Builds Volvo 2 - C304 from totally neglected to something different

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21 July 2018

Working today so morning rush out have nice breakfast then and do shopping errands. Collect the new race seats for the Volvo and deliver them before heading to the office but not after going to the Garmin shop to sort out the continuing insane issues with the crap product the GArmin 585 GPS and its associated software. Then its 12.00am in the office and again at 4am to 8am sigh,
Andrew has been busy measuring up the rear panel to get the template ready to have it laser cut.

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After working the last 3 weekends I'm worn out.

It's going to be 3 weeks before I can work on the VOlvo unless I finish the deadline Tuesday So I can have Saturday on the Volvo before I work the night shift sigh.
 
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21 July 2018

Working today so morning rush out have nice breakfast then and do shopping errands. Collect the new race seats for the Volvo and deliver them before heading to the office but not after going to the Garmin shop to sort out the continuing insane issues with the crap product the GArmin 585 GPS and its associated software. Then its 12.00am in the office and again at 4am to 8am sigh,
Andrew has been busy measuring up the rear panel to get the template ready to have it laser cut.

20180721_121613.jpg


20180721_121652.jpg


After working the last 3 weekends I'm worn out.

It's going to be 3 weeks before I can work on the VOlvo unless I finish the deadline Tuesday So I can have Saturday on the Volvo before I work the night shift sigh.
 
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5 August 2018

Worked the last 4 weekends I have no idea which day it is. But quitely in the background Andrew has been weaving his magic on Volvo 2.

Since the front panel was 2 piece Andrew replicated it exactly - no I'm not replacing the orignal 1.2mm with a single 2mm front plate. Side view of the two plates joined.
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Side view of the two plates joined.
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Old front panel was removed from the top panel.
20180728-WA0003.jpg


Now it's ready to be welded in.
20180728-WA0005.jpg
 
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11 August 2018


Wife went to screen printing class I went to work on Volvo 2. Axle assembley day.


Took us 4 hours but eventually we got the axles assembled. Now I have to go buy 24 new diff lock nuts and replace every diff nut one at a time. Then every portal bolt - 8 per wheel as some of them are shwoing signs of stretching and wear from the portal bolts not being kept tight or locktighted by the previous abusers used on them they have worked their way loose and are now useless.

Landcruiser II Discs and callipers adorn the portals and all new bearings all round.

Front axle
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Rear axle.
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Oh I also bought Volvo 3 now affectionately know as Volvo 4. Went half's with my buddy the boat builder. Delivery is Wednesday.
 

Pacer

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11 August 2018


Wife went to screen printing class I went to work on Volvo 2. Axle assembley day.


Took us 4 hours but eventually we got the axles assembled. Now I have to go buy 24 new diff lock nuts and replace every diff nut one at a time. Then every portal bolt - 8 per wheel as some of them are shwoing signs of stretching and wear from the portal bolts not being kept tight or locktighted by the previous abusers used on them they have worked their way loose and are now useless.

Landcruiser II Discs and callipers adorn the portals and all new bearings all round.

Front axle
20180811_164650.JPG


Rear axle.
20180811_164706.JPG


Oh I also bought Volvo 3 now affectionately know as Volvo 4. Went half's with my buddy the boat builder. Delivery is Wednesday.
Ah, got the memo now.
 
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1 September 2018

Long weekend and I gave myself 3 days complete rest after the long hours at work then the kids home kayaking trip I decided rest was needed.

Went and visted Volvo 2 and 4 while they welded up the mighty Isuzu's exhaust.

They have completed installing the Axles under the chassis and it's standing back on its sneakers.
20180901_151622.jpg


The cabin front panel is welded in and looks completely factory. Only the "A" piller repair remains/
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The engine mounts look like they are getting closer to being completed.
Volvo 4 looks bad in places but definately not as bad as VOlvo 2 was.
 
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6 October 2018

After collecting new winch cables for Volvo 1 and the new fridge from the shop it was time for lunch then work on Volvo 2 for the afternoon.

Work is held up on Volvo 2 engine mounts due to the unexpected Pinzgauer engine rebuild going on on the restored Pinz. 2 people took the engine apart and then got removed from the workshop so the poor workshop owner is trying to put it all together after balancing the pistons and conrods. This truck needs to be finished to give Volvo 1 a bay when it's transported from IPOH to Kuala Lumpur in the coming weeks.

Meantime we decided to work on the new doors and sanded them down ready for primer and tapped all the dents out from the transporting from Sweden to Malaysia.

All was ok until breakfast decided to upset my stomach sigh.
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The engine mounts look like they are getting closer to being completed however then the other PINZ decided to spit all its oil out the dipstick on startup in the afternoon. Oops another rebuild needed more delays to Volvo 2.
 
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9 February 2019

The cabin has been sitting there for over 5 months while we worked on Volvo 1 we had one day when the new apprentece came over and got panel beating lessons. I had the new sidekick work on a few of the dents to teach her the basics of panel beating.

The engine mounts look like they are getting closer to being completed however then the other PINZ decided

February the new sidekick wants to learn how to build these trucks so start at the beginning almost basic panel beating.

We got her to tap down the high spots and using the ruler to check the flatness of the panel.
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Concentration is intense from the new apprentice.
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There is always time for Zing who seems to get attacvhed to all the females who turn up to the workshop.
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Tap tap tap.
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28 April 2019

There is a break with Volvo 1 so I was sick of the rats running over Volvo 2 cabin it was time to pull it out and clean it up ready to drop Top cabin on it. A heap of effort from the 3 of us dragged it over the gravel driveway then gave it a huge bath. The rat jumping out inches from my face did not impress me.
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Cleaned and moved into it's new room.
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1 May 2019

Volvo 2 day decide to get rid of the surface rust on the roof of Volvo 2 it's getting bad with the huge amounts of rain we are having. 5 hours of wire brushing and 600grit sandpaper I have it cleaned up and painted. It looks surprisingly good only a few spots need some body filler applied.

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Then its onto the rear panel the little corner I have cut out and bent up is missing I need to remake it sigh.
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It's a great view as I head home knowing forward progress is being made. Once Volvo 1 is complete Volvo 3 will join Volvo 2 in the same bay.
20190501_172754.jpg
 

Pacer

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You have just taken over the workshop, lol, full time adventure trucks for Cicak :steer:
What did this shop do before you showed up with your fleet?
 
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Wahoo the JD Squared 32 bender has arrived from the USA at some point we can commence to build the roll cages for Volvo 2 and 4 once we set it up on the shop floor and relocate the notching tool and the vice etc.

However its missing a PIN from the parts kit. We cannot finsh assembling it until the vital pin arrives.a
 
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