Volvo 2 - No not another one

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Oct 15, 2005
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Malaysia, Kuala Lumpur
 
Ok so while rebuilding the Volvo I got the idea to restore another and do it faster this time and do the work myself where posible.
Volvo's here for sale are few and far between.

Suddenly we had one for $70,000rm(15,000EU) "restored" looked terrible. Then one popped up for 16,000rm (3,000EU) I rung and got an appointment. To my surprise when I viewed it he had turned down offers for the truck as people only wanted the axles.

I made an offer showed him pics of Volvo 1 and he said SOLD.

So this is the story of a secret build (my wife has no idea) until I finish it.

It will not be a expedition truck but i'm leaving it here as there is no forum suitable on this site for it's eventual style.

Pickup condition

It's ROUGH I know the tourist resort it ran out of and saw it being abused never thinking I would ever own it.



Right rear cross member is ripped of the chassis. Left side is bent.


It seats 12 people FRU policeman in full riot gear lol!


It's nice side


The wheels turn


Looks better in the setting sun in my friends private ship salvage workshop or does it?
 
Joined
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21 September 2016

First nights work on it remove the ugly front winch mount




Finished looks nicer already


Removed the passenger seat and cleanup up. The rust becomes apparent.


The pile of scrap metal starts to grow. I'm sure they will make a compact Ford out of this soon.
 
Joined
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16 October September 2016

Two of us attack the rear tray object is total removal of it over the coming days


3 hours later and 38 cutting wheels are consumed but the sides are removed.


The pile of scrap gets bigger


Peter runs around and takes pics of the inside for me.
















 
Joined
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23 October 2016

New Makita 7" grinder in hand.

Commence to cut the bed up. A plasma cutter arrives Tuesday

2 hours I got this far.


Then I got a process going and 4 hours I had the left side removed.


The pile of scrap grows



So what is the plan.

Since Volvo 1 is 2 hours away I am planning to work on Volvo 2 at night after work until I finish Volvo 1.

This is the idea so far:
- Bad Arse big offroad tuck like they have never seen in Malaysia
- 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
- Bob the rear chassis 12inches
- 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 (4.1 litre 4 cyl diesel) 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
- Air suspension kit has been ordered and the air guy came around to look at the truck.
- Rollcage made in IPOH rest done in KL at a workshop near work or home.
 
Joined
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1 December 2016

Had some free time tonight so decided to try and remove the flat tire and start removing the wiring loom or do the rollcage.

So first task get this flat tyyre off finally. Heat 3 minutes one side of the nut and then about 60 seconds on the other whack the breaker bar with the 4lb hammer a couple of times and hey presto I had a result.


I decided it was late so started on the rollcage template and see how the sketch looks like in full size. I will finish it all off on Saturday so far it's looking good.
 
Joined
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3 December 2016

Had a few hours after the Kids CSR day at work so off to the Volvo with the repaired tire.

Started pulling the wiring loom while the light was good this truck is just full of surprises rodent nest inside the dash sigh. I'm still expecting a snake to slither out.





The rodent nest


Finally got the tire back on after cleaning up the ends of the studs with a cutting wheel to emove the burrs etc. Cheeck the other wheels all te same need to be heate removed and then cleaneed up and re-atached sigh need another 2 butane bottles lol.
 
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4 December 2016 Sunday

Told wife going to help someone on a PINZ lol. Headed over and started on the removal of the wiring loom and everything from the dash.

By the end of the day I have removed the dash panel and labeled the wire ends.


The brake/clutch pedal braket sigh its been bent by someone over pushing on the brakes HARD and rewelded what a mess. Need to strip it off repair, remove rust and the ugly chicken s*** welding reweld, and repaint.

Still trying to figure how I will get a 36 year old wiring loom out of the fire wall. I think I will have to cut it and label every wire sigh.

Worked on the PVC rollcage then time for home as the whole of next week is on Volvo 1
 
Joined
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April 2017

The Volvo 2 has a new name "BADASS".

The tow truck picked it up from the current secret location.


Then it was ready to transport to the next stage of it's transformation into BADASS.


Then it arrived at the panel shop. So shocked they were they locked the doors lol.


Daylight inspection shows the damage.


Right rear cross member missing. Middle Bent from a bad recovery the wire and the left side also BENT. It will be cut off and replaced by me later at the RACE shop.


The inside is a mess floors non existant.


Front is pretty bashed up as is the top of the cabin.


However, Rahmat says all fixable and I'm welcome to come down when they start and work on the truck also.

It's now in the queue in the workshop Stage 2 will commence when they finish the current jaloppies, Including a 1968 mustang and a 1950's chevy.
 
Joined
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7 September 2017

They asked me to go down visit Volvo 2 as they had made progress and cabin not long from being separated from chassis.

