Volvo C304 4x4 Build/Restoration - WR002

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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 1:51 am

12 January 2020

Letting hotpants loose with the welder and grinding lessons.
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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 1:51 am

18 January 2020

Mighty 80 Series Landcruiser needed some front hub attention so we kindly let Hotpants strip the front axles and install the new chrome molley axles and the new bearings and regrease it while we all supervised.

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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 2:06 am

1 February 2020

Frustrating time last minute issue with the speedo wiring a broken wire in the loom meant we had to relay the speedo sender wiring to the dash panel. Now we need to drive the truck exactly 1 mile to set the programmable odometer. Now since the police station is only 400 meters away i need to have brakes first in case they pull me over.

Parts shops are still shut after Chinese New Year damn so cannot get parts.

Started early Saturday and spent the morning and arvo checking all the bolts and bolting down all the panels and tested the relayed window washer tubing and it all works finally. Then we cleared the truck out and found a RATS nest sigh in the wheel covers - ruined chewed through by a rat family.

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The brakes test I did not brake hard in the video there was insufficient brakes still lol.



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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 2:24 am

[youtube][/youtube]10 February 2020

Oh dear working from home the COVID-19 virus has made work send us all home until further notice and work from home.

Test run of the brakes working. Yes they failed.

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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 2:30 am

22 February 2020

After the brakes failure is back to stripping everything out of the Volvo. Pedals out Callipers out and strip and rebuild.

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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 2:31 am

5 May 2020

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

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

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

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

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

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

Bleeding the brakes we find the issues the pads are not moving enough. It's back to stripping everything out of the Volvo again. We pull the portals out callipers and all Pedals out Callipers out and strip and rebuild and refit but I could not get the callipers with PADS to install. Finally we see the problem. The callipers had been pulled and rebuilt previously with new pads installed but they did notice that the old pads had had 3mm trimmed from the middle of the pad so it could clear a portal bolt resulting in the pad not clamping the disc correctly. Fitting the PADS after the calliper bolted in caused the pad to hang on the portal bolt.

We fixed that and refitted the pads and checked for correct operation. Still no proper BRAKES. We elect to start building up the brakes to the before 2010 status.

We add a vaccum tank and the brakes are better we add another tank and build a rack of 3 tanks and add the cross member vaccum tank back to the setup. More brakes now it stops from 60kph but still will not lockup. Investigation to a bigger master cylinder is continuing.

Pulling the portal and discs and callipers off
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Zing is very happy to have us all back in the shop especially at thunderstorm time he has someone to hug.
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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 2:33 am

25 May 2020

Test run day again make sure everything is working. However the battery start problem plagues us and we need to be jump started by a 1000CC car lol.

It's a reflective mood in the carpark outside the place is full of buses as there is no tourists or planes to the airport they are all stored up more than 300 of them.
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Yup I'm not happy why will the fan not cut in.
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Construction on the buildings have not restarted yet either its nice and quiet.
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Then the radiator thermal fan decides it's time to not work and the engine gets to 105c and I play around pulling cables and restarting and pouring water on the radiator and then it cracks into life and the test drives can continue.

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A pair of BMW high cranking 900cca batteries are ordered for the Volvo and we are splitting the 3 serial deep cycle batteries into 2 starting and one deep cycle battery and segregated.

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geckoadventure
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Jul 16, 2020 2:34 am

4 July 2020

Spent SUnday afternoon refitting the door top halves to try and get rid of the horrendous gap that was showing air. Installed the new rubber spacer in the middle of the 2 halves and wow it worked. Now have to spend time again adjusting the hinges and making a spacer and filler for the hinge pins to stop the sloppy play.

Still have the new GPS speedo sensor to weld on the holding bracket and piping to hide the wiring and mount the window washer piping on the rollcage as I do not want any piping running through the inside of the cabin or holes drilled in the cabin to mount anything.

If only the brakes would work we could get the inspection done.

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