Our Volvo C304 Restoration Project
We have acquired a Volvo C304 (4 wheel model only) and in the process of restoring it.
26 July 2010
As we pulled it out of the storage park with my BJ75 on 26/07/2010. It was not running but would tick over.
The BJ75 struggled to pull it it appears the brakes were frozen on.
So onto the tow truck and down to a performance tuning shop hahaha.
Once they removed the spiders and cobwebs from the fuel tank it started.
Then they changes all the fluids. But they could not fix the brakes so I made decision to do the DISC conversion first before the rust treatment. I drove it around at nite for 2-3 weeks testing it out - without brakes (and almost without lights like two flat torch lights) and only using the gears and handbrake. I learnt what was good and bad in the truck and what needed fixing. Now I have a 40+ item list to attend to.
Then last Saturday I took it to the Rawang 4x4 hospital (escorted by the BJ75 to get me home) which was entertaining saw this on the way out. Oh yeah I burnt off a 22R powered LC II on the way up a hill it could not pass until the downhill part haha.
This is it after being washed and driven for a few weeks. Mr Grumpy my neighbour hates it and all 4x4's the other neighbours in the street think its neat including the ("SIR") who I took his kids for a run in it now he wants to book a jungle trip with me.
The interesting one is my car illiterate neighbour she I quote "that engine sounds so sweet" its nicer than my Honda. Then where is that big beautiful 4x4 on Sunday she asked.
Then the serious stuff removing all 4 wheels and portals - yeah yeah thats me working on the Jalopy.
Me working on the last wheel. The mekanik did 1 I did 3. Not bad for my first ever working on a Vovlo and no manual either.
7 hours later a stack of portals.
Once that was done it was over to the BJ75 and pulled the WARN 8274 out of it it has water in it - rats and the new axle to be fitted and a new knuckle this week and new leaf spring bushes and it also has a brake problem.
- LC II Front Discs front and rear as this is a part which is readily available.
- Install the WARN 12,000lb winch for REAR recoveries
- Fix the tail lights with LED lights
- Fix the indicators
- Fit new headlight wiring and H4 halogen bulbs and new reflectors
- New radiator hoses and break hoses.
- Battery Rack for 2 solar batteries and 2 120amp batteries and a 150AMP Alternator.
The rest of the truck is STOCK. I have previously been in (and out) a C304 during the RFC2007 when we got flooded and I was in the BJ75 in the same small convoy of 6 of us. I know what it can do - awesome. I cannot wait to take mine offroad here.
Latest status is PORTALs with DISCS being assembled and fitted this coming week. Rewiring of HEADLIGHTS, REAR lights and Indicators being done this week along with new fuse boxes. Rear 12,000 WARN WInch being installed sometime this week also but not wired up thats my job later. Maybe it might be ready to roll out of the workshop this week then it will be driven for a week before going to get the RUSTed front removed and replaced. Fixed the passenger door lock up on saturday finally it opens.
The portals being fitted with DISCS and BEARINGS
The finished product and it moves.
Well after waiting almost 5-6 weeks brakes are done and more mods done. Came out of workshop with new disc brakes working but not well so new master pump seal kit and strip and rebuild the vacuum pump and hoses and wow they work very well long soft travel. It's now boasting Landcruiser II Front Callipers and new rotors and Pajero front callipers on the rear discs but its not stopping well.
Took it to a workshop and they stripped the master cylinder fitted a new seal kit and stripped the 10 tonne Hino vaccum cylinder and repaired it and wow they told me it had brakes again. Not bad for a MAYANMA mekanik who got instructions from the cantonese mekaink I told in broken english who only speaks Cantonese and I used bahasa and english and cantonese to explain what was wrong to him hahaha.
New air filter box fitted and vacuum lockers are to be swapped this week for air as cannot buy the rubber seals here - rats more money.
It's almost ready for a trip to the jungle.
The new look with 6 stud FORD rims - FORD - mmmmmmmm gotta fix that.
Front Wheels now offset an additional 60mm with the FORD rims.
Offset from the hub to the edge of the tire hs now widened the track 60mm each side.
The brakes in the Volvo are now AWESOME is all I can say long soft Travel and powerful extremely impressive for its weight and considering its a truck.
First offroad trip a shakedown run last Sunday.
Spent all Sunday afternoon changing the two engine fan belts don't ask its a prick of a job as the alternator has been changed previously then we noticed the belts etc do not line up the alternator is 3-4mm out :( . This needs to be fixed in the coming weeks.
Then we changed the radiator hoses as they had RUST in them. Then we tested out that mighty PTO winch yup it worked also. By 5.00pm we are ready to go to the jungle Ulu Slim some 90k away.
By the time we headed into the jungle its gettting dark. Stupid us but we really wanted to test it out.
At the first steel bridge we take the creek and yes we got stuck as the Volvo stalled as it was missing under 2,00rpm as I crossed the river.
Then we were stuck no way back and no way forwards and by ourselves duh!!!!!!!!!!!!!!! and then we realise only 2WD is working and we have no front drive :(
Cleaned out a rock or two from behind and then we reversed out and then drove over the creek at a faster speed hahaha. Up the hill and it was very slippery wet and muddy we decided to turn for home. Then we only had high beam and a missing truck under 2,000rpm. Back home at 9.30pm after driving flat out at 4000 rpm at 80k for the 90k home hahaha.
