Volvo C304 4x4 Build/Restoration - WR002

[geckoadventure]

20-07-2012

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 is the BUGGY look.




Another visit in 3 weeks when the exo cage is built.

[PuddleJumper]

This should be Will be watching this!

[DieselBoy]

Awesome!!!!!

Worth noting, and I'm sure you are aware, Alloy radiators are pretty much unfixable if they get damaged

[tow99]

go to forklift wreckers they have awesme radiators for tight spots. does the C304 have the portal type axles?

[geckoadventure]

if you want the full story it is here.

http://www.geckoadventure.net/ga3-volvo.htm

[geckoadventure]

Awesome!!!!!

Worth noting, and I'm sure you are aware, Alloy radiators are pretty much unfixable if they get damaged

YEs I know. Brett is mounting it behind the cabin and sitting on a bar running across from the exco rollcage at about 80 deg angle to allow the air to flow over the cabin via a shrowd into the radiator.

[geckoadventure]

go to forklift wreckers they have awesme radiators for tight spots. does the C304 have the portal type axles?

The Volvo C30x family only came with Volvo portal axles. Ys he same style The hummer borrowed and enhanced it further.

[geckoadventure]

Yay progress

The external cage/roofrack is taking shape.

The front view still not complete.


Side view


The rear tray floor frame is also taking shape.


The Radiator on the left and the intercooler hanging in place on the right will be the exhaust.


more pics soon as I get to sit in it Friday and we look at how to set the 14 gauge dash out (VDO gauges) and make it all waterproof plan to make the whole instrument cluster sealed in a box with only one wire hole or a series of holes on one side only later siliconed up.

[Cameron]

can't wait til you finish it mate. going to be a cool machine.

saw this on a tumblr site the other day. bit of volvo p0rn i suppose!

[geckoadventure]

Oh My that's stunning.

I'm putting 27" Trepadors on ours.

[Nivapulledout]

wicked Going to subscribe to this thread.

another great report coming out of the rainforest!!

[geckoadventure]

Do not worry I am writing up the story of the weekends charity trip back up to the aeroplane

Once the truck is finished there will be plenty of adventures with it to document.

[geckoadventure]

Friday went up to see the Volvo


The dash layout with actual size of instruments and layout.




The layout and the dash and the steeering wheel




Trying out the position of the Dually LED light for the front side facing positioning.




The harness seatbelts holder between the two windows and they are anchored to the floor.


Side view the rollcage is now attached to the rear of the cabin in 3 spots per swde.



The position of the exhaust (almost in the spot) the radiator (fan to be added), the intercooler (to get its own fan) and air cond unit.



The rest of the next two weeks will be spent fitting everything around the rear of the cabin sealing it all up and isolating the radiator from eveything else, positioning the highlift jack etc inside, intercooler connected up with the correct size piping , radiator connected up etc and all the other recovery gear ready to then start the rear cabin.

The exhaust is to go out over the roof and yes it will have one of those cute little flaps which lifts up. Im so excited about this.

After XMAS is the next best finish date now.

[niblik]

this thing is aweshum...! lovin the name also, thunderbird 2!

with the box for the gauges, if ya seal the gauges in with a light bead of silicon sealant and have the wires entering your box from below, this should create a header pressure area and keep em oober dry..

this reminds me of landrovers forward control..

[geckoadventure]

this thing is aweshum...! lovin the name also, thunderbird 2!

with the box for the gauges, if ya seal the gauges in with a light bead of silicon sealant and have the wires entering your box from below, this should create a header pressure area and keep em oober dry..

this reminds me of landrovers forward control..

well im in that age group who watched thunderbirds and its going to be a utility truck so what else to call it.

We are mAking a pod (completely sealed) for the instruments to sit in and it will be alloy anodised with single wire exit point on one side how he seals the top I do not care so long as water cannot get it.

[geckoadventure]

go to forklift wreckers they have awesme radiators for tight spots. does the C304 have the portal type axles?

Everything being replaced is new.

[geckoadventure]

New shocks purchased AMADA's new PIGGY back shocks.

Valved for a 80 Series Landcruiser they should almost be correct we will correct once its on its feet and driving.

FYI $2800rm or $1100NZD for the set of 4 shocks.

