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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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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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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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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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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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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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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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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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Thu Dec 31, 2020 1:11 pm

31 December 2020

We are so close to having it ready. We decided to go down the path of getting new brackets made for the brake callipers as the old 3mm ones were flexing a little hmmmmm quite a bit. So while we were at it we decided to add twin callipers. So a new matching set was obtained. They are being made of considerably thicker steel lol I heard 12 or 10mm and machined down.

Its now had the parts in the machine shop for 4+ weeks. rear brake callipers are ready and a test fit worked. The fronts have had 2 sets of callipers made due to issues. We are hopeful today or Monday they will be ready.

The list of items to complete before inspection is about 9 items only.

Updates and pics later.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby Cameron » Thu Dec 31, 2020 4:44 pm

Still watching! Good work man

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Tue Jan 05, 2021 12:31 am

01 January 2021

Hi all after months of COVID and finally a couple of adventurous holidays (boat trip and a round Langkawi isand in 14 footers lol ) in the COVID breaks we were allowed to travel, a family tragedy (lost whole off December) and not doing much the brakes were started sometime in October.

New brackets were decided for the Volvo and some other mods to make them fit better. So new 12mm steel brackets were designed by an engineering shop along with twin callipers for the front discs.

New Callipers were purchased to match the existing ones. Then we waited.

The big ginger cat who has been my constant annoyance sitting on my keyboard and stealing my food etc went through chemno treatment for cancer and after losing 50% of his body weight lost the battle breaking my heart.

The new rear side windows were installed (compliance to make it not a commercial verhicle).

Hotpants the apprentice has been dropping in to visit us and learning new tricks on how to turn the customers and friends into bumbling idiots turning down all their requests for phone numbers dates etc.

The Africa 80 Series Landcruiser build progresses slowly in the back ground

July

Marked out the windows location after receiving the windows back from the factory. THen we discovered that they had not made the flange big enough so could not bolt them in had to glue them.
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August
Then slowly each window hole was made carefully one at a time took about 60 minutes for each window to be cut in with a tight fit.
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Before and
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After
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Then its the drivers side to be done
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Making sure the windows are level.
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Wah finished someone offers assistance to help bolt them all down. Yes im getting fat I've put on 20kg since I stopped exercising
with my heart problem lol.
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At last only the new extra bolt holes to go.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Tue Jan 05, 2021 1:21 am

Next is the fitting of the new bolt holes. Hotpants decides she wants to help.

Some outakes of Hotpants trying to put in RIVNUTS.






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Then it is time to drill more mounting points for the removable panels making sure all are lined up. I get some assistance.
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Then they are all bolted in with stainless steel button head bolts.
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October

Strip the brakes off to go to the engineering shop for the new calliper brackets to be made and source a new pair of front callipers to make it twins on each front wheel. The old brackets were 5mm thick and flexed when we were testing the brakes under close scrutiny.
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Then it was the big workshop cleanup we moved Volvo 2 to its new location in the workshop ready to start work once Volvo 1 is completed.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Fri Jan 22, 2021 11:12 am

05 January 2021

Well I had a few days leave and did not want to travel far due to the growing COVID issue here and people running all over the place for a holiday. My JETBOAT boat is still in the shop getting new headgasket after the last Elephant hunting trip disaster.

So I decided time to paint the truck again the oil stains in the paint have become unbearable to look at.

I managed on Saturday to collect the new brake parts from the shop and we will begin assembly Monday morning.

Started with the doors easy to fix and sand and undercoat. Yes I'm doing outside in the workshop. The paint is real paint mixed and canned for me. The new colour is Desert Kakhi.