Took them lunch also. THis is the first view I got neat Rhamat and crew working on it.


Bracing on the inside some work had been done on the front sides to pull the panels out to make them all flush again.


The rear view nothing to see here.


Inside view then the cheeky workshop cat decided I had food and started to investigate next time I will take him food. YUp the floor is rotten and are some of the interior panels.


Rahmat starts dreaming when its all finished I can go for a ride in it - maybe - lol






Yup its uite messy inside


Drivers floor is non existant. I have given them a plan to follow to make it easy to restore.


I like it.


Now the plan.

Next week late the cabin comes off. I take the chasssis to the workshop and we start work on the rollcage and the new rear tray. Will make a decision in the engine and gearbox. Once all done then the suspension and be done and by that time the cabin should be ready to be reinstalled (XMAS) just like a real car manufacturing production line lol.
 
Joined
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16 September 2017

Visit to Volvo 2 cabin workshop

First the cheeky workshop cat.



They have done tonnes of work stripping the paint off with a heat gun looking for holes and repairs etc.


The rear looks ok apart from the rear panel it has a few bad spots.




Then I started on the cabin template from plywood/ Next weekend will finish the front side so we can build the roll cage while the cabin gets surgery.
 
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21 October 2017

The Cabin and chassis have been separated after some difficulties with pulling the steering wheel off.


The chassis is ready to go to the rollcage workshop.


Saturday morning they have stripped the roof with a heatgun no sign of holrs or rust. Sandblasting is next.


The tow truck eventually arrives and is loaded up.


Then it's dropped in to its new home. It will have a PINZ for a roommate.





Work starts next week on the rollcage after a design discussion.
 
Joined
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Saturday 11 November 2017

After working till 2am for the Single day sales I was in no shape to go to IPOH 190k away so 1pm I'm in Volvo 2 workshop some 15 mins from home.

First pics of Volvo 2's stable mates one immacutlately restored PINZ and


the other almost finished its transformation to covered long distance touring wagon.


The puppy is really happy to see me.


We mount the wooden cabin template raised 4" and then I start cutting of the rear bent up cross member. hours later its all made mincemeat with the 7" angle grinder and the little 4" grinder and it's ready for us to get the new one cut.


The truck is ready to go. New engine and gearbox has been ordered from the wreckers lets see if they can deliver a 3.0 ISUZU diesel and auto gearbox from a DMAX.


Front view of the cabin.


The wooden cabin gave us an idea and now the rear will have two parts. One will be old school wooden tray and sizes (for dressage) all removeable and the other will be alloy (for COMP and hooning)

More progress pics as we progress.
 
Joined
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23 November 2017

Work on VOlvo 2 continues. The steel for the rollcage is being ordered.

The engine and gearbox is to be lifted out.

Even better news is I had little choices for engine and gearbox combo's.

I cannot obtain and ISUZU engine and gearbox so went the other extreme since I hate the remaining alternatve of Mitsubishi engine/gearbox or toyota 1KZ/auto.

A 2JZ Toyota Supra VVTI 1/2 cut has been obtained and will be mated to a 4x4 auto gearbox.


Then it's going to a wireman to recover the loom and give me a turnkey engine and gearbox.

A lot of the other parts from the Supra can be used - DASH etc Radiator and all the overflow bottles and the headlights and indicators etc.
 
Joined
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2 January 2018

Volvo 2 is in 3 workshops.
Chassis in a shop near my office. Where rollcage and engine will be fitted.
Cabin in another workshop 10k from work - progress reports are not coming in neither are pictures - not happy. I am hearing from other customers from this shop they are really unhappy and just want a decent days woirk from this shop and it not be closed each time they turn up for work review and unasnwered phone calls.
Engine and gearbox and portals are taken to a 3rd shop 30k away where he is a trusted mechanic to do what I need.

Work on Volvo 2 continues. After work I drop round to Volvo 2 workshop since it's 10 mins away from work and on the way home.

Had the 2JZ-GTE engine and gearbox in the Isuzu.

So we jacked up the Volvo onto it's new stands. Started pulling the Vovlo axles off. They do not get the last of off till next day as the broke 2 bars and went through 2 bottles of gas heating up the wheel nuts.

The engine was unloaded using the car hoist. I will collect the portals next week to take to the other workshop to get converted to Totota Discs and all new bearings etc.

We are waiting for the new bending machine to arrive from the good old USA before the rollcage bending can start.

The puppy decided he should help out.








The 2JZ is to be converted to single turbo and a general cleaup to make it a lot slimmer and less chances of hoses splitting etc. Currently it only has 1.5CM to fit inside the cabin tunnel.
 
Joined
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Messages
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2 February 2018

The engine and gearbox is out now that they have a portable engine hoist in the workshop and is all leveled out on the workshop floor.

 
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