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Old 10-24-2016, 09:58 AM   #1 (permalink)
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Volvo 2 - What not another one

Ok so while rebuilding the Volvo I got the idea to restore another and do it faster this time and do the work myself where posible.

Volvo's here for sale are few and far between.

Suddenly we had one for $70,000rm(15,000EU) "restored" looked terrible. Then one popped up for 16,000rm (3,000EU) I rung and got an appointment. To my surprise when I viewed it he had turned down offers for the truck as people only wanted the axles.

I made an offer showed him pics of Volvo 1 and he said SOLD.

So this is the story of a secret build (my wife has no idea) until I finish it.

It will not be a expedition truck but i'm leaving it here as there is no forum suitable on this site for it's eventual style.

Pickup condition

It's ROUGH I know the tourist resort it ran out of and saw it being abused never thinkin I would ever own it.

2 September 2016

Collection Day



Right rear cross member is ripped of the chassis. Left side is bent.


It seats 12 people.


It's nice side


The wheels turn



Looks better in the setting sun in my friends private ship salvage workshop or does it?

Last edited by geckoadventure; 10-24-2016 at 10:43 AM.
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Old 10-24-2016, 10:00 AM   #2 (permalink)
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I would so DD one of those things if you could find them easy and cheap.
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Old 10-24-2016, 10:01 AM   #3 (permalink)
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21 September 2016

First nights work on it remove the ugly front winch mount




Finished looks nicer already


Removed the passenger seat and cleanup up. The rust becomes apparent.


The pile of scrap metal starts to grow. I'm sure they will make a compact Ford out of this soon.
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Old 10-24-2016, 10:02 AM   #4 (permalink)
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16 October September 2016

Two of us attack the rear tray object is total removal of it over the coming days


3 hours later and 38 cutting wheels are consumed but the sides are removed.


The pile of scrap gets bigger


Peter runs around and takes picd of the inside for me.












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Old 10-24-2016, 10:03 AM   #5 (permalink)
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Last edited by geckoadventure; 10-24-2016 at 05:59 PM.
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Old 10-24-2016, 06:00 PM   #6 (permalink)
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23 October 2016

New Makita 7" grinder in hand.

Commence to cut the bed up. A plasma cutter arrives Tuesday

2 hours I got this far.


Then I got a process going and 4 hours I had the left side removed.


The pile of scrap grows



So what is the plan.

Since Volvo 1 is 2 hours away I am planning to work on Volvo 2 at night after work until I finish Volvo 1.

This is the idea so far:
- Bad Arse big offroad tuck like they have never seen in Malaysia
- Rugged shopping trolley to go to expensive malls and jockey park it beside the farking porches ferraris's and Bentley's if you think I'm joking I'm not lol.
- Toss the rear tray steel round tube tray with alloy tray and slightly chopped.
- Full restore of cabin covered in a comp spec rollcage - think Dakar truck - Rahmat from Rahmat playhouse garage is already crying after seeing the pics
- 2 winches probably 8274's
- fix missing section of right rear chassis
- Bob the rear chassis 12inches
- Rear mounted radiator and intercooler etc
- Air suspension and if I can get past road transport a-frame suspension
- 2 sets of doors one with windows chopped off other full doors (handbag days out with wife).
- fit race harness seats and belts
- Engine possibly 15B-T (4.1 litre 4 cyl diesel) and Toyota auto gearbox and that will be it one big fun offroad truck that I may use in comp to show because I CAN lol
- Air suspension kit has been ordered and the air guy came around to look at the truck.
- Rollcage made in IPOH rest done in KL at a workshop near work or home.
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Old 10-25-2016, 11:44 PM   #7 (permalink)
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Sounds like a great plan. I hope you get it done faster than the expedition rig. I've been following your build for ages.
If you're not tired yet of throwing money at Volvo's you might want to check out the disc brake conversions for Volvo portal axles these guys do:
Kurzbesuch in Rumänien – Volvo Scheibenbremsumbau | gelPlog | tigerbus.de
I've heard good things about them, but the price tag is certainly not for the faint hearted.
Hope to see pictures of it at the mall parking lot next to a Porsche Cayenne real soon
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Old 10-26-2016, 12:01 AM   #8 (permalink)
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Originally Posted by ilten View Post
Sounds like a great plan. I hope you get it done faster than the expedition rig. I've been following your build for ages.
If you're not tired yet of throwing money at Volvo's you might want to check out the disc brake conversions for Volvo portal axles these guys do:
Kurzbesuch in Rumänien – Volvo Scheibenbremsumbau | gelPlog | tigerbus.de
I've heard good things about them, but the price tag is certainly not for the faint hearted.
Hope to see pictures of it at the mall parking lot next to a Porsche Cayenne real soon
Local Disc brake conversion is one using Toyota Landcruiser II front discs all roundd and costs us $5000rm (or about $1200USD . Their is somewhere in excss of $40,000rm for us or 10,000USD or more- sigh. Local wins.
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Old 11-07-2016, 04:19 PM   #9 (permalink)
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5 November 2016

One day tomorrow is Volvo 1 day.