[geckoadventure]

Spoke to the builder last night he is saying end of February to complete it he wants to get it out of the workshop as he knows I have 3 more rollcages for him to build into my Landcruisers. Its also costing me business to have the Volvo off the road.

Now I gotta give him the VHF radio, new stereo and speakers, the remaining new VDO gauges, the side and rear LED lights and then the new switches for the interior.

I am taking the shocks up this weekend for a test fitting and let my wife see the truck.

Last week I was in the jungle for 6 days 2 days real corporate team building with 30 pax and straight out home repack and a 5 hour drive that night to pickup a discovery channel film crew (12 Pax and 2 stars) with 3 of my trucks and 6 others for another 4 days of filming 4x4's in the jungle. The Volvo was needed lucky I took my TOYOTA troopy along it took nearly 50% of the kit. Discovery channel said they would be back for more jungle filming. Volvo has to be finished . THe only casualty for the 6 days as a BLOWN up 8274 winch motor (blew spectacularly )

Discovered to my surprise the Toyota TROOPY can take 34 camp BEDS and 5 passengers and a crap load of camping kit and still recover vehicles.

will do some pics sunday nite.

[fullthrottle]

Hey Dave

Good to see some more progress on your baby.

[geckoadventure]

Visited the Volvo in the hospital yesterday no pics the light at 5pm in the workshop through the skylight just made taking pics impossible.

1. Shocks fitted for a test and removed the REAR piggyback will hit the Springs and the other way too round too easy for bamboo or a vine to wrap around the wheel and tear the piggy back off. Piggy back down also impossible things will hit and tear them off. A quick call to the AMADA shock shop and they will convert the rears to REMOTE for me in a few weeks. Wonderful
2. Put the wife in the passenger seat realised the floor needs to have a 50mm platform as her feet not touching the floor resulting in loss of circulation
3. Fuel tank inspected after builder consesses to making it 1.5mm ALLOY and not 2 or 3mm so its now an experiment we will 1/2 fill it (140 liters) when the truck is finished and drive and see if it bursts open - oooooooooppps.
4. Wife inspected the proposed composite material for the outside and gave it the thumbs up
5. Work resumes on 15/1/2013 when the builder finishes the order of 15+ military trailers
6. CHecked everything else on the truck all seems to be progressing ok. Cabin rollcage is complete.
7. More pics in 3 weeks time when I visit the hospital again.

[tomsoffroad]

Shame about the pics. This is an awesome and unusual thread. I'm loving it

[geckoadventure]

Shame about the pics. This is an awesome and unusual thread. I'm loving it

Frustrating for me taking so long its now costing business as the Volvo can be utilised for trips then I can restore the Yellow school bus is really starting to show the damage inflicted by previous careless misuse (rust). I suspect when the VOlvo comes out of hospital I will be spending weeks fixing up minor things (soundproofing etc)


The school bus in the johor jungle last week.

[fullthrottle]

Frustrating for me taking so long its now costing business as the Volvo can be utilised for trips then I can restore the Yellow school bus is really starting to show the damage inflicted by previous careless misuse (rust). I suspect when the VOlvo comes out of hospital I will be spending weeks fixing up minor things (soundproofing etc)

Soon Dave, soon. Throw that Aussie a slab of 4 X and that should redirect his interest

[geckoadventure]

Frustrating for me taking so long its now costing business as the Volvo can be utilised for trips then I can restore the Yellow school bus is really starting to show the damage inflicted by previous careless misuse (rust). I suspect when the VOlvo comes out of hospital I will be spending weeks fixing up minor things (soundproofing etc)

Soon Dave, soon. Throw that Aussie a slab of 4 X and that should redirect his interest

C304.jpg

I have this pic stored away I want to see how close mine looks to this at the end.

[geckoadventure]

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

[fullthrottle]

Looking good Dave.

What's the ETA for mud now?

[Cameron]

Can't wait to see the first trip report for this thing after it's rebuild!!

[geckoadventure]

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 3feet 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.

Not long before the thump of a 14B-T diesel splits the air.

[Cameron]

I guess if you have a gap between the cab and body you can run a sweet snorkel and exhaust stack up there too

[geckoadventure]

yup snorlkle and exhaust all roof entry/exit bound and shovel and hilift jack and recovery gear all stored in this area both sides as it will all be surrounded by mesh floor/door etc

6' Hilift jack will run across the floor just above the engine.