Volvo C304 4x4 Build/Restoration - WR002

[geckoadventure]

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.

[geckoadventure]

There isn't a scale to measure how awesome this thread is!!!!
How do you get at the exhaust and stuff between the cab and body for repair or servicing once the body is complete?

The 2 side 18" doors drop down and it makes it easy to get to as you can see from the left hand side one, bottom half flips out and down as a ladder (and the recovery kit (straps and shackles etc) is in here) the top of the left side unbolts to get to the radiator. The top lifts back to allow topping up of radiator etc. I will take a pic of this next visit.

The air intake being built also next week by Brett.

The truck is actually 3 parts now REAR CABIN, Middle service area and front cabin and there is 3 ROLL bars hidden in it. All designed to get around JPJ design rules here .

The whole rear floor panel unbolts and can be removed for major work or field work.

[geckoadventure]

The to do list to get to 1 March 2014 completion date

02. Buy Garmin Colorado - wednesday morning
05. Design Overhead Console
06. Build Overhead console
07. Position for Inverters and USB chargers
08. Design Rear Side bars and access to replaced removeable doors - completed0
09. Wiring
10. Sandblast and undercoat and paint chassis and body
11. Fit Alloy body panels
12. REfit every part.
13. Sound proofing fit (after back in Kuala Lumpur)
14. Collect shocks from Malacca
15. Buy leaf springs (after back in Kuala Lumpur)
16. Power STeering do (hydraulic assist from USA)
17. Buy 3+3 seats for rear $600rm each) and harnesses - Wednesday morning
18. Fit rear seats
19. Tie Down points identify and fit/create
20. Hammock connect points fit
21. 100liter Water Tank Make (Anivsah to supply 3 filters) - Next week
22. Roller slides purchase 4 - delivery January from Australia
23. Buy 4 MAxxis Bighorn 762's
24. Buy 200' of 11mm winch wire for the PTO and 125' of 9mm for the M12000 winch
25. Design PTO winch lock (Lever by vaccum) to replace canvas strap
26. Oil leak in DIFFS fix
27. Electric pump for engine radiator
28. REplace CV booties
29. Buy 2 200 amp batteries - have cost can order anytime
30. Buy Reversing camera
31. Buy Icom VHF radio speaker
32. Buy driving camera.

[catalystracing]

Assuming thats a March 2014 date, or this is a very late post

[geckoadventure]

Assuming thats a March 2014 date, or this is a very late post

Yes its a march date and it will also be missed 1-2 weeks with no workers in the workshop looming yes I would say sometime in april which means it does not make the trip its so desperately needed on.

[geckoadventure]

30 January 2014

Quick visit to the workshop (very quick on way to chinese new year dinner).

Dropped of the final 3 gauges Vaccum, 24volts voltmeter and the fuel gauge and matching sender.







and 4 of the 6 rear passenger seats and one harness the other 5 are on back order



Update before Brett headed off to go motorcrossing before he had to be home for CNY dinner also. Wiring is to start this week which I thought was finished and the seat frame buildig will start also as will the middle access doors will be laser cut and drilled.

Next visit is unknown as I have 4 weekends of other stuff to do.

I have 2 seats and 5 harnesses on back order.

[geckoadventure]

23 February 2014

Ok time for a wrap up of the design and the intention.