Then we ran over to the engineering shop to collect the Portals and brake components.
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The top coat looks good a nice light green. Clear coat is a matt clear 2 pack and will dry nice and hard.
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The monday I managed to get the painting done and we got the new rear brake brackets installed.
Tuesday I ran around getting parts for the brake assembly and unfortunately took all day and still could not find a "T" for the front brake hoses to connect too. Visited 4 hydraulic shops in Kuala Lumpur and I could find nothing. In IPOH they would have made them up for me. The Monday evening we watched a COVID raid on the building site across the road all the Bangladeshi workers lined up getting tested and put in the buses to be carted away. Hundreds of them.

The next weekend no work on Volvo wife grounded me with a COVID scare in the family so I was grounded. Then the workshop mekanic announced he had COVID lucky I did not see him on 1st-3rd and we were all told stay away for 2 weeks. SIgh.

It's now 19 January 2021 and I am unable to work on the Volvo our Malaysian govt has put a lockdown out for food only) on us since 11th Jan to 26th it will be longer for a radius 10k from home and we are not allowed to cross city boundaries so nothing open and there is a roadblock near the workshop I cannot get past.

My workpermit also expired on 11 January and HR took too long applying for new one so I am also stuck at home anyway while the new one is processed.

I do not know if the workshop is open and they are working on the Volvo or not.

Stay healthy everyone.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Feb 01, 2021 12:49 pm

1 February 2021

I still have no news from the workshop whether they have put the front brakes on or not. The longer I wait the longer the delay in finishing Volvo 1 and starting Volvo 2 again and then starting on Volvo 3. I also have my troopy and the magnificient RED truck being sold Once Volvo 2 is ready.

I suspect this COVID thing is going to alter our lives for a long time to come.

We have no idea when we will be getting a vaccine shot or who from. We are now having higher infection rates now than before the current lockdown started and they are talking about removing the lockdown I have no idea why.

Now time for a bigger update.

Over the past 9 months or so I have been squirrelling loot away to the boat factory and I have finally reached 80% payment and they are ready to start building the hull duly christened Shanty 3. The boat is a 28 foot alloy which is being built to allow us to stay longer and in more comfort for our lake camping and elephant hunting expeditions. Its coming with Small galley and Toilet. The shanty hammock design remains as will being able to steer the boat from a hammock and hang in a hammock as we are travelling along.

Meantime Shanty 1 will be up for sale soon. Now i'm hunting down big screen navigation gear from Garmin I can get here as we cannot get the same touchscreen stuff available in USA. I will be doing all my own electrics etc in Marine wiring same as I have down in Shanty 1.

We are getting out on SHanty 1 as soon as the lockdown is lifted and we can travel for a 4 day Jungle camping trip to hunt our favourite animal the humble Asian Elephant and of course for me the Giant Snakehead.

After our perilous adventure at Langkawi Island we decided no more 14footer adventures it has to be in luxury on the 28footer.

I have also managed to score a huge discount (25%) on a new outboard (225hp) which was not moving as it was a reverse propellor unit from a matching pair which got split. It should power it along nicely and I still have the Toyota 1HDT engine i was going to use as the inboard now to be reassigned for use on Volvo 3.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 3:55 pm

7 February 2021

Painting prep continues much work has been done in the 3 days.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 3:57 pm

11 February 2021

There is a lot of work done and tonnes to go.

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However 2 coats of undercoat and 3 coats of top coat the colour looks good.
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The front needs quite a few patchups.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 3:58 pm

13 14 February 2021

Progress continues and the front cabin is all undercoated. THe roof still looks WW3 was fought on it but I'm not beating the panels out the character can stay. Doors are all undercoated. Some new surface rust killed and prepped.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:03 pm

20 21 February 2021

Progress ii's the rear doors prep and painting - the taping takes the longest.

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THen close inspection of the service hatch panels show the crease marks from the folding press I have to sand and put body filler in and redo the paint job sigh. However, the end result is it looks much better. Almost professional.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:10 pm

27 28 February 2021


The rear gets undercoated and painted in about an hour. It looks really cool.

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The frame gets undercoated.

