Volvo C304 4x4 Build/Restoration - WR002

[geckoadventure]

Wait till phase 4 when we convert it to coil suspension lol

It now has a name too "Dakar".

Videos will commence again when the Volvo is back on the road.

[geckoadventure]

Monday 12 March 2018

Ok 12 March I knew something was wrong getting exhausted climbing a set of stairs - wanting to pass out after being under the Volvo when I stand up etc. I went to the docs at work got sent to the cardio immediately and was grounded for 2 complete weeks.

Some friends collected the Volvo window templates from IPOH and brought them to KL for me.

[geckoadventure]

Saturday 24 March 2018

Chauffer turns up early in the morning and we order the front windows yet again for Volvo 1 and hand over the perfect template which are 3mm smaller than the window frame.

[geckoadventure]

Saturday 31 March 2018

I'm back on deck after 2 weeks of complete rest. Lets see how I go.

Up early eventually leave the house 5.25am - what the heck the highway is crowded and it's pouring down. It's impossible to even stay on 120kph the idiots are all over the road.

Eventually after 100k the rain stops but the idiots down't and I eventually arrive IPOIH 190k away at 7.30am for a nice breakfast and a rest before the workshop opens 8.30am,

Wife informs me it's Chinese ancentor Grave Clearing next 2 weekends evryone is coming back to clear the elders graves.

The 8.30am meeting shows they hAave been busy. The rear of the cabin is all soundproofed and 2 layers of insulation added. Its all bolted down and looks really ace. The batteries have had an inspection hatch cut into the floor

My job today is parts collection first while Ranjit does the making of the air intake, starts to mount mudflaps and also bend the leading edge of the service hatch covers deg to make them nice. My job is to mount the panels and the watertank and paint the new battery box hatch and the parts run and work on the clutch.


Afternoon for something different we mount the wheel studs on the tire carriers and then a test load and unload one of the studs on each carrier spins - DAMN we now have to remove and find bolts and weld them in. Damn more wasted time.


The rear panel and roof look really ace.


The new 80 litre Stainless steel water tank is washed and prepared ready to mount tomorrow and test fitted


I have the clutch starting to work it no longer leaks and pressure is building in the clutch line.

[geckoadventure]

Sunday 31 March 2018

8am start. I do the Sump 2.5 hours later the sump is bolted in after complete preparation of the sump and the engine block.


The air intake is completed and the connecting pipes made up.


By early evening we have the water tank mounted and 3 panels bolted in and sealed


One mudflap mounted with more to do to stop early wear etc


Ranjit has bent the leading edges of the service hatches inwards 45deg to make it look tidy.


The water tank looks ok


The air intake is completed on the left or the birds nest as it's been named after the tiny finches who made a home in a fluro light in the workshop.


home time 6.30pm. Little did I know it was going to take me 5 hours to get home/

Next morning is the hospital checkup - I fail I'm grounded indefinately until the heart recovers. The workshop has agreed to finish the Volvo to registration passing and also to transport it to KL.

[Cameron]

hope you come right mate!
looks like she's getting to the pointy end of things! be so good to see this thing running and driving

[geckoadventure]

hope you come right mate!
looks like she's getting to the pointy end of things! be so good to see this thing running and driving

Thanks - 16th is checkup day lets see if the heart is still erratic or settled down. Else I will be investigating a pacemaker.

[Cameron]

my mother has had a pacemaker for about 9 years now to re-time her heart when it goes out of whack. pretty successful!
no welding after that though!

[geckoadventure]

Have heard from someone who dropped in the new front windows to the shop the Volvo looks good.

They have finished the mudflaps and fitting the service hatch internal cabin spring loaded latches.

They are finishing a 10 trailer order then back on the Volvo sometime late this week.

If I had any doubt that I was sick it was confirmed Saturday morning when I picked up and carried Volvo 2 axle tubes 10 meters because the meckanic has had a KIdney removed so he is not 100% well my heart went balistic took 10 mons each time for it to settle down so I didn't feel like passing out - sigh.

I failed another heart checkup Monday and am grounded for another 3 weeks while they change my MEDS. Only good news was the range of beating has narrowed to a 10 beat range over a few seconds. No pacemaker my heart beat is too high.

[geckoadventure]

Volvo 1 is coming home to Kuala Lumpur will be sometime after 1st September as I am away the next 2 weekends with the kids kayaking adventure. So Volvo 1/2/4 will all be in the same workshop. and I will finish 1 first then 2 and then 4.

[geckoadventure]

Tuesday 28 August 2018

Got 3 pictures sent to me.