The perspex windows need to be replaced before it can go out at nite again its too hard to see out the front windows.
Monday arvo dropped the Volvo back to the workshop at Lunchtime to find out why the front axle not engaging and picked up the Landcruiserr II and drove it back to work the first time I had driven the Landcruiser in 5 days. They also to remove the radiator and flush it .
On the way to work I notice:
- WHats that long green thing in front - oh yeah a bonnet.
- Why do the brakes feel so heavy (and GREEN is a delight to drive) to push
- Why does the steering wheel feel so vertical and FAT?
- Why does it not stop as good as the Volvo
- Oh shit almost hit that car the brakes need too much pressure to work hahaha
- Steering feels heavy even with power steering
- Hey its got window wipers why do I need them
- The Volvo sits better on the road - ooops whats wrong with me hahaha.
- Damn where is that music coming from - oh really its got a stereo.
- Wow its cool in here that airconditioning stuff really is cool.
- Why do the front windows not open forwards and let air in? ,
well next was update 4 weeks later.
new tempered glass in the front window and the perspex ones tossed away wahooo now I can see driving at night. now need new wiper motors.
Rear doors had new latches fitted so the doors no longer open by themselves. Now I have to fix the PTO its slipping under load.
Next is either diesel conversion or high ratio diffs or the bus factory for rust removal not sure which depends which one I can afford first :)
[list=]Rear facing WARN M12000 winch installed and removed so the winch motor can be repaired.
PTO Fixed and running
200liter (50 GALLON) fuel tank installed.[/list]
Well after much mucking around and people loosing sketches and plans of the Volvo I have finally found commitment to get the cabin restored and then the rear cabin.
3 weeks time it goes into a workshop (4x4 Hospital) in IPOH to have the front of the truck repaired or replaced - replaced is what I want.
Options to be done are twin headlights and get the front read for an intercooler. Radio console to be installed - hydrualic steering to be installed.
The truck is now a daily driver after the carby rebuild and here is it in recent action with 2,200kg of drinks in it at a charity event for work.
26 June 2011
Next weekend it ventures into the jungle for a charity trip and will have 500 rubber plant sapling in the rear for a 52kilometer trip one way and a 80+kilometer trip back out.
However, it broke down last nite (25th JUne 2011) looks like coil failure so I have to go retrieve it today.
01 July 2011
Then we took it on its first real and last jungle trip before it was going to the hospital for the restoration work.
The Volvo resting at log collection point.
Unless its a busted Mitsubishi the VOlvo always attracts attention
Then in the middle of the traffic jam the Volvo excelled
and flew up the muddy slope and then had a rest for 2 days in a muddy camp site
After the cabin rebuild they are going to make a ALLOY rear cabin with rollcage "ROOFRACK" etc in it and a few other options to turn it into a camper/rollout kitchen/utility jungle truck as it has a date with the RAINFOREST challenge 2011 in December and its not going to miss it and it will have a 13B-T engine installed also.
30 August 2011
Yahoo and Boohoo - this weekend (30 August 2011) is the big day for the Volvo its off to the IPOH hospital for the rust removal from the front of the cabin and a few other mods.
- Rust removal
- Creation of a cage for VHF radio and stereo
- Air conditioning installation
- Rollcage "officially its a roofrack" external
- Recaro Seats will be removed and replaced
- possibly redo the cabin interior in CANVAS not paint.
- Hydraulic steering
- Relocation of the vaccum brake kit from the rear cabin to underneath.
- upgrade lighting - http://WWW.RIGIDINDUSTRIES.COM lights coming etc.
- LED lights for interior
- airtight it from the engine bay heat
once finished stage 2 - pics as we progress.
- rebuild of the rear cabin
- build one in ALLOY with
- Drop sides
- front half will have rollout drawers for the rollout kitchen and spares.
- raise roof 12-18"
- install solar charger
- add two 200amp batteries for winch.
- add new 12,000 front facing winch as a spare.
- add two 145 liter fuel tanks and remove the recently installed 200 liter tank.
- roll out awning to roll out either side for a 20'*30' tarp.
- and a few more goddies including LED lights
Sunday Nite at the workshop and the rust is revealed
3 months I cannot wait.
3 weeks Progress report
Its all apart : ( took them the first two weeks - The rear cab removed - The front top of the cabin removed - The front bottom of the cabin removed.
They have pressure hosed everything and the engine and gearbox out today to have the engine replaced with a 15B Hino Diesel which we will add a turbo and intercooler separately. Turned out its now a 14B-T 3.7liter 4 pot Diesel. Shocks being measured up so I can order a very nice set of shocks from amadaextreme.com if they can make one big enough :) . Chassis is now being stripped and we are going to sandblast and paint it the final colour :). We am looking at painting it this colour
[url]http://www.tamiya.com/english/products/list/spray.htm[/url] and colour number TS-46 Light Sand
which is of course one of the USA desert storm colours as close a match as I can get. Can anyone else give me a colour code so I can give it to the painter :) . I can paint my truck military colours but not malaysian army colours :) Today I go to collect the 18,500lb electric which I have put a deposit on :) it runs 24Volt so the Volvo is going to be converted to 24Volts which will not be an issue as the 14B-T engine is probably going to be 24volts anyway.
The Volvo B30A engine sitting on the floor.
A close up set of shots of the damage to the front cabin.
