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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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#118 ·
This is my mate Rob's view of our involvement in the Malaysian Floods last December Jan Feb March

His poor DR 650 was given a rest a few days and he jumped in with me.

https://vimeo.com/124296412

FYI The black Landcruiser and the blue landcruiser were mine both of which I drove over various weekends and some trips all 3 of my vehicles were out there driven by my 4x4 friends.

and yes that is me stuck at the end being recovered by my mechanic lol.
 
#119 · (Edited)
Status of the Volvo is total chaos. We are really struggling to paint it. For the past 4-5 months we have been tryig to srt out colour and a paint shop. We have had stupid quotes such as 5-6K local which i basically like saying USD 6,000 to paint a cabin only whihc only needs to be lightly sanded as its already undercoated.

Then we get oh my workers have run away due to the currency devaluation (the ringgit has drooped some 30% against the USD this year) .

Also the builder is now away at the Malaysian 4x4 Rainforest challenge for the past 9 days it it finishes tomorrow so maybe Wednesday he will be back unless they win and he will be drinking lol. We had a long chat on last Sunday abou it his mates there also giving him a hard time get it finished lol. The paint shop across the road from the workshop wants to bodyfill the car even though there is nothing wrong with it. Hes getting them to look at it on Thursday and explain what I want no FILLER.
 
#120 ·
12/12/2015

Well the builder run me Thursday come up and see me I'm sick of the painters quotes.

So Saturday took the trusty Isuzu and attached the boat and trailer, had a swiush breakfast and then headed to the workshop 190K away. Fark me holiday traffic and 3.5 hours later.

Reversed the trailer in for the addidtion of rollers to combat the issues on steep boat ramps and a dry pull out and to make it 3 feet shorter. No the dog is not the trailer tow dog. He is also still deciding whether to rebuild the new fuel tank/seat which has leaked again 3 weeks after the boat shop repaired it looks like the did mig welding and not tig on the fuel tank so its split - YIKES!



Then onto to the real purpose of the trip the Volvo.



The final requote they got was $4800 and oh we will do you a favor we will paint it in the workshop for you. 4800 just for the cabin and the roll cage its laughable.

So it was decided. In the workshop we will get our own painter and paint it in the same area they paint the trailer axles So sometime in the next 10 days it will be painted and assembled. The winches and all the chassis stuff will be attached in the next 10 days (Winches and wiring etc). I marked all the areas which need a little putty before the top coat is applied.

Before you ask the beast beside the Volvo is a 2WD 400HP Nissan V6 powered Landrover Alison gearbox etc and yes it goes. No its out of scope for this story line lol.

The Build has recommenced the target is before my birthday in March.
 
#121 ·
24/12/2015

Good news cabin split in two and removed from chassis to do the touch up welding send putty work.

So next week almost ready for painting.

So merry XMAS to you all from me and my friend Mr Cheshire.

My little friend Cheshire happily sleeping on my chest. So go give your pets a hug for XMAS.


Honest it was me that made this mess it was the black cat at the door "Fury" is his name. Yes the mess was really made by Cheshire.


May all your offroad trips for 2016 be action packed. Laying out the practical course for charity group 4x4 driver training lol what they never saw lol.
 
#123 ·
That makes at least 2 of us then.

Btw- for $4600 I'd just spray paint the hell outta the cab and keep a can or 3 on hand for touch ups. That's a ridiculous quote for paint.

Merry Christmas and a happy new year to you sir.
 
#124 ·
2 Feb 2016

I rung for a progress report and got told none so I asked why he said no staff to do the body work. So being years since I prepped a body I volunteered to do my own vehicle.

Monday wa a pub holiday and they offered me the workshop for Sunday and they would help me Monday.

So Sunday morning 9am im 190k away from home at the workshop. I start had a quick look at the Cabin and did a quick plan of attack. All day I played with small amounts of body filler. By the end of the day the cabin wac starting to look close to being ready for paint. Original dents etc were left alone

The frame as Sunday morning



My companion while I did the top of the cabin was the workshop new guarddog the cazy happy 7month old mongrel


The rear panel is a bit of a mess but its been decided its original we leave it.


Filling the repair work from the patches added to the roof.


Oh yeah the pooch likes ICE as its over 34c here at present


Preparing the paint


Inside of the cabin top painted


We sat this here this morning ready to paint then we realised the sealant we added at lunchtime took 24 hours to cure our mistake for not picking it up yesterday


So after 2.5 days work of pure hard work in the heat I have made a lot of progress.
Early this evening we moved stuff around to enable the rear cage to be painted.


