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Old 09-08-2017, 05:49 PM   #26 (permalink)
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really great project, hope it comes together for you
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Old 09-09-2017, 07:44 PM   #27 (permalink)
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So Saturday visit to Volvo 2. Clean the truck then see what else can be done. Clean out all the putty from the cabin join and see all the rust in the joint area sigh such a negelected Volvo. I remove the side windows and finally the cabin strip is completed.

Out comes the pressure washer and it just blasts holes in the rust in the cabin. The chassis is fine and all the years of mud get washed off. No other issues with the chassis found apart from the rear cross member issue.




OMG the pressure washer just disintergrated the floor.




So after the wash we decide to see how bad the rsut is and any repairs have been done. We heat the paint and peel off sections to see where the damage is we find a TREE hit with a poor repair above and below the grill resulting in rust underneath which means bith sections need to be replaced. The quality of the old repair work is well shonkey to say the least.

End of the day its hometime all I have is a pile of peeled off bodyfiller and paint on the floor and the tar seal from the inner floor with about 30% left still to stripp out.


From here on its all posative as they can finally start the rust removal surgery.

Went and called in at the other workshop had dinner with the them and they will store the VOlvo chassis in the new paint shop until their workshop relocastion is completed. Anyway we have a plan we can execute.


Oh the workshop kitty relaxing

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Old 09-17-2017, 05:06 PM   #28 (permalink)
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Visit to Volvo 2 cabin workshop

First the cheeky workshop cat.



They have done tonnes of work stripping the paint off with a heat gun looking for holes and repairs etc.


The rear looks ok apart from the rear panel it has a few bad spots.




Then I started on the cabin template from plywood/ Next weekend will finish the front side so we can build the roll cage while the cabin gets surgery.
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Old 09-18-2017, 07:22 AM   #29 (permalink)
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plywood is for templating only right?!
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Old 09-18-2017, 05:38 PM   #30 (permalink)
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plywood is for templating only right?!
Yes im not turning it into a wooden wonder mosquito lol.

Chassis and cabin will be in 2 separate workshops by Saturday provided the new KL workshop completes the concreting and the security fence for theiir relocation..
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Old 09-21-2017, 02:44 PM   #31 (permalink)
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cool project man i can,t imagine the work in these good luck keep going
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Old 10-21-2017, 09:07 PM   #32 (permalink)
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The Cabin and chassis have been separated after some difficulties with pulling the steering wheel off.


The chassis is ready to go to the rollcage workshop.


Saturday morning they have stripped the roof with a heatgun no sign of holrs or rust. Sandblasting is next.


The tow truck eventually arrives and is loaded up.


Then it's dropped in to its new home. It will have a PINZ for a roommate.





Work starts next week on the rollcage after a design discussion.
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Old 11-02-2017, 09:57 PM   #33 (permalink)
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thank you for sharing your adventures with us,,,
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Old 11-13-2017, 04:43 PM   #34 (permalink)
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Saturday 11 November 2017

After working till 2am for the Single day sales I was in no shape to go to IPOH 190k away so 1pm I'm in Volvo 2 workshop some 15 mins from home.

First pics of Volvo 2's stable mates one immacutlately restored PINZ and


the other almost finished its transformation to covered long distance touring wagon.


The puppy is really happy to see me.


We mount the wooden cabin template raised 4" and then I start cutting of the rear bent up cross member. hours later its all made mincemeat with the 7" angle grinder and the little 4" grinder and it's ready for us to get the new one cut.


The truck is ready to go. New engine and gearbox has been ordered from the wreckers lets see if they can deliver a 3.0 ISUZU diesel and auto gearbox from a DMAX.


Front view of the cabin.


The wooden cabin gave us an idea and now the rear will have two parts. One will be old school wooden tray and sizes (for dressage) all removeable and the other will be alloy (for COMP and hooning) .

More progress pics as we progress.
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Old 01-07-2018, 09:04 AM   #35 (permalink)
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No news from the cabin shop they shut up shop for 3 weeks and have not offered progress pics despite being requested to send time for a anger visit.

Chassis the portals have just been removed and are now ready to take to the workshop for Toyota Disc conversion.

The Toyota 2JZ-GTE with 4x4 auto I collected and delivered to the shop not before being pulled over and charged with having an illegal roof rack and transporting an engine/gearbox in a non commercial vehicle and having the pickup loaded up past the tray sides. Unbelieveable.

So the engine and gearbox can commence installation but not before we convert the twin turbo to single turbo. We only have 1/2 inch 1.5cm spare in the cabin due to the width of the 2JZ-GTE.

Pics coming soon.

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Old 01-14-2018, 01:28 AM   #36 (permalink)
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Volvo 2 is in 3 workshops.
Chassis in a shop near my office. Where rollcage and engine will be fitted.
Cabin in another workshop 10k from work - progress reports are not coming in neither are pictures - not happy. I am hearing from other customers from this shop they are really unhappy and just want a decent days woirk from this shop and it not be closed each time they turn up for work review and unasnwered phone calls.
Engine and gearbox and portals are taken to a 3rd shop 30k away where he is a trusted mechanic to do what I need.