My drivers floor - ooops Flinstone brakes hahaha
I got an SMS from the engineer - "The Volvo ICU situation is critical but can be cured with TLC and money".
Couple of weeks later (September 2011)
I loaded up the new seats and the now repaired 12,000lb winch and wait for it the 18,500lb winch I acquired to military specs :) - my my my what a fool but I could not resist it its going to be mounted to be the spare front pulling winch if the Volvo ever gets reaaly stuck and the PTO dies :) :) :) . I also found the headlight grills and its all being delivered to the engineering shop I hope tonite so I get my first look at it stripped as they wanna talk to me about where the relocated fuse boxes etc are to be located and the radios and the stereo and how the sounds proofing is to be done. The location of the 18,500lb winch is yet to be decided but I want it under the rear but my friends want it in the front and VISIBLE - damn thing is so heavy I cannot even pic it up without help :) . At 18,500lb I can pull wait for it 4 LWB Landcruiser II's with a SWB Landcruiser II on the end just for fun hahaha - haha 12,000lb DING DONG winch who needs one hahahahahahahaha. The WARN winch 12,000 which was busted and 4WD system shop would not look at till September has been repaired by 4x4 Shoppe and is now running. It is also being converted to 24V soon still costing a motor.
The cabin also needs to be cut to accommodate the 14B-T - that damn pesky turbo gets in the way. I bought the engine Friday - while the 3.0 Petrol engine and gearbox was out I thought DAMIT toss it and replace with a diesel as the cabin needs mods to fit - Toyota 14B-T and not a 15B I decided $17,000rm+++ for a 15B (total modified cost) and then turbo'd and manifold etc was too much so went down the already turboed path of the trusty and proven 14B-T (3660cc) in line 4CYL diesel with this engine I should pull 8kilometers a Litre rather than the 3-4k I get around town and 5.2k on the highway and the diesel torque is what I am really after :) . Before anyone asks the Toyota 1HZ and 1HD not even in the picture they start at $20,000rm ++ for a well used unit.
The new diffs arrive from the UK this week I hope with the 5.99 ratio and the diesel will have no problem pulling it along.
I will find the 14B-T specs later as they are rather elusive on the web only the 14B specs avail and the turbo has was more grunt than that.
Drivers side repair almost completed
Front view almost all completed
Passenger side almost all completed
The PTO levers used to be here not sure where they going next but not here the 14B-T will melt the hoses.
The roof surprised me full of little holes :( .
Police grills are going they are rust magnets
The sexy naked chassis
The engine and gearbox ready to be lowered into place again for the 14B-T Engine mounts to be welded in place. Sump needs to be cut a little to accommodate the front drive shaft. See the PTO on the REAR right (farest wheel) above which will sit the two electric winches.
Next set of pics the cabin will be back on the chassis with the 14B-T underneath I hope.
24 September 2011
I saw the Volvo yesterday
- Cabin fully completed and sat back on the Chassis.
- Chassis and cabin wired brushed and no more rust found :)
- 14B-T engine dropped off for installation to replace the B30A engine. 14B-T is 3660CC 4 cyl turbo diesel from Toyota (Hino/Diahatsu). its 5" shorter than the B30A and a lot heavier.
- All "holes" and been welded up.
- Air cond vents installed and air cond grill installed.
- New Dash is now to be constructed with PTO levers and all winch controls located on the old area above the radiator cover.
- New radiator cover also made to keep the hot air out.
- Rear cabin is not going back on and to be replaced by an all ALLOY tray to save weight we estimate 300-400kg saved.
- Seat positions checked and sorted.
- Radio and stereo and GPS console to be installed
- External Rollcage design and size agreed.
- Intellitronix DASH to be installed. - Sacrilige - yes I'm tossing the original DASH its got 3 sets of instruments in it so we going to function and simplicity - unless someone knows a better dash I can use?
- Power steering to be installed soon - unfortunately from a FORD tractor.
- Mercedes brake booster installed under the steering wheel and all other brake stuff tossed.
- Two electric winches layed out and ready to install on 8 MM plate and will hang upside down from the chasis just behind the PTO.
- Fuel tank (180L or 37Gallons being designed) for left side underneath basically I have 22"*12"*42" to fit a tank in (or 55cm*30*107) minus a bit of angling will give me 170-190 liters) -
- 3 Batteries to be installed on right side. Air intake to be sneaked out the right side by the rear drivers window with possibly a Toyota Air Box etc fitted.
The truck looks so good I just wanna drive it now and its only a shell I just cannot believe the transformation.
It's back to being a DUNE buggy
The buggy from the rear with the WInch plate ready to mount the rear facing WARN M12,000 and the T-MAX 18,500 for forward operations. THe REAR pintel hood has been removed/relocated and will be lifted to give more ground clearance for dropping into rivers etc.
Maybe another month and it will be finished.
Battery box for the 24 volt batteries made and the 12v volt battery box is there but not so visible. That's a 12v 48KG battery sitting in the tray to show it all fits :) - will be covered this week also (to stop the frigging thieves taking them) and a fuel tank being made for the left hand side more progress to report in 2 weeks as Brett has been away at 4x4 Rain Forest Challenge Sri Lanka so all work stopped on it.
Engine now in place on new engine mounts.
Long discussion on ROLL CAGE etc and positioning of SOLAR battery and they 12V battery box.
- New hinges made for engine cover so it no longer slides out and fills the cabin with hot air.