Rear cage 2/4 sanded tomorrow they can finish it and paint it
 
#127 · (Edited)
8 February 2016

Chinese new year Holidays

Arrived monday morning to the pleasant sight of the rear cage and all parts painted that I had left the week before.




Brett stuck the engine and gearbox on the forklift and then left for CNY lunch and said you can install and oh yeah learn to drive the forklift lol.

2 hours later I had it all installed but need new gearbox mount bushes.



Then started on the 18,500lb winch install. Success again took me about 2 hours plus searching and cleaning up parts areas to get stuff out.
 
#128 ·
9 February

Had assistance from the builder all day and we managed to get the cage installed and bolted down after installing the WARN 12,000lb winch and tightening the 18,00 bolts down correctly.




Then dinner time for both of us and we packed up at 5pm after getting the fuel tank reinstalled yet again and the gear change installed and bolted it. A whole pile of parts washed and a list of parts needed to buy.
 
#129 ·
10 February

Morning starts with washing the dusty parts and yeah playing with the puppy.


And the finl result is washed parts eventually and a half washed puppy


Lunchtime and I have the radiator and the intercooler bolted down everything is connected except hose clamps it all takes time including cleaning out threads etc.


Then late arvo it's all hands on deck to mount the two rear panels while I have been testing that all the front panels are fitting and doing final trimming and I take the second hand 80 Series muffler out for a scrub




At the end of the day what do we have well it's starting to look pretty good. It's time to head off to my chinese mums place and collect wifey for the longg drive home.




 
#131 ·
19 February 2016

Friday morning dashed up the 190K to the workshop and arrived just after the workshop opened at 8.10am

Idea was to run arround and get parts etc ready for Saturday and Sunday

After much running around and forgetting parts I pulled the wiring loom out after shoving the wire eating pupppy outside we layed it out for the morning.


So a the end of Sunday what do we have apart from my employee ringing me and saying my RED truck as funny noises from the rear after they took it offroad. So we pack up early for the 20k run down the road to check it out then another 175k home. Fark TOW TRUCK back to Kuala Lumpur turns out the rear locker
tore itself apart after it was stripped today (Wednesday).

We have a wiring loom sitting in the truck all cable tied up and a few connections done. Rear taillight has a broken bolt and rsuted insides so I need new ones from sweden first.


All the wires hanging out of it. The cabin is not on as there is still issues with the engine area. The 12 alternator took me a day to get it to fit properly and belts fitted inluding 2 trips to the spare parts shop to get them correct.


Little Joe has some fun with the puppy after spending 2 days stripping paint.


Then we have a pile of parts to paint or electropaint and anodize.


Oh yeah then the 2 weekend helpers the stripper and the wire man.
 
#133 ·
Sunday 6 March 2016

A quick dash up to IPOH. 1hour 15 mins a new record time and the 190k slides by early in the morning air - go ISUZU.

Finally I have the pesky alternator installed after a couple of days effort


Then it's time to lower the cabin bottom onto the chassis after lunch.


And hey 2 hours later we have it sitting on the chassis


The junior driver Joe


OK so I'm happy is installed


Then we install the service ladder for fun


Monday 7 March 2016

I decide to cleanup the items I have been cleaning up at home and get them painted. Grill, Engine cover, PEdals, Air cleaner, front prop shaft etc


Es gives them a coat of axle undercoat black


Then the cabin had to be removed as the turbo cooling sill not worked out properly and the power steering hoses need to be installed.

I pack the doors to take them back to Kuala Lumpur to work on next weekend. Then it's time or the long haul back to KL.

Sunday 12 March 2016

Doors sitting in the ISUZU at home. I am in 2 minds strip the complete outside of the doors or and and add another coat off paint. I decide strip and reunderccoat and top coats as I don't want 6 layers of paint

Doors ready for stripping


A pair of doors now ready for final sanding and a minor repair and then painting.


Stripping the paint revealed 2 war wounds from it's days as a RIOT squad truck I assume from the grills. They will be further sanded down as part of the character being left on the truck.

I have a growing list of parts to get or deal with. Tomorrow is the dash parts to the powdercoaters.
 
#134 ·
19 March 2016

Saturday morning finds me and an assistant Rob at the workshop before 8am collect the keys

greet the happy puppy an then go have breakfast and discuss the plan as Rob has to be back in

KL by 4pm.


