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Volvo C304 Restore and semi expedition or jungle taxi

115K views 378 replies 57 participants last post by  geckoadventure 
#1 · (Edited)
Hi my first Pirate Post.

I'm(we my wife and I) from Malaysia - most people call me GECKO (my nice neighbour he just calls the police hahaah) due to the large GECKO tatto I have on my arm. We (yes she told me to buy it or she would leave me) have acquired a C304 (4 wheel model only) and in the process of restoring it.

As we pulled it out of the storage park with my BJ75 on 26/07/2010. It was not running but would tick over.




The BJ75 struggled to pull it it appears the brakes we frozen on.

Onto the tow truck and down to a performance tuning shop hahaha.



Once they removed the spiders and cobwebs from the tank it started.

Then they changed all the fluids.

But they could not fix the brakes so I made decision to do the DISC conversion first before the rust treatment.

I drove it around at nite for 2-3 weeks testing it out - without brakes and only using the gears and handbrake. I learnt what was good and bad in the truck and what needed fixing. Now I have a 40+ item list to attend to.

Then 20 August 2010 I took it to the hospital (escorted by the magnificient BJ75) which was entertaining saw this on the way out. Oh yeah I burnt off a 22R powered LC II on the way up a hill it could not pass until the downhill part hahha.


This is it after being washed and driven for a few weeks. Mr Grumpy my neighbour hates it and all 4x4's the other neighbours in the street think its neat including the ("SIR") who I took his kids for a run in it now he wants to book a jungle trip with me.


The interesting one is my car illiterate neighbour she I quote "that engine sounds so sweet" its nicer than my Honda. Then where is that big beautiful 4x4 on sunday she asked.



Then the serious stuff removing all 4 wheels and portals - yeah yeah that's me working on the Jalopy.


Me working on the last wheel. The mekanik did 1 I did 3. Not bad for my first ever attempt at working on a Vovlo and no manual either.


7 hours later a A stack of portals


Once that was done it was over to the BJ75 and pulled the WARN 8274 out of it it has water in it :( and the new axle to be fitted and a new knuckle this week and new leaf spring bushes and it also has a brake problem.

We are going to put on in this round of fixes:
1. LC II Front Discs front and rear as this is a part which is readily available.
2. Install the WARN 12,000lb winch for REAR recoveries
3. Fix the taillights with LED lights
4. Fix the indicators
5. Fit new headlight wiring and H4 halogen bulbs and new reflectors
6. New radiator hoses and break hoses.
7. Battery Rack for 2 solar batteries and 2 120amp batteries and a 150AMP Alternator.


Once we
So thats my intro. I will post up stories as I slowly restore it.
The rest of the truck is STOCK.

I have previously been in (and out) a C304 during the RFC2007 when we got flooded and I was in the BJ75 in the same small convoy of 6 of us. I know what it can do - awesome. I cannot wait to take mine offroad here.

I also own a:
Toyota LC II - 13B-T monster very jungle ready
Toyota LC II 1KZ auto handbag jungle car
Toyota BJ75 - jungle ready
ISUZU pickup and
TOYOTA VIGO pickup.

My favourite is the BJ75.
 
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#52 ·
10 January 2014

The to do list to get to 1 March 2013 completion date
01. Order Tiny Tacho - ordered and delivered to my house
02. Buy Garmin Colorado
03. Order Digital Fuel Gauge from US - ordered VDO gauge as REMARK industries never answered email or fone - on way today
04. Order Air and Vaccumm gauges - ordered on today
05. Design Overhead Console - designed by brett
06. Build Overhead console
07. Position for Inverters and USB chargers
08. Design Rear Side bars and access to replaced removeable doors - designed waiting for Brett to make
09. Wiring - started
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 - not heard if rebuilt yet :(
15. Buy leaf springs (after back in Kuala Lumpur)
16. Power STeering brett has ordered kit from USA.
17. Buy 3+3 seats for rear $600rm each) and harnesses
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 still waiting)
22. Roller slides - to be made for the Volvo
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
30. Buy Reversing camera
 
#54 · (Edited)
Because there is 8" difference in height between the top of the front cabin and the rear cabin.

The original POLICE rear was an Canvas top on top of a MESH frame which was 18" higher than the front cabin.