Collect the boat from the shop have breakfast and 1pm we are ready to cut with the new Plasma cutter

Finally we get the plasma cutter up and running





3.30pm time for home I got the Sultan's birthday bash to attend

2 more cuts and one half of the rear bed comes off.





Final result from todady is a lot of cutting



2 more cuts and one half of the rear bed comes off.




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Old 11-21-2016, 06:30 AM   #10 (permalink)
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13/14 November 2016

Evening shift. The workshop is only 8k from the office, beats the 190k to IPOH every weekend. No the wife still does not know.

However tonight i've come straight from Ipoh (190k+26k) to the workshop via dinner where I witnessed a stupid motor bike accident across the road from dinner when the motor bike ended under the night market stall afer a car turned right in front of it hilarious stuff.

9pm I'm in the workshop

Awesome 2 cuts and a big chunk of the rear comes off later I find it's a 35kg chunk lol.


Midnite cutoff time and wait the 30 mins to see if any fires etc are starting and look at progress


Yeah it look pretty good


One more night of cutting and I can take it all to the scrap shop.

Still I cannot remove the wheel nuts fom the flat tire. I snap a breaker bar using a 6 foot pipe to assist me. The air rattle gun will not move the nuts either. I need a bigger compressor damn.
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Old 11-21-2016, 03:22 PM   #11 (permalink)
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Quote:
Originally Posted by geckoadventure View Post
13/14 November 2016



Still I cannot remove the wheel nuts fom the flat tire. I snap a breaker bar using a 6 foot pipe to assist me. The air rattle gun will not move the nuts either. I need a bigger compressor damn.



I know this will sound dumb as hell, but did you try spinning them off the other direction?
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Old 11-22-2016, 04:20 PM   #12 (permalink)
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16 November 2016

Night shift dinner with wife then cruise off to work on Volvo 2

This is my goal tonight cut the remainder of the rear tray off.


By 11.30pm it's done




The pile of scrap steel has stopped growing


17 November 2016

Visit the workhop where the rollcage will be created. Oh my my mates Pinzgauer is also there getting its makeover so I eventually leave 8pm afer a 2+ hour visit. My rollcage design gets the thumbs up.

18 Nvember 2016

Friday night I load up almost all the steel (turns out 260kg) into the trusty Isuzu then 10.15pm arrive at hospital to pickup my mates "wife" and take her out for dinner after she got kicked out of ICU 10:05pm so I can get the low down on his bad operation.

So I realise he is going to have trouble running his workshop after so a set of car ramps and a lie on trolley etc are being organised to be delivered to his workshop before he goes back to work in 4 weeks.

Last edited by geckoadventure; 11-22-2016 at 04:21 PM.
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Old 11-26-2016, 02:39 AM   #13 (permalink)
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It will be a great truck when finished,are you keeping the gas engine or planing a diesel conversion?
Cheers,Tuk
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Old 12-01-2016, 09:02 AM   #14 (permalink)
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It will be a great truck when finished,are you keeping the gas engine or planing a diesel conversion?
Cheers,Tuk
Original not keeping. Looking at a Supra 2JZ with Auto and or a Toyota 13B-T diesel modified to hell like my current Red Toyota (14B-T Fuel pump, timing gear, Supra turbo internals (VNT conversion if can find) , front mount intercooler, 21 psi boost) , yes it has grunt lol.
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Old 12-01-2016, 09:03 AM   #15 (permalink)
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1 December 2016

Had some free time tonight so decided to try and remove the flat tire and starrt removing the wiring loom or do the rollcage.

So first task get this flat tyre off finally. Heat 3 minutes one side of the nut and then about 60 seconds on the other whack the breaker bar with the Russian 4lb screw driver a couple of times and hey presto I had a result.


I decided it was late so started on the rollcage template and see how the sketch looks like in full size. I will finish it all off on Saturday so far its looking good.

Last edited by geckoadventure; 12-01-2016 at 03:23 PM.
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Old 12-07-2016, 02:41 PM   #16 (permalink)
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3 December 2016

Had a few hours after the Kids CSR day at work so off to the Volvo with the repaired tire.

Started pulling the wiring loom while the light was good this truck is just full of surprises rodent nest

inside the dash sigh. I'm still expecting a snake to slither out.





The rodent nest


Finally got the tire back on after cleaning up the ends of the studs with a cutting wheel to emove the burrs

etc. Cheeck the other wheels all te same need to be heate removed and then cleaneed up and re-atached sigh

need another 2 butane bottles lol.


4 December 2016 Sunday

Told wife going to help someone on a PINZ lol. Headed over and started on the removal of the wiring loom and

everything from the dash.

By the end of the day I have removed the dash panel and labeled the wire ends.


The brake/clutch pedal braket sigh its been bent by someone over pushing on the brakes HARD and rewelded

what a mess. Need to strip it off repair, remove rust and the ugly chicken shit welding reweld, and

repaint.

Still trying to figure how I will get a 36 year old wiring loom out of the fire wall. I think I will have to

cut it and label every wire sigh.

Worked on the PVC rollcage then time for home as the whole of next week is on Volvo 1
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