- Power steering filler mounted in a easy to get to place.
- Intercooler purchased and ready to mount (very nice unit will take pic when in place) to fit behind the passenger cabin seat and has own fan etc built in.
- Custom 3 core radiator to come from the USA as the local builder decided to build us something we did not want and offerred us a $100rm ($30usd) discount and was told to stick the poorly made radiator back in his car and leave - fool lost out on 3 as we needed the same one for 2 other trucks hahaha fool.
- Fuel tank to be build this week on left hand side some 170-200+ liters (40-50US Gallons)
- and construction of the roll cage will commence and the bar for the harness seat belts to be made and fitted also.
- 12volt Alternator to also be fitted next week.
Roll cage ("roof rack") is now next to be started. Pics after XMAS as I have my WEDDING Chinese TEA Saturday so no time to visit the Volvo in the workshop. I am trying to get it ready for an 4x4 EVENT in 23-24 February where it will be BOSS recovery truck :). The builder rung me today after I asked him if he could locate the radiator behind the CABIN. I am trying to get it ready for an 4x4 EVENT in 23-24 February where it will be BOSS recovery truck.
The builder rung me today after I asked him if he could locate the radiator behind the CABIN.
Yes is his answer and he likes it as then no MUD can ever clog up the RADIATOR and it will be located beside the INTERCOOLER also and we can put a BIGGER radiator in now also.
A scoop now to be put on the roof pulling air down behind the CABIN and all protected by the ROLL CAGE. A radiator is to be sourced from summit racing (USA)
Long time since we have posted an update. Brett the builder has been in Sri Lanka at the SRI LANKA RFC 2011 and then we both at Malaysian RFC (Rainforest Challenge) 2011 so there is 20+ days gone
Here is latest progress fuel tank built 180 Liters approx (45 US Gallons) with 5 liter internal tank. Steel frame to be built around it also.
He is too busy to work on the VOlvo he has a BIG trailer order and he is currently fixing up his 4x4 LandRover rally car (making it V6 3.0 TURBO NISSAN powered) for an event in FEBRUARY which I am playing RESCUE for (I wanted the Volvo finished but ALAS it will now not be ready.
Went down to the workshop Saturday to discuss whats left to do and the issues with this:
- External "roofrack" sorted out (roof rack here as external roll cages not allowed). I'm going to loose 6" behind the CABIN (this is a CAB/TRAY vehicle as delivered to the Malaysian Police).
- The Radiator is being mounted on the LEFT Rear of the CABIN scoop from roof to pull air down. Radiator from USA to be imported. This when mounted will give me 4'10" of MUD before the MUD touches the RADIATOR :)
- Intercooler to be mounted on the RIGHT side same height same reason and the AIR cond condensor also.
- REAR canopy to be made of ALLOY over steel frame. front 1/2 of the rear will be a raised PLATFORM of approx 19" to allow 4 military boxes per side to be slipped in. Left side will have a slide out DRAWER for the COOKERS. The rest on the same side will have drop down panel for kitchen PREP. exactly same as I have in my TOYOTA TROOPY now so we know this design works.
- The side panel for this side will be lift UP (from below the fuel TANK) to provide shelter to cook under and gas struts to hold up
The other 1/2 of the left side will be DROP SIDE and lift up and out for shade etc
- The RIGHT side will be drop sides and lift up doors with gas struts.
- The area between cab and chassis on right will hold recovery STRAPS and recovery kit and possibly the highlift JACK.
- The rear will be swing down twin SPARES and drop rear and lift up and or off door for kayaks etc to stick out of.
- The front where the Radiator used to be will be 40 liter water TANK (and pump to kitchen area) and a 12V SOlar battery and will be blocked. The built in fan from the intercooler will provide the air movement under the gearbox etc.
- Solar PANEL on the roof.
- Inside cabin sound proofed and im looking at GREEN canvas over 6mm marine ply to finish it with nice fastenings (quick release). STereo and VHF radio and GPS etc and of course AIR COND.
- 5MM alloy 5 bar checker plate for the rear floor. SInce I have over 200lb of winches (3 winches) sitting over rear axle saving weight is cruicial 8)
- LED lights all 12V.
- Paint job will not be military look due to ever driving it through southern Thailand I may become a target for the militants
Basically I can pack everything under the platform in 8 military boxes head off to the jungle and it will look empty in the rear.
It's going to end up looking like a DAKAR truck reminiscent of the VOlvo 1983 entry *_* .
Due to be finished 15 April 2012.
3 March 2012
Not much to report as we are waiting for the new pipe bender to turn up. There is 4 vehicles waiting for work and they all need the pipe bender.
The handbrake location modified as the 13B-T turbo clipped it.
The old roof of the rear cabin was in bad condition especially since it was only 6 years old.
The positioning of the military boxes for the new lifted platform we can see its going to work. 3 boxes long each side.
The rear rack over the rear wheels is to hang the two 18,500 and 12,000 winches underneath.
I will draw up a rough plan so people can see what I have in mind.
No progress to report im afraid. The workshop still busy pushing out TRAILER orders not one thing has been done since November :(
and I have been very SICK :( for past 4 weeks - I got a dose of LEPTOSPIROSIS or WEILS SYNDROME.