The wiper arms and brackets are finally installed





And the dash is starting to look completed


What's left before it's sent the 190k to Kuala Lumpur on the flatbed:
Bleed clutch again
Brakes redo the rear piping
Fill/check all oil levels in everything
Finish air conditioning (KL job)
Wiring is almost finished so internal panels can be installed
Windows installed
Wiper arms/blades
Install doors.

They say 1-2 weeks before is ready to come home finally.

[Checkerhead]

Mate the amount of stuff you have to get remade is heartbreaking. And I make most of my own stuff twice.

I did enjoy the speed camera traps you laid though!

Hope your progress and health are going well.

[geckoadventure]

Mate the amount of stuff you have to get remade is heartbreaking. And I make most of my own stuff twice.

I did enjoy the speed camera traps you laid though!

Hope your progress and health are going well.

After a 5 month holiday the workshop is now working on the Volvo without me being around.

I am much better than 6 months ago and probably about 90%.

Update about to be added.

[geckoadventure]

Thursday 20 August 2018

Got a set of pictures sent to me of progress.

Headlights back in.


It's up on the hoist so they are working on it.


Work on the wiring continues.






The maze of wiring looks not so much of a maze and now looks connected up.


The interior lights etc and batteries are connected.


The dash panel is now almost completed and the water temp etc all connected and working.


Tacho and Speedo connected and warning lights etc connected.


Progress is being made. Today the wiper arms etc are supposed to be connected I guess then the windows can be installed.

I hope to collect it on 29 September and bring it to KL.

[wjw]

looking good, but 29th August?

[geckoadventure]

My bad stupid me. 29 September is the date I hope to collect it.

[Smurf]

So Close, So Close

[geckoadventure]

Saturday 29 September 2018

Quick trip to IPOH 190k away to drop the kids home kayak trailer in for surgery after someone got the gap between the racks wrong and also fit 4 wheel disc brakes to it.

So what's been done to the Volvo quite a lot:
-Window washer 15litre made and ready to fit sits where the radiator used to go.
-Fuel pump wiring relaid to avoid andthing trouching them.
-Both forward winch cables are not enclosed in a tube for most of the underneath to stop any cable drag and protect all engine underneath delicate areas.
-All wiring is completed and we tested everything yesterday
-New fanbelt tensioner made and fitted
-Compressors etc work.
-Engine starts and runs nicely but very noisy I will assume that will change once its outside and all covers are on.
-Fan being installed to haul air over the turbo when its idling to stop radiant heat
-All the cabin panels are installed
-Window wipers work
-Rear camera up and running
-lockers work etc

What's left to do before it returns to Kuala Lumpur:
-CLutch test
-Brakes test
-PTO to be made running with new vaccum switches
-WARN winch to be tested
-Cable for Factory PTO to fitted
-Bolt down the dash
-Prime the aircond
-Check the radiator cycles properly
-Fit the rear internal lights
-Install the turbo fan
-Test the odometer
-Test the tacho
-Install the seats
-Fit the doors
-Fit the front windows
-Fit the rear seats

Whats to do when its back in Kuala Lumpur:
-Inspection and re-Registration
-Get interior panels made up for the centre console
-Fix 18500lb winch
-Road test
-Repaint to the new colour since the current colour holds oil stains/dirt etc.
-Get it ready for it's income making role.

They think it will be finished 5 Oct 2018 but we may leave it there for another week of testing.

Side views not much to see


The 2 colour interior lights work


Slowly its getting complete - right view


Front view


It's so close its quite exciting.

[wjw]

[Sausager]

Whats to do when its back in Kuala Lumpur:
-Repaint to the new colour since the current colour holds oil stains/dirt etc.

You're repainting it? I'm guessing that's a full tear down again?!

Either way, what an awesome build and an awesome vehicle!

[Cameron]

So exciting mate!

[geckoadventure]

Friday 5 October 2018

Late night pics I guess they were working on the lights.

Next weeks work:
-CLutch test
-Brakes test
-Install the seats
-Fit the doors
-Prime the aircond

What's left to do before it returns to Kuala Lumpur:
-PTO to be made running with new vaccum switches
-WARN winch to be tested
-Check the radiator cycles properly
-Install the turbo cooling fan
-Test the odometer
-Test the tacho
-Fit the front windows
-Fit the rear seats

Whats to do when its back in Kuala Lumpur:
-Cable for Factory PTO to be fitted
-Cable for Warn Winch to be fitted
-Inspection and re-Registration
-Get interior panels made up for the centre console
-Fix 18500lb winch
-Road test
-Repaint to the new colour since the current colour holds oil stains/dirt etc.
-Get it ready for it's income making role.

Lights all done.

[geckoadventure]

Friday 9 October 2018

A fleeting visit to have a discussion on progress and what's left to do before I take it home. Home date is agreed now 17th October 2018. The Tow truck is booked and confirmed.