1. Restore the truck to a factory new level - rust removal etc.
2. Add DAKAR truck look.
3. Add a Diesel Engine (14B-T) and make it JUNGLE and long distance touring capable. Added HIGH Ratio Crown and pinions. Still looking for a T230 Xfer case and RR gearing
4. Add Rollcages (roofracks for purposes of registration.
5. Remove rear doors and seal up
6. Extend the rear cabin roof line back up 8"
7. Cockpit add gauges (14 including water temp, boost, ET, 12 and 24v gauges, air pressure, vaccume gaugeand stereo and airconditioning and harness seatbelts and seats power steering and rebuild the cabinn to remove the rust.
8. Add console for the extending all the controls to be in range of the arms when strapped into the harness
9. Add 12v and 24v 12v for lights and rear cabin lighting.
10. Relocate radiator, air cond, intercooler, air filter, exhaust and recovery gear all to a middle 18" utilities area. All of them out of water and mud randge.
11. Toss off the rear cabin (440kg +30kg) and replace with a new gullwing cabin with alloy skinning and 2 rolling out slides and hammock hooks etc and also optional drop in sides (remove the 4 doors first) and 6 seats and harnesses
12. New fuel tank of 187liters.
13. two spare tires mounted at rear of truck
14. Add LED lights front and sides etc
15. Add a WARN 12,000 rear mounted winch and a T-MAX 18,500lb winch to sit beside the factory PTO winch
16. Brake Disc conversion been done
17. Rewire the complete truck
18. New Maxxis 35" Bighorm 762
19. GPS Speedo (still finding out about VDO speedo connected to a GPS sender)
20. Reverse camera
21. Fridges etc connected
22. JUngle camping gear not camper setup its too heavy for our environment.

I have to be able to do this type of terrain in it (this is me in my almost stock OPEN diff landcruiser just a highly modified WARN 8274.)



Did I mention mud lol


Deep and steep mudholes the after.

[tomsoffroad]

"Adam, Adam dont wee in the river!" Classic

Envious as hell of the thing you get up too. Keep it up

[geckoadventure]

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


Speedo cable - GPS


Tacho


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

[geckoadventure]

7 March 2014

Got a call from Brett - how many type of seat belts you sending me. So far I have 3 types - oops. Looks like the last set I sent up were 3 point and he does not want them in the rear so he selected a SPARCO 4 point which I had spare. Now I have to go buy 5 more oops at a cost of $150usd each lol. So the rear seat frames are now finished and all the harness mount points set for SPARCO harnesses only. and he received the TAcho and Speedo. The TACHO looks so good im going to put one in both my other DIESEL trucks.

Still no pics I will push him for pics next week maybe by end of next week the rear frame will be ready for sand blasting and painting.

[geckoadventure]

14 March 2014

The steering column is being done this week they have not worked on the Volvo Monday-Wednesday

They are fitting it and then fitting a alloy casing around it and the power steering part.

I await pictures of this.

More pre-occupied with what has happened to MH370 this week.


21 March 2014

Quick call to the workshop progress.

• Rear Floor finished
• Seat belt connections all done for the 6 rear passenger bucket seats.
• 100litre water tank contstruction started today.
• Air intake/snorkle being built and is 1/2 completed once this and the water tank completed it will be sandblasted (late next week)
• Wiring clips all added this week ready for the wiring loom to be laid through the truck next week
• INstrument panels and overhead console will be laser cut and weleded up in the coming 1-2 weeks
• Wiper motors and wiper arm lengths yet to be worked out
• Steering column still being worked on.

Pictures to be sent to me next week when they reinstall the seats to drill the holes into the floor to mount the seat frame retaining bolts.

New Maxxis 37" Trepadors ordered for it collection in April

[geckoadventure]

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.

[geckoadventure]

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


Water tank

[geckoadventure]

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.

[geckoadventure]

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


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 40kg.

[CLUMZ1]

More pics!

[geckoadventure]

More pics!

You want more pics I want it finished lol.

I will ring him today if I get a chance for progress I know he was working on the power steering fitting and the covering of the steering column with alloy sheet.

[badnuz]

Nothing like a couple extra inches

[geckoadventure]

Wahooo progress - Builder has stated next friday will be sent off for sandblasting and painting so I have 1 week to sort out the final colour scheme.

The steering column is getting final shroud and mount finished this week.

new Window wipers all fitted


Pics tomorrow - I hope with new sneakers on also.

It will probably not make the Orphanage trip on 13-16 September damn but I estimate end of september it will be finished.