It nearly killed me and I am very lucky to be alive after 10 days in hospital and 3 in ICU and then 2.5 weeks off work and now 1-2 months complete rest (trust me im totally exhausted at 3pm each day) before I can start exercising. This disease is killing quite a few people here and in my case I had RENAL failure and severe HEART issues. The only reason I'm still here is the CARDIO told me you have a very very strong heart.
I am visting the truck in 2 weekends time as by then they are starting the rollcage. We are changing the colour scheme due to the issues in southern THAILAND so im going from military colours so something rather loud so if I ever drive through (and it highly likely) then no mistakes.
Updates soon as progress is made.
New date is to be ready for 15 Sepetember event.
At present I'm preparing the inside of the cabin I have bought 6mm MARINE ply and 3mm sponge sheets and GREEN canvas.
I am still deciding whether to take the canvas to take to a upholsterer and get a set of stitching made up on it. The rear panel i'm investigating whether to make it one piece or have to split it for when the seats are in. The cabin will be painted then sound proofed then covered with the above and fixed by stainless cupped screws unless someone can give me a better or nicer idea. The other solution was to use 2mm alloy with sponge glued to the inside and and it to make it dull (by sanding it in swirl patterns) it looks really good I have done this to 3 of my landcruisers already and fitting also with stainless PKK roundhead screws.
6 June 2012
Work has started on the rear FRame see the arrow.
The kitchen area layed out with 4 boxes. The farest away box will be a slide out draw for the cookers.
The cockpit with the air cond unit under the passenger front.
The pilot seat with the mockup dash sitting in it. It will all be lifted about 50mm and the left side about 100mm during the rear dash makeup.
Over the weekend - Saturday I arrived at the workshop 11.00am and left 4.30pm. We discussed over 5 hours so much stuff. Final plan decided
- I sat in the pilots seat and we put a seat in and sorted out the DASH position and what it will look like - next time I go up a blank new DASH will be made which will allow any control to be reached while wearing the harnessss seatbelts. sinx im 6' 2" it has to be correct for me and the SHORT friends who will drive it. as it is a small very cockpit and we are not changign thelayout at all.
- We discussed at length the new pipe bending machine (the quality of the bends is unbelievable not one crease) and the location of all components of the "ROOF RACK" the KAYAKS have to fit somewhere and the design completely including position of LED LIGHTS hanging off it. After watching a MAN DIESEL in the BRESLAU and a few VOLVOS (all cabovers) I changed the location of the LED light rack to on top of the roof as all VOLVO''s go a long way into the water/MUD on entry - oops (usually up to the bottom of the window). The whole roof rack will be tacked together in 2-3 weeks ready for my viewing.
- The LED lights will allow FLOW of air over the roof to the RADIATOR scoop and Intercooler SCOOP.
- The positioning of recovery kit was decided and including the highlift JACK and shovels etc
- I cut and fitted the rear cabin panel then we looked at it and Brett said I can make it easier and nicer we use the new alloy composit material - he showed me and im hooked 3mm thick and LIGHT as and easy to work and even easier to clean and it will lighten up the CABIN - same for REAR CABIN also. The outside of the rear cabin will also be same material means I do not have to paint it - colours we are thinking of are GREEN or RED or bright PINK .
- All electrics apart from the WINCHES and the STARTER and alternator will be 12Volts a 12V alternator to be fitted soon - I will now proceed to order all the parts slowly there is a list of about 30 items to be purchased - List later im still flabergasted after I starting writing it out
- The rear cabin will be totally ALLOY protected by the "ROOF RACK" - man it will be light I estimate under 100kg. It will also be prepainted as it comes in COLOURED allow so all I have to do is pick the colour I like (BRIGHT YELLOW) and thats the final lCOAT . Then the cabin has to be paited to match only. Saves me about 2-3,000 in painting the rear inside and out.
- 1 Month has been allocated to do the wiring alone.
- Position of everything inside the cabin worked out Wiring BOX will be on the roof and flip down and a full length console for securing stuff. Air conditioning controller already installed.
- Radio and VHF will be on the roof.
- The Solar panel is gone they (solar shop) maintain I need to use two panels and two batteries I maintain we need only one 100amp battery and panel so I removed it altogether.
- KILL switch for everything will be in reach of both PASSENGER and PILOT.
- Rear floor will be wait for it a PLASTIC FLOOR - LIGHT 10mm thick and everything proof - it comes from NZ and is for CHEMICAL cabinet making More on this one later.
- We discussed painting and underseal and soundproofing. Once the cabin is finished it will be removed and sent to Kuala Lumpur once I find a place to underseal it here. Then take it back to IPOH (it may even be painted in Kuala Lumpur first also since we only have to colour match it to the rear external panels). Then the internal soundproofing can be installed and then the alloy finishing and the fitting of the dash and the overhead consoles and the wiring can be completed.
Got to visit the Volvo (C304 4x4) Saturday. It was in pieces again
Cabin one side of the shop. The new 12v battery box sitting in the front and another to be made beside it.
Through the rear panel into the cabin.
And the chassis on the other side
The Engines mounts redone so they can be unbolted.
The 12v Alternator is being mounted in reverse on a bracket so it faces back to the engine as there is no room for it to actually sit on the engine.
The new radiator built for a hot rod from Summit racing in the USA. If you think its big is 18" wide by 31" high
The final pic for the day is the BUGGY look.
Another visit in 3 weeks when the exo cage is built.
Completion date? we have no idea.