It rained the whole 190k up to Ipoh and the whole way back to KL. The drive back listening to Sting, Pink Floyd and Fleetwood Mac made the drive easier.

So progress since my last visit such a long time ago. They have finished the mods to the Orphanage's Kayak Trailer it's also ready to come home next week also.

A lot of little fixes and mods have been done, Fuel pressure issue has been resolved and the fuel filter moved to give more room for access. Air Tank moved also for more access to the engine bay.

The tube made and fitted under the chassis to allow the winch cable to not catch on anything is made and installed.


The rear side view and the new quick release tow bar for the kayak trailer all fitted


Brett smiling as he tells me it can go next weekend and holding the remote for the interior coloured lights. The rear tire carriers have also had the studs welded on now and not pressed in.


The front view and yes the doors are on for the first time in 7 years. Only the top halves to be fitted now.


Grills fitted on top of the rollcage to protect the radiator and air conditioning.


Everything almost fitted in the interior one seat and the gearbox cover to go. Leaving only the covering of the tunnel to be done and some minor painting of black around the window.




I hear I'm going to have a big issue at road transport inspection as I have changed the interior layout and also lined the cabin sigh! We will find out on the day.


The interior looks pretty good. The steering column cover is still to be found else they will have to fabricate an alloy one.


I can see all the instruments from my seating position.


The console looks good. Everything works except the 18500lb winch and the 2 air cond switches need to be fitted.


Right side view. The issue with the bottom of the poor gap at the bottom of the drivers door to be fixed in KL.


The lights in the rear 2 colours and the new black handles for climbing into the rear.


Green lights


Still one side panel to fit and the tree deflector is fitted to the top of the rear cabin.


View as the CIA satellite will see it lol.


View as the monkeys in trees will see it in Malaysia.


Yes it drives. Clutch pedal had the pivot point changed to make it work. Apparently it's a very heavy clutch, I will need to install the Toyota spring assist kit to fix this. They drove it out in the workshop but there is no brakes they ned to replace the vaccum pump as it's leaking and the air conditioning the shop needs a "new" fitting to prime the air cond.

So 8 days and it's home couldn't be happier. We have a small water leak to deal with at the water pump. Then I try and get inspection done the following week since everything that's needed to work for inspection works.

Still to do before next Saturday mooring. Steering Column cover. Fit floor. Fit PTO winch vaccum switches and panel. fit the door tops. fit the front window and the window wipers and washers. Fit door handles.

[1bad4x]

Dam, Thats looking great!

[Cameron]

So good mate cant wait to see some vids!!

[geckoadventure]

Saturday 27 October 2018

5.55AM my chauffer arrives and I give him the keys to the 80 Series Landcruiser I'm borrowing/buying while my Isuzu is in the workshop for new master cylinder for the past 2 weeks. The aircond dies lol its a hot trip up.

Biggest day in the life of the Volvo it's coming home the tow truck is due to arrive in IPOH 9am, The 190k cruises past as my chauffer wheels his way north.

I say hello and goodbye to the all restaurant staff whom I've eaten breakfast at for the past 2.5 years.

Inspection time Brett and myself inspect whats done whats good and whats left to do.


Bolted all up for the first time its starting to take shape with only the transmission tunnel and the

repaint the obvious stuff to complete.


Pensive as I look it all over will it make the 24th November deadline.


The roof console and the reverse camera.


The harness seatbelts remain to be bolted in and the engine cover is finally bolted down.


The fuel pump and fuel tank filler area is cleaner with the fuel filter and compressor tank moved tight to the cabin. The fuel feed issue fixed with the minor leak repaired.


Planning the next vehicle? Or discussing RFC next event they are both going to attend.


Number plates now attached and the Kayak trailer tow bar is fitted. The rear panels all bolted in we found a water leak at the end of the journey.


Spare tires all mounted we need to mount a anti vibration rack later and a wheel mounting slide/guide pin.


The newly powdercoated grill and the tool kit is now bolted down behind the drill. The new front windows were only fitted Friday afternoon.


The moment for it to be squeezed onto the flatbed it fitted by inches.


The journey home uneventful apart from the tow truck struggling up every hill.

Pic of it in it's new home tonight. I took it for a drive before parking it in it's new bay while we finish it. Very night drives quite well apart from the shuddering steering which we think we know whats causing this.

[wjw]

[geckoadventure]

28 October 2018

They took pics on Friday night. It looks pretty cool with it's green and red lights.

Underneath from the rear


Roof and grill. Still need to make a air scoop for the radiator.

[wjw]

I think I need one of those for the wife for the school run

[Smurf]

That look bloody awesome, She's been a long time in the making but here's hoping it was all worth it. I'd be as happy as a pig in shit with that to play with.