Then the second owner ripped the rear apart and made it flush with the top of the front cabin and put cheap steel and plywood in it.

Then when I wanted to make the rear 18" higher again for more room we realised that it was too high for the jungle trees and bamboo groves would mean lot of chainsawing as all the other vehicles in a convoy would slip underneath on a tight track. So we compromised on 8" extra height - also I can slip a solar panel underneath the exo cage at some point. with a SOLAR battery. It also allows the Air intake and the exhaust and the Intercooler and Radiator air intakes to be protected also which are all sticking over the front cabin.

I hope to have some more progress pics on 24th when I go past SIMPANG PULAI (the workshop is 195K from my house) when I go to a wedding in Penang Island on 24th-26th. I can also drop parts off to the workshop I also hope if the gauges turn up this week. I have to buy SEATS and harnesess also on the way up.

I do like the look of your bending kit now you have me thinking as my builder is the only one I know with a proper bender here. How much to ship one to Malaysia?
 
#55 · (Edited)
13 January 2013.

More progress. The new custom toolbox has been built and its holding tray. New 12v battery holder built since we are going from 2 12v batteries back to one really large one.

Wiring is almost completed. Fuse boxes etc all installed in the new center console.

Water tank construction starts later this week.

my next visit is on 24/1/2014 on my way to a wedding in Penang.

By then I hope to have the remaining gauges to take up also.
 
#56 ·
18 jANUARY 2014

Latest progress

all the door handles and latches for the side doors have beeen purchased including the central locking.

Fuses and fuse boxes all connect up also. Power steering units have arrived from the USA and the first one is being fitted to the workshop racing Landrover (V6 Nissan turbo engine it does go rather rapidly lol) and tested so they can sort out any issues and then apply to the Volvo.

Switches and warnign lights to be purchased next week and fitted. They are all going to be bright and approx 1" in diameter each no tiny stuff in this truck.


The gauges finally on their way next tuesday from the USA no way they will make it for the friday run to the workshop in IPOH. So will have to courier them up after sigh.

The new secure toolbox (where the radiator used to be) is built and mounted in its new home.

Priced two new 200AMP batteries this morning from my local supplier 200USD each - sigh.

Next Friday go and buy the rear passenger seats and harneses on my way to the workshop.

I managed to find the big switch I hope to use as a STARTER button - yes its 3" in diameter lol.



Then the kitten knicked the measuring tape
 
#57 ·
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.
 
#58 ·
The to do list to get to 1 March 2013 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.
 
#59 ·
Interesting build. Must be costing you an absolute fortune ! Realistically though, with the height, and weight of that rear cabin framing, high COG etc, can you really see it being capable of getting close enough to stuck RFC vehicles to actually perform as a recovery truck and use all those winches.
 
#60 ·
h

The truck is not being built for RFC recovery its for other serious 4x4 trips. I have personally not been to RFC since 2011 and I have my reasons for not attending but my trucks (The mighty RED truck) have been going (lent to an australian last 3 years). I prefer tougher tracks lol than the RFC dishes out (there is very little offroad driving any more) and picking tracks where im not being turned back by flooded roads and I can actually get to camp at a river or waterfall not in a shop on the side of the road. LIke I say to people who go to the RFC and then see the pics of places I go pick your tracks and you will see stuff not a rugged campsite 500 meters off a main road so you still have internet connection for the press to write fiction stories of hardship.


The Volvo is quite capable of getting itself into and out of trouble which is the intention of the 3 winches - 2 forwards and 1 rearwards.

The COG has not increased much with only 8" being addded in height. There has also been a big weight shift - 200 litre fuel tank now underneath and no longer in the rear cabin. THe radiator and fluid is about 20kg The intercooler about 2kg and the air cond condensor about the same. don't forget the volvo is 1.99m wide not 1.6 like a Toyota or Nissan.

The all steel REAR back cabin (440kg + 30kg swingaway) removed and the new steel frame and alloy skinning has to weigh less and we dropped it 2" lower than the previous floor. Two winches 66kg and some 56kg added directly over the rear axle. THe roll cages are built into the walls so they almost are invisible.

Yes I will be happy in 2 months when it is all finished and I stop the monthly payment to the builder.
 