10 August 2012
Quick visit to discuss issues
The roof rack is taking shape.
It goes where?
The factory PTO
The 14B-T waiting to be started
The T-MAX 18,500lb winch
7 September 2012
Quick visit to discuss issues and progress. The complete rollcage is tacked up.
The new instrument cluster laid out and it fits second time around. All 14 gauges will fit in.
Seat and instrument cluster and steering layout checked.
The layout of the LED side lights checked (yellow arrow) another will sit beside it facing backwards.
The new harness rack sits between the two passenger side windows ready for the harness's to bolt to the floor.
The rollcage is now attached to the cabin at 3 places and bolted to existing bolt holes to make it more rigid.
Left to right. The radiator tacked in place. The intercooler (electric fan cooled also) and the air cond cooler. Exhaust is almost in the correct spot along with a exhaust exiting above the roof.
Ok getting there work has restarted
Work is progressing.
Intercooler mounted and pipes made fan on intercooler to go
All tack welds now permanent on the cage the ROOF CRoss steel is being recut due to some "errors".
Radiator final fitting next week.
Cooler for engine oil to now be added not sure where it is being mounted yet. Muffler and exhaust to also be mounted this week. Old rear body weighed 440kg and is now a Chinese body part for a jeep I hope as it was sent to the scrap heap.
Rear floor will be 3mm alloy sheet it was decided.
OK quick visit Saturday on the way to mothers day dinner.
The Volvo radiator and fan connected along with piping - we will work our during testing if the 14B-T water pump will pump the water up the extra 3 feet during testing.
Only a bracket left to hold the pipes
The side view I loose another 6" from the rear cabin rats.
The front rollcage is almost complete.
I have to find a 80 series AIRFILTER (4.2 Diesel) - easy ordered I have to deliver it this week and then it and the exhaust can be installed. The air filter will fit in the hole behind the drivers seat.
Two weeks into June and the Volvo progress has accelerated.
Looks like the Exhaust is mounted but the air intake is not. However, the 4 wall frames are up and so is the roof frame and the floor frame is done.
I expect better pics this week with the Alloy roof or the rear wall completed. Also found this last week after spending 3+ hours to find stuff walking from speed shop to speed shop previous saturday - finally I have a starter and kill switch. But I need to find a 12v to 24v RELAY to kick the starter solenoid with it.
20 July 2013
A long visit today to the Volvo Hospital. First the tour.
The doors all fitted and all with gas struts to hold open - wow gull wing style.
Right side view doors up and out gas struts fitted.
Left side view.
Then upstairs to the Wiring diagramv
Yup its all layed out in red and blue red is 24v and blue 12v then as we go thru it with my switch diagram vs bretts count we have a discrepency I have more in the end we agree looks like my 42 is very very close and bretts 36 could be short.
Back downstairs 1.5 hours later.
We have decided - roughly 1 month to paint everything except the alloy skin - second paint round. Then the fitting of everything including the proposed 6 seats (we are talking 6 high quality customer seats) in the rear and the removal of the doors to be replaced with side rails.
The winches and yes he is installing a 30 litre water tank and with our simplicity motto its going to be gravity fed.
THe new target date of mid November is looking good. Many surprises on vehicle launch to be revealed *_*
Next visit I gotta hand over the newly sponsored LED lights - The stereo - the rest of the instruments and the OFFROAD controls switches for the winches and a new albright controller sigh the other one is on a comp truck now lying in the workshop after its rollover in Ride N Seek TV program which I'm sure you all saw and two wheels.
Next visit should see the floor cut and fitted the water tank completed the dash started the winch wiring etc all layed out and ready to install.
The rear rollbar
8 August 2013
A long drive to IPOH due to the public holiday traffic. Handed over the 35" Maxxis sneakers, the 4 small LEDS and the 50" LED and the stereo and a strip of LEDs.
Inspection revealed Hi-lift jack holder almost finished. Shovel holder next. Hammock loops being prepared, handgrabs for all ladders done.
Roof for the Radiator and intercooler etc ready locking mechanism to be designed. My seat area has been pushed back allowing my seat to move back 75mm which is huge when you are 6'2".
Inspection of the new AMADA shocks reveals 3" too much travel so looks like the shocks will never work hard.
New sneaker and the removeable entry ladder in place
The positioning of the http://www.ufilta.com 20 litre water containers roughly in place we will allow for 3 to be stored and removed. Due to keeping with simplicity no fixed internal tank or pumps to fill it.
The front wall frame is now finished and the hi-lift jack holder is tacked into place. nExt is shovel holder and air filter.
Over all the frame is now finished.
What's left to do well the DASH and Console and the wiring, power steering, fitting of seats, air cond (fitted just needs to be connected How to start and stop the 14B-T donk. 6 seats for customers in the rear and a removeable side rails so that the 4 rear doors can be removed when necessary. Floor to be cut out and boltdown points welded in. Roof to be cut out. The middle doors and panels to be cut and punched out, the mesh for the radiator roof to be fitted.
We have divided DASH into Driving needs - OIL/WATER TEMP/Speedo/TACHO/Fuel Volts/AMPS to the right and recovery DASH. Air pressure and vaccum will be above on the roof along with the lockers and 4wd vaccum switches.
Next week I have to deliver ICOM V8000 VHF radio, the remaining gauges and the fridge slides and we discovered the 2 200 AMP batteries were dead oh dear there goes $1500rm and the final issue - where oh where is the ground ANCHOR going to go.
