

Sunday run up to IPOH as I did charity work on Saurday.

Take the doors up to IPOH will work on them next weekend.

I work on the Air Compressor tacking in the brackets for the tank

Then I spend time (over an hour) polishingg the door pins to a nice shine and then apply a coat of undercoat to them.

Then it time for home after I lay quickly an locker air hose and shield it and sheild the alternator wiring.

 

[cicak]

27 July 2016

Collect enough steel to fix the door pin tube I had to cut ready for the weekend.

and the ARB solenoids to remove air locker hoses from the cabin are collected.

 

[cicak]

29 July 2016

Take a day out of the office and head to IPOH on the Friday morning.

First interruption for the day is the puppy he snatches the rat trap down from the gas bottles with the two rats in it and proceeds to run rampant around the shop floor carrying and barking and pushing the cage. Then I go get undercoat paint and air hose fittin and pucase 3 vaccum hose sets and fittings.

The stainless steel 70mm bends I bought are now being prepared to go from the air filter to the turbo working backwards a lotof cutting and tig welding is required.

Slowly it takes shape.

30 July 2016

I have the taillight brackets they need 2 more bends and they are ready to paint and be mounted permanently.

Brett tig welds in the plugs the ends for me for the door pins so its easier to knock out next time.

The air intake pipe is taking shape

Then I tackle the doors starting to cleanup with the wirewheel and the paint tripper again.

It's going to be a lot of work

31 July 206

Help has arrived so we have 3 working on the Volvo today - Today's todo list.

The air filter's new locaion takes shape

A happy sander knowing the sanding is almost finished

4.45pm the doors look good and sanding with 1000 grit only left

By 6.30pm I have the 2 doors completely painted althouh I only get a pic of 1 pair.

Then we bend up the tailights bracket and its time to get kicked out of the workshop.

it's a long drive home 3.75hours to go 190K a rolled over CO2 truck caused chaos.

 

[cicak]

8 August 2016

Saturday was charity day with the kids

Sunday

Took the wife for the 190k drive to IPOH

Only 3 hours on Sunday on the VOlvo arrived 3pm at the workshop and checked the doors etc I undercoated the previous weekend. Finished the tail light brackets off.

Undercoated one of the service hatch doors and a few small issues wih a few high spots on the doors.

The count of painted vs unpainted parts is now looking much better.

Still outstanding delivery of speaker panels, overhead console, steering wheel wih race boss. gear lever with new bushes.

6pm time for dinner with mother in law then discovered the puppy had eaten the trailer wiring off the boat trailer I was taking home- oh s***.

and then the long drive home another truck issue caused us to take over 3 hours to get home again sigh.

Slowly i'm geting there.

 

[cicak]

13 August 2016

Saturday one day trip - Sunday I'm in the plane to Kong Kong for 2 weeks

I'm tired long hours I wake up late and step on it the 190K flies past and I arrive outside the workshop 8:57am same time as the owner pulls up.

They are repairing my tire wiring since the puppy chewed it all off.

I see they have finished the radiator inlet piping all nicely tucked away just the radiator outlet to finish.

I have today 2 doors to top coat. The repaired rear panel to strip and undercoat and top coat.

The service panels to apply top coat, The air filter and taillight brackets to paint oh and rubber seal parts to hunt down.

The heat shield will be welded up by the workshop during the week and mounted.

I stripped the rear panel then it was time for the shopping before some of them close 1pm

I received instructions to a rubber shop. Bonus they had the seal for the rear cabin I bought enough for 2 Volvos. The second oh year I bought another Volvo last Saturday after the Kids charity day lol.

Bolts (and RIVNUTS) collected and more undercoat from the paint shop back to the workshop 2.30pm

By 5pm the rear panel is stripped sanded and undercoated along with the rest of the bare metal parts.

By 7pm the tail light bracket and the air filter are painted and the air filtter bolted down

The service hatch doors dry and when they are dry enough I mount them on the truck to keep them safe. A small resand and final top coat need to fix a few little mistakes. Wow they look ace.

9pm and I'm still clearing out parts and trying to clean up

Taillights look ace also then I try to bolt them in. The RIVNUTS will not fit in the holes damn I got the wrong size. I don't bother to try and redrill the holes im too tired.

Then I realise the issue. Oh no the rear panel some paint is lifting despite high pressure hosing and sanding the paint stripper has had revenge. Some of the doors need to be resanded and a few body filler marks fixed. The thunderstorm during painting has left huge amounts of water in the air tank some has come out on the doors also.