[derk]

Looking good mate hey whats your winch setup in there I know you jokers over there are pretty fond of godwinches so I'm guessing that big sucker in the middle is probably one with an oversize drum leckie one behind it as a backup

[derk]

Just looked at your gecko adventure site that's a big sucker factory pto winch tucked in there

[geckoadventure]

Looking good mate hey whats your winch setup in there I know you jokers over there are pretty fond of godwinches so I'm guessing that big sucker in the middle is probably one with an oversize drum leckie one behind it as a backup

Actually the DRUm is a Factory PTO fitted after it was bought from the Police by the previous owner.

worse I need to go buy 2 new cables (and spares) for the PTo (180') and the warn (100') and a spare for the 18,500 there goes 1,000rm minimum.


I have a GOD winch on my RED LC II with 180' wire and soon to be 220'

[geckoadventure]

Just looked at your gecko adventure site that's a big sucker factory pto winch tucked in there

The factory winch has a built in clutch to stop the cable snapping. Needs adjustment when truck is finished to stop it letting go too easliy. Cannot wait getting excited as the workshop is also building the trailer for my new 19footer alloy inland fishing boat and the Volvo will be registered to tow it they may both come out of the factory on the same day. Yes I have decided to relax a little more and fish more on my spare days off as my time is filled with 2 jobs and helping the orphanage and other charity work.

[geckoadventure]

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.













My new assistants

"Fury"
[img]http://www.geckoadventure.net/Volvo/2014_08_02_Fury_11.47.19.jpg[\/img]

"Fury" the 12 week old kitten thanks to my employees for giving it to us and being "hugged" by "Cheshire" the 11month old wild kitten yes the measuring tape stealing cat.

[img]http://www.geckoadventure.net/Volvo/2014_07_23_Fury_20.33.18.jpg[\/img]

[geckoadventure]

3 September 2014

Ok so have a few spare days after breaking down in the jungle about 20 days ago and had to wait 2 days for parts and got back to work on the wednesday so immediately went on 2 weeks compulsory leave due to our leave policy.

Today popped up to work on the Volvo before its stripped.

Cut out the 12mm round bar for the tie down points and some loops have 3-4 to cut out tomorrow and then we will weld them in. 13 done 3 to go in the morning.

Last item to do is to fit the step release whichis inside the cabin where yellow line is where the internal step release will be placed tomorrow.


Details - side bars all fitted now can remove panels and have it 1/2 opened at the rear or completely paneled up. Front two uprights on the bull bar fitted. New rollcage rules might make my external cage legal here now


Tool box in the front grill is visible. Some holes to fill the painter will advise how to fill weld or braise or hole sealant.


Top view looks cool only exhaust exit bit to do.


Seats all sitting in place nothing to do except bolt down.





37" Trepadors are going to cause an issue we need to fit them tomorrow and look at the offset they are going to touch the front guards.

KInda happy - more reporting later on Friday.

[geckoadventure]

4 September 2014

Finished up the top hatch locking tabs. Welded in the tie downs points and finished the fold down steps locking pins.

Then it was the time for the strip. All the bolts are undone 8 to go in the morning to lift the rear out.

The doors have an internal rust issue to be dealt with






Front cage off and the wiring loom stripped and labelled.


All the doors frames etc removed


Side view






Tomorrow the LIFT off.

[Cameron]

can't wait to see this finished chap!

[geckoadventure]

5 September 2014

Continuing the stripping today all stripped and all touchup welding done and then we discovered that 2 braces had been missed on the rear body and the 6 contact points with the cabin needed more work.


















Damn fit the cage back on and redo the welds took us an hour to fit it properly to effect the repair.






Time for home to repair the busted CV joint on the mighty troopy they had one set of welds left to do.


Monday finish the remaining touchups on the body

Tuesday off to the paint shop for the sandblasting and undercoat.

[tomsoffroad]

you must be grinning
Cant wait to see the paint.
Good looking workshop too. Is it close to the ocean? Doesn't seem to take long for bare metal to sheen over?
Sad in a way that the builds nearly over, but will be watching with great interest for the "using it" thread

[Taz]

You have the patience of a saint man! haha

Good to see progress is still going in the right direction though.