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My new Volvo T-shirts arrive Hotpants drew it up from a pic they look cool.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:11 pm

5 6 7 March 2021

After working long hours in the office due to stupid issues - Banking SOftware sigh I elect to take the next 5 Fridays oss work as Im forced to use the days I carried over from 2020. We still cannot travel out of the state and I celebrate 1 year of working at home and the 5th is my birthday. Only better birthday would be to drive it.

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By Sunday night all the big panels on the rear are painted good progress.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:19 pm

12 13 14 March 2021

Front painted. Then i see the run and and the fix ruins the valance under the window sigh this will be fixed later.

I cannot paint the front bumper as it's holding the the truck up with a giant stand.

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Right frame undercoated.

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The alloy door panels are now ready to attach. However the door tops still need attention.

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Up with the floor now to paint the frame black with epensive single all in one paint. Then we find the shrew squirrels have been using the fuel tank as a dining room sigh. So I start building a shrew fence from the firewall frame from a LandRover 109 lying in the workshop.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:20 pm

19 20 21 March 2021


The frame looks good.
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So do the door bottoms.
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I finally finish the front half of the frame.
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and start to prepare the rear. Sound proofing also commences to stop the rattles emerging from the floor.
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and give it the magic one coat paint.
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Then its time to start testing the truck facilities the hammock test and fan test are conducted
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The rear panel is prepped and undercoated
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:24 pm

28 29 30 March 2021

I needed a new workbench so the frame being made for the indoor restaurant for 350k away which got cancelled is recycled into a new all purpose work table by hotpants.

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Meantime I paint the inside of the doors.
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Work claims the weekend sigh.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:25 pm

4 April 2021

I lift the floor over the fuel tank and oh no the damn shrew has had covid parties on the fuel tank again along with his friends. Now I'm pissed, I'm waiting for the rest of the fence to be tigged up. I now feel like Bill Murray in Caddyshack. Further lockdown can only travel inside our district - lucky the Volvo workshop is inside the district.

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The soundproofed floor is ready to install.
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Office work takes the rest of the weekend

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:26 pm

11 April 2021

Part 1 of 3 of the shrew fence is installed.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:27 pm

25 April 2021

cannot wait the floor is reinstalled so I can strip the service hatch down ready to be one coat black.
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12 May 2021
Lights and fan testing continues to see current draw on the 150am deep cycle battery.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:29 pm

16 May 2021

I share lunch each sunday with Zinc he's getting good at it. He's not as cute as he looks he took a piece of 4 people in one day drawing blood on 2 including the owner. I have scars on my arm from an incident. If he is not wagging his tail and watching your hand do not touch him.
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Full fan and lights test continues and the service hatch is now black and drying for 24 hours.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:32 pm

22 23 May 2021

Work now commences on preparing the flexible solar panel it will magnetic stick to the service hatch panel. I have 2 more for the new boat project which has the cut list prepared and waiting to be routed out in Singapore in coming 2 weeks.
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I paint the 2 indoor panels which I missed.
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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Mon Jun 07, 2021 4:35 pm

26 May 2021

Then it's time for the panels all to be bolted back to the truck the change in the trucks appearance is now amazing. So it will now pass the inspection rules of ONE colour.
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I manage to do my first wet camp site test with the chair inside the truck and lights and fan running. Perfect all passed.
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Left side panels attached
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It may be extra time etc for me to paint the interior but its been worth it. Just the ceiling to paint in the coming weeks.
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Service hatch panel re-assembly.
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Thats it for 3-4 or more weeks we are in total lockdown until 14 June and workshops are closed as are parts shops and 2-3 weeks after to reopen - if the covid numbers drop which they are not. I suspect it will be 2 months or more.

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Re: Volvo C304 4x4 Build/Restoration - WR002

Postby geckoadventure » Sat Jun 12, 2021 2:26 am

NO!!!!!!!!!!! the lockdown is extended till 28th June and then another 2-3 weeks after that to be allowed to open the workshop up, They cannot get a permit to open the workshop sigh.

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