1 November 2013 visit
The 50" LED light frame is built on top of the cabin.
The T-MAX 18,500 (yellow) and the WARN 12,000 to the left all mounted in their mounting point.
The winch controller box is also ready
The top view of the winches and winch controller box.
The crane to lift the spare tires up and down ready to connect to the warn winch is ready
The top hatch is ready with the hole for the exhaust.
The doors now back on :)
The seats are mounted.
Next visit the dash sould be completed then its painting time.
The water tank is to be built next a size of 150w x 400d * 1700l cm should give us 102 litres it will bolt to the rear panel.
The floor and walls alloy panels are all cut out and bolted down and has been removed so they can continue to work on the steel bits.
27 November 2013
The builder off to the rainforest challenge (RFC2013) tonight so I got a quick update and worse the worker doing all the welding resigned.
Dash is built and console - overhead console not done but all gauges will be up on the console except the speedo (Garmin colorado GPS) and the tacho - tiny tach.
So work has stopped for 2 weeks until the 15th at least. My goal is just after Feb - ideally for my birthday on 5th March I want it on the road.
Once the dash is built and the overhead console done its sand blasting and painting time.
26 December 2013
Long visit to the workshop on Boxing Day since the mechanic was working on the truck XMAS day I had no issue having a vist. Arrived 11.30am time for chit chat and then lunch and then the serious stuff. First the office we started with a blank sheet for the control panel and worked our way through switched 1-26 which need to be on the control panel.
Then the discussion on 12v vs 24v everthing discussed and reviewed again.
The empty switch box ready for me to reach when harnessed in.
Slowly the switch location emerged till we had this on the full size drawing.
The wiring diagram revisited all red is 24v all blue is 12v.
After 60+ minute time to go to downstairs and discuss Bretts list then mine.
Whats been done - all the ALLOY panels are cut out and now waiting for the rear seats and Drawer system to be installed.
There will be a raised platform at front 1/2 of the rear to sit fridge on (no it will not slide) and underneath will be a sliding table to be used as a cooking bench it will slide out approximately 600-800mm and will be 39" wide (1 meter).
The exhaust is now in place along with the hi-lift jack (6ft) and the shovel and chungko will also go here. The air intake will also fit up beside the exhaust.
I now have the depth of the fuel tank the matching gauge and sender from VDO can be ordered.
Then onto the rear seats 6 of these to be fitted they are 22" wide each we have 68.5" to fit them in. See our wonderful crash test dummy not smiling as we get the seat height correct. Once fitted then we can strip the rear sandblast it and undercoat it for the panels to be fitted. The seats are to only be fitted when the doors are removed and fixable sides designed along with harness seatbelts. So it will be a 8 seater when taking passengers.
Underneath the winches are all ready with new guides welded to the axles for the T-Max 18,500lb winch. Guides on springs to hold up the t-max and Volvo PTO winch cables to be fitted.
The seats have been removed ready to get the wiring done now it will be started this week.
Starting to look complete.
Water tank relocated and redesigned its either now 94liters (24 gallons) or 104 liters (26 gallons) and will be on the front wall of the rear cabin.
It's first real trip will be 26-28 April when we have a 3 day trip to Cengal Besar (big tree) everythng ahs to work as this track is now really cut up.
2 months to go till d-day.
24 January 2014
Quiet visit to the workshop on the way to a wedding in Penang. I handed over the new BIG STARTER button much to his amusement I do wanna use it.
Then it was time for the visit to the truck and to discuss the small progress made.
The new 12v Battery location (under where the radiator used to be) with the 120AMP battery sitting in the location.
Looks naked without the grill
Then it was onto the new tool and spare parts holder.
and then to move it into its new location. A release it being made for the grill to release it from the inside.
Then I wandered around and decided to test the new door and pull down ladder to the roof out. It works so easy to get onto the roof.
All the door fittings were viewed and we decided 2 locks per door and the central locking will all fit nicely. The locks will be fitted next week we hope but its Chinese New Year so nothing will be done as the only welder left is CHinese lol so figure 2 weeks before anything happens. The water tank also commences being built next week. I will be delivering the remainig gauges they finally left the USA today according to FEDEX webpage and buying the rear seats and harnesses wednesday as I will be on leave and heading to IPOH for the my CNY family dinner. So close to getting the rear painted and skinned. The Door skinning might start next week also.
5 March 2014
yes there is no updates. No progress for past 6 weeks. Waiting for the workshops new employee to start (last Thursday) to finish the welding up of the water tank and the rear seat frames and the side rails then the rear frame can be removed, sandblasted and painted so the alloy panels can be attached finally. I have had delivered the new VDO speedo which is driven by a GPS and a VDO tacho (max revs 4000 ) :) it will sit with the Digital Tiny Tach. I also picked up a few bits for the VHF radio triple ariel switch and cables so they can be installed when the overhead console is made.
Speedo cable - GPS
The cat ("Trouble") is not impressed with the Volvo progress and is lying on the keyboard in protest lol.
I await the next update from the workshop
26 March 2014
Got some pictures today from someone who was collecting the rims from the workshop for me. Looks like its very close to sandblasting and painting time the wiring is being laid out. Wires sticking out of the headlights as the loom gets laid.
Workers working on the wiring
Stripped down no seat belts nothing left inside.