Rob preparing the dimensions for the cutting out of the service hatch panels and the

surprise. They are to be laser cut and prepare in the coming weeks.


By lunchtime I have quite a bit of the soundproofing done in the cabin.


It's too hot for the workshop puppy he just lies around stealing stuff and breaking it. 39c

is very hot lol.


Then it's time to take Rob back to KL and then dinner refuel and the nite drive back up. End

of the day 570k travelled.

20 March 016 (Sunday)

I also apply paint stripper to the one door I have to work on and commence to get rid of the

body filler. The black is the rust converter.


More soundproofing work continued.


I gotta get rid of these holes. ooks like the welder has to come out and I have one more to

fix and the roof needs a repaint we found a istake which needs fixing.


Even the front of the window is being soundproofed.


The dogs collection of damaged kit.


Then I mounted the doors and checked alignment - opps some bending required.


 
#135 ·
Then I install the front windows again and try and find the seal rubbers cannot.


21 March 2016 Monday

The overhead instrument console is layed out getting it ready to take to Rob to get measured

up to get laser cut.


Then it's time to do the console instrument layout check with the new steering wheel. The

console will be remade its not right.


I move onto the overhead console and lay it out until im happy with it. It's also to be

laser cut.






Then the afternoons progress is slowed by the arrival of Nazir who has come to collect the

Volvo's old engine for his C303 restore project. Happy restoring Nazir I will come and visit

you in Taiping soon. That is a cool old Chev pickup he has.


Then the final task for the day is to swap the sneakers and empty more junk from the

workshop wow 7 pieces removed in one day.
 
#136 · (Edited)
26 March 2016

First task connect the Powersteering inspection reveals the banjo bolt is missing hmmmmmmmmmm I
know just the shop. A quick run down to the parts street gets me the parts I need 8mm 12mm and
10mm hoses and connectors etc


Then the task of fitting the turbo water inlet. Since we had to chop the top of the thermostat
housing off which contained the turbo cooling inlet and outlet taps. We have a donor location
from the left side of the engine unfortunately. Worked it all out another trip to the hydraulic
shop and the same assistant lol.


On the way back I drop into a chop shop collect 12 military boxes and 6 special ones. Reveal on
these later and also pickup a diesel filter and housing as this was missing from the engine
when I bought it.


More puppy damage a new scraper destroyed before I even used it.


Then the arduous task of removing the broken sump bolt. Drill it out then try and find the
eaziouts I bought in the morning. Searched for ages could not find. In frustration I climb the
office stairs and then spy a pile of rubbish near the Landrover and investigate yes the eazi
out packaging destroyed along with the plastic case.


Recover the eazi outs and finally have the errant bolt out. Victory finally. Now sump can have
the oil temp sender fitted and fit it back.


Turbo cooling hoses connected. The turbo shielding needs work. Will install this one and build
another fancier one out of alloy in coming weeks as this one has transport damage.




The left side of the engine almost completed change al of the vacccum hoses to new blue silicon
until I ran out more needed. Only 2 pipes need sorting out still. Power teering pump hoses all
connected - mounts to cabin but that may change soon as engine needs to drop out as a complete
unit from the cabin.



Hometime 7.15pm and long horrid drive home ensures in the dark. The brakes stink by the time I
get to the restaurant in KL by 9pm from the heavy braking from 150-170kph constantly.

Next visit we will be changing the wiring loom to split it with a military plug at the cabin
and hopefully filling the engine with oil and starting it. Well it's the goal.
The consoles may also be cut and ready for test fit. The dash's will also be fitted and the air cond parts.
 
#139 · (Edited)
3 April 2016

Quick trip up Sunday morning to Ipoh 190k whizzes past quite fast.

Today's goal is to finish the soundproofing in the cabin and then move on to whatever is left.

First install the last turbo cooling pipe adapter for the 10mm to 8mm tubes.

My helper today is little Jo.

We both tackle the soundproofing until we realise we are out with 1-2 sheets needed. The little cabin has consumed 8 sheets. So we move onto the doors and remove the door handles ready for powdercoating.










Then the puppy decides he wants lots of attention from Joe


Seats are fixed up after we realise a base is not screwed in corretly.

Then the doorhandles are stripped with the wire wheel.


End of the day we have 90% of the soundproofing done.


Suddenly it's hometime.
 
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