Packup the workshop and make a list. To fit the cabin all I need is the heat shield mounted and the radiator outlet completed and the last bend of the air intake done.

10pm Home time - hook the trailer and boat up and its time for home for that long 190k drive home. I stay awake all night prepare 1 car for a charity event for a kids home for a friend to drive and the ISUZU is prepared for the employee to collect and do running around to fix the 8 broken ATV's from our business, packing for HK. I finally fell asleep 5pm in the Hotel in Hong Kong on Sunday.

Progress sometimes is tiring lol.

And that Volvo it's in really bad shape. I know the resort it used to run on taking tourists and saw it being abused.

Right rear cross member ripped off etc.

 

[cicak]

awesome that you've got another! what's the plans for the new one?

So this is the idea so far:
- rugged shopping trolley to go to expensive malls and jockey park it beside the farking porches ferraris's and Bentley's if you think i'm joking i'm not lol.
- Toss the rear tray steel round tube tray with alloy tray and slightly chopped.
- Full restore of cabin covered in a comp spec rollcage - think Dakar truck - Rahmat from Rahmat playhouse garage is already crying after seeing the pics
- 2 winches probably 8274's
- fix missing section of right rear chassis
- rear mounted radiator and intercooler etc
- air suspension and if I can get past road transport a-frame suspension
- 2 sets of doors one with windows chopped off other full doors (handbag days out with wife).
- fit race harness seats and belts
- engine possibly 15B-T and Toyota auto gearbox
and that will be it one big fun offroad truck that I may use in comp to show because I CAN lol

Rollcage made in IPOH rest done in KL at a workshop (or rent half an engineering shop still looking) by me and yet to be found

 

[cicak]

4 September 2016

Yes it's a Sunday, Saturday was spent taking the long narrow boat to the boat factory 2 hours north of the workshop where the Volvo is, so hence 4 hours north of Kuala Lumpur (370k away) and along with the new tank and gauge for the boat I'm getting renovated/rebuilt read for the 1-9 October trip.

Unfortunately I arrive at the boat factory 15 minutes after it closes thanks to a truck accident which blocked the highway tunnel off for 60 minutes means I gotta come back Monday morning.

So I gotta crap load of work to do remove the fuel tank there is a pile of diesel on the floor again. is time it's drastic action required.

Tank is removed and washed out an dried ready for Mondays fixup.

Then I find the reason for stuff (food ) disappearing from the back of the truck the errant puppy can climb and walk on beams.

Then we weld up the exhaust heat shield and is a bust it neds to be remade sob as it WARPS after the tacking welds.

Then it's onto the roof I have the remainder of the 5 holes to weld up grind weld up grind.

Eventually its done but the bends in the roof from its life as a police riot squad truck are left.

Tank I'm ready to create a new bung Monday.

5 September 2016 - Monday

Early morning - 7am to be exact I'm back on the road 2 hours or more up to the boat factory drop the boat off and deliver the new fuel tank and see the transformation of the restored boat

Then it's a long haul back to IPOH coming

Big delay on the way back due to this rolled truck sigh another hour lost.

I cut the new bung out of 8mm alloy block and drill the hole and tap the thread and hand it over to be welded to the tank. When we shut the factory at 6pm it's tacked in.

 

[cicak]

10 September 2016 - Sunday

Work is on the rear panel final sand and preparation. I spend most of the day working on this.

The new bung is in the tank and I re-mount the tank and put 72 litres of diesel in it. Bravo 8 hours later it's not leaking. It's finally fixed. Only the tank cover to go.

11 September 2006 - Monday

 

[cicak]

16 September 2006 - Friday public holiday

Sunday morning hit the roof with body filler all the tape is where body filler small amounts have to go.

By early evening I have the cabin top sanded and undercoated

17 September 2006

Finally it's painted then I see the mistake the leak in the paint can has leaked onto the valance sigh

Rest of the day is spent preparing a RHD steering asseembly for a guy in Melbourne which I salvaged from a wrecked Volvo.

Now for the long break next weekend is collect the boat a prepare it and my camping for my 1-9 October holiday of camping and fishing.

See you all in a few weeks.

 

[cicak]

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

 

[cicak]

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 workshop 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

 

[cicak]

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 of the floor so it 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

 

[cicak]

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.

 

[cicak]

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

 

[cicak]

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

 

[cicak]

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