#61 · (Edited)
Thanks for the reply and info on the RFC. I'll cross that one off my 'to do' bucket list then. I'm a little interested in why you saw fit to go to the extra expense of adaptors, to retain the Volvo transmission and not use a LandCruiser 5 spd one. The crawl ratio would be no worse but you'd have a higher cruising gear, and there are aftermarket crawler ratio options for the Toyota transfercase. In my experience with my portal axled LandRover, anything less than 100:1 crawl ratio is insufficient for the more difficult tracks that you, or I prefer to tackle.The stock C303 crawl ratio with 5.99 axles of 53:1 IIRC on 35"tyres doesn't really allow enough precise and safe control in the more extreme conditions.The dream option IMO would be the Toyota 5spd mated to a Landrover LT230 transfercase and an Ashcroft crawler box on the back of that.
I've built a couple of Volvo axled LandRovers and although Australian Authorities don't permit widening the wheel track width by more the 25mm per side, I do wonder about the ability of the front steering knuckles to cope with the extra leverage of your extra 60mm per side. Volvo axles are very common in Malaysia so any weakness in this area would probably have shown up by now I guess.
 
#62 ·
The C303 is stock with 34.7" tires and before I changed the engine it crawled ok.

I did not want to chanage the gearbox as I am trying to keep the chassis/cabin and running gear as close to stock as possible. If I do i would put a C306 gearbox in or a BMW 7 series auto converted to manual shift. and im still researching the BMW gearbox.

You are the second person to mention the LT230 transfer case and I and looking for a RANGE ROVER LT230 case and putting a new set of gears in it. thanks for this info also.
 
#63 · (Edited)
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.
 
#66 · (Edited)
Ok time for a wrap up of the design and the intention.

1. Restore the truck to a factory new level.
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.)



2013 07 14 Cengal Besar trip Blue Bank - YouTube

Did I mention mud lol


Deep and steep mudholes the after.
 
#67 · (Edited)
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
 
#69 · (Edited)
6 March 2014

I got a call late yesterday progress report

2 frames made for the rear seats harness seats fitted and harness connection points to be made today.

Wiring 1/2 the fuse box (yes that ugly box in the middle of the console completed)

New steering column fitted the volvo steering is no more. Now I have indicators and lights etc all on the steering column.

Amazing what happens when the new worker started last thursday.

I am awaiting pics this week so I can post.

So close to removing the rear frame and painting it.

I am couriering the Tacho and Speedo up today.

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.
 
#70 ·
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.
 
#71 ·
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 welded 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
 
#72 ·
I hope everyone affected receive 'closure' one way or another re MH 370.Very sad.

I know there are a lot of Bretts around, but your builder wouldn't happen to be an Aussie from South Australia by chance ? I knew such a person that managed a similar workshop in Hanoi Vietnam who was also a LandRover enthusiast, but last I heard he moved back home.
 
#73 ·
MH370 is already sad its going to be a long time to sort it out. The media making it worse the media beatup is unbelieveable as is seen by the latest crap the ATC tapes - all false and made up sigh.

Nah Brett is not the LR vietnam Brett. He used to make Bed Matresses I believe as an engineer.
 
#74 ·
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.
 
#75 ·
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
 
#76 ·
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.
 
#78 ·
Update no updates this week the builder is away till tomorrow (and no progress last week either) and i'm in land of smiles (Thailand ) with mrs me

I hope to report some progress next Saturday if I can get up there I have to discuss the outside tarp setup design with him.
 
#80 ·
Nah I wish sorry been in land of smiles then a 4x4 trip and a 4 day kayak fishing trip.

Latest status is
Power steering kit from USA been sent to a engineering shop to fit into the Honda CIVIC steering column

Wiring all completed and now cannot be changed ready for the fitting to the conduit.

Next stage is to sandblast the rear frame and the body and undercoat it.

37" Trepadors have arrived have to collect this Saturday.
 
#83 · (Edited)
Our next trip is a recce to the same area to look at installing 2 picohydro schemes for 2 villages. Solar is too expensive. Then we have to raise the funds to do the install.

recce 31st this month.

just for you here is me in the Tourism Fishing Malaysia add

 
#85 ·
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.
 
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