28 March 2014
Got these pics sent to me while I was preparing for a 3 day 4x4 trip so no time to upload. Wiring loom layout is about 70% complete. Water tank (80 liters) is complete.
Wiring loom down through the engine bay
Water tank in place
Rear underfloor wiring loom
Rear roof wiring loom
5 April 2014
Quick visit took another Volvo owner up also to see the restoration process - yup he fell in love with it and wants the same lol.
Power steering mounted on top right of the underneath.
The new console ready for the Tacho and Speedo only rest of the gauges will be at head height.
Side view of the inside doors off ready to be painted.
The central locking locks in place for the rear.
Skeleton side view
Skeleton view from the top wiring loom visible
Wiring diagram is now complicated
3-6 months for completion I'm told.
23 May 2014
Decided the 35" MAXXIS Bighorns (764's) were too lacking in grip so decided to buy the 37" MAXXIS Trepador's instead. So Picked up 4 today and 2 more to go the RED truck can only fit 4 at a time lol.
I will weigh them later I estimate 42kg. Tires 38kg and rims 6kg.
1 August 2014
Progress pics of the Volvo power steering setup.
New steering wheel grafted in and power steering unit grafted into the steering shaft by an engineering shop.
1 August 2014
Progress pics of the Volvo power steering setup.
New steering wheel grafted in and power steering unit grafted into the steering shaft by an engineering shop.
11 Sept 2015
Latest update its been undercoated and the top coat is due to be done next week.
More updates when I get a painted PIC.
2 Feb 2016
I rung for a progress report and got told none so I asked why he said no staff to do the body work. So being years since I prepped a body I volunteered to do my own vehicle.
Monday was a public holiday and they offered me the workshop for Sunday and they would help me Monday.
So Sunday morning 9am im 190k away from home at the workshop. I start had a quick look at the Cabin and did a quick plan of attack. All day I played with small amounts of body filler. By the end of the day the cabin was starting to look close to being ready for paint. Original dents etc were left alone.
The frame as Sunday morning
My companion while I did the top of the cabin was the workshop new guarddog the cazy happy 7month old mongrel
The rear panel is a bit of a mess but its been decided its original we leave it.
Filling the repair work from the patches added to the roof.
Oh yeah the pooch likes ICE as its over 34c here at present
Preparing the paint
Inside of the cabin top painted.
We sat this here this morning ready to paint then we realised the sealant we added at lunchtime took 24 hours to cure our mistake for not picking it up yesterday.
So after 2.5 days work of pure hard work in the heat I have made a lot of progress.
Early this evening we moved stuff around to enable the rear cage to be painted.
Rear cage 2/4 sanded tomorrow they can finish it and paint it.
3 February 2016
The doors are being taken apart a there is a small rust issue in the top/bottom join area.
3rd coat on the top of the cabin.
So next Monday Chinese new year to be spent in the workshop.
8 February 2016
Chinese new year Holidays
Arrived monday morning to the pleasant sight of the rear cage and all parts painted that I had left the week before.
Brett stuck the engine and gearbox on the forklift and then left for CNY lunch and said you can install and oh yeah learn to drive the forklift lol.
2 hours later I had it all installed but need new gearbox mount bushes.
Then started on the 18,500lb winch install. Success again took me about 2 hours plus searching and cleaning up parts areas to get stuff out.
Had assistance from the builder all day and we managed to get the cage installed and bolted down after installing the WARN 12,000lb winch and tightening the 18,00 bolts down correctly.
Then dinner time for both of us and we packed up at 5pm after getting the fuel tank reinstalled yet again and the gear change installed and bolted it. A whole pile of parts washed and a list of parts needed to buy.
Morning starts with washing the dusty parts and yeah playing with the puppy.
And the finl result is washed parts eventually and a half washed puppy.
Lunchtime and I have the radiator and the intercooler bolted down everything is connected except hose clamps it all takes time including cleaning out threads etc.
Then late arvo it's all hands on deck to mount the two rear panels while I have been testing that all the front panels are fitting and doing final trimming and I take the second hand 80 Series muffler out for a scrub.
At the end of the day what do we have well it's starting to look pretty good. It's time to head off to my chinese mums place and collect wifey for the longg drive home.
19 February 2016
Friday morning dashed up the 190K to the workshop and arrived just after the workshop opened at 8.10am.
Idea was to run arround and get parts etc ready for Saturday and Sunday.
After much running around and forgetting parts I pulled the wiring loom out after shoving the wire eating pupppy outside we layed it out for the morning.
So a the end of Sunday what do we have apart from my employee ringing me and saying my RED truck as funny noises from the rear after they took it offroad. So we pack up early for the 20k run down the road to check it out then another 175k home. Fark TOW TRUCK back to Kuala Lumpur turns out the rear locker
tore itself apart after it was stripped today (Wednesday).
We have a wiring loom sitting in the truck all cable tied up and a few connections done. Rear taillight has a broken bolt and rsuted insides so I need new ones from sweden first.
All the wires hanging out of it. The cabin is not on as there is still issues with the engine area. The 12 alternator took me a day to get it to fit properly and belts fitted inluding 2 trips to the spare parts shop to get them correct.
Little Joe has some fun with the puppy after spending 2 days stripping paint.
Then we have a pile of parts to paint or electroplate and anodize.
Oh yeah then the 2 weekend helpers the stripper and the wire man.