Work on Volvo 2 continues. After work I drop round to Volvo 2 workshop since it's 10 mins away from work and on the way home.

Had the 2JZ-GTE engine and gearbox in the Isuzu.

So we jacked up the Volvo onto it's new stands. Started pulling the Vovlo axles off. They do not get the last of off till next day as the broke 2 bars and went through 2 bottles of gas heating up the wheel nuts.

The engine was unloaded using the car hoist. I will collect the portals next week to take to the other workshop to get converted to Totota Discs and all new bearings etc.

We are waiting for the new bending machine to arrive from the good old USA before the rollcage bending can start.

The puppy decided he should help out.







The 2JZ is to be converted to single turbo and a general cleaup to make it a lot slimmer and less chances of hoses splitting etc. Currently it only has 1.5CM to fit inside the cabin tunnel.

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Old 02-16-2018, 07:45 PM   #37 (permalink)
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The engine and gearbox is out now that they have a portable engine hoist in the workshop and is all leveled out on the workshop floor.



9 February 2018
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Old 02-16-2018, 07:46 PM   #38 (permalink)
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Info for all followers:
1. The cabin is in a workshop 13k south of my office
2. The chassis is in a secret workshop (hidden behind a 12 foot high fence) 5k from my office and is on the way home lol. Its a great place to drop in at 7pm on way home from work and see all the PINZGAUERS and my VOlvo in there.
3. The Engine/gearbox/Axle conversion and restoration work etc is all done in a my long time 4x4 Toyota professors workshop 30k north of my home

Got this picture of the Volvo from the Cabin shop after much hounding as the shop was always closed and they did not answer calls etc for progress. They have not made much progress.


I called into the shop earlier that day and got the myanmar worker who speaks little english. I saw little progress.

They rung me and said they wanted another 7 months to finish the cabin. I told them they have 2. What they don't know is if I don't see progress in the next month im going to get it myself and do the work in the secret workshop. I hvae indicated to them I want to see progress I cannot wait.
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Old 02-16-2018, 07:47 PM   #39 (permalink)
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Made this template while in IPOH for the door frames as the cabin shop indicated they having trouble with getting it lined up correctly.



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Old 02-16-2018, 07:47 PM   #40 (permalink)
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Unbelieveable Andrew managed to get a auto tranny workshop on CNY eve to come and join the autogearbox to the engine.


A frame is now being build above the Volvo 2 chassis to hang the engine and gearbox from so they can lower it slowly and correctly into it's correct alignment.

The rollcage bender is arriving from USA in coming weeks but nothing will be done until the cabin is returned. However, the engine and gearbox will be fitted and got running in the meantime.

Meantime same day while I was standing in the secret workshop I got the bad call from the Toyota Professor.

The AXLES are bad. Chipped crown and pinions. Smashed locker mechanisms and one ruined HUB. All can be repaired with MONEY please send lol.

The DISC conversion has been done and is slowly being assembled onto the axles.
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Old 03-17-2018, 05:38 AM   #41 (permalink)
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Big day I'm officially grounded for a 7 days with my heart playing up. Hence no visit to work on Volvo 1. I decided it was Volvo 2 day instead so I got a friendly chauffuer and we trooped out to collect the portals after a hearty breakfast which are now converted to run Toyota discs oh and the bill crikey that also caused more heart issues.

First a replacement portal was obtained for this welded up missing pair of teeth. I also know a machine shop 190k from here which can produce these so I will make trip to them to see their costs etc.


Then the broken locker was replaced this one is only good to recycle into a complete Mazda car.


Then we noticed the twisted axle so thats now being replaced if we can find a part here.


Then we loaded up the newly converted portals and trooped off for lunch with a well earned beer and a pub meal.


Then it was off to the cabin shop and we inspected the cabin - little progress has been made apart from the cabin being split into 2 but it was back together again with 2 bolts holding the cabin together. Progress will accerate this week with 2 other car body's being removed from the shop today. No pics from here since it looks same as last visit. Yes I'm a little frustrated but progress is moving forward.

Then it was off to the Chassis workshop and the portals were put into storage and we discussed the engine/gearbox being dropped onto the chassis. It is expected to be completed this coming Friday along with the water tank for Volvo 1.
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Old 03-17-2018, 09:15 PM   #42 (permalink)
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This thing is perfect
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Old 03-28-2018, 05:27 PM   #43 (permalink)
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How wrong could I be, since my last visit to the cabin workshop they have not answered the phone nor have they been open when I have popped by for a visit.

Others have also been trying to visit their vehicles and also getting the same results.

Needless to say i'm getting rather pissed. it costs quite a bit of loot to go through the road tolls to visit the cabin shop and it turns out its a 1 hour round trip for the 26k to this workshop.

We may have access to borrow a cabin from another workshop so we can get it down to the chassis workshop to get the rollcage built started. Will find out after Sunday when the owner of this spare cabin is back.

Meantime, I am getting the new half shaft delivered and about to order new high ratio crown and pinions. I have a set of new Alloy toyota PCD rims and ordered new tires so we can move the chassis around soon. I have to be able to move it as 25 cars are turning up to this workshop for a movie shoot in the coming weeks and the 10 crash cars.
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Old 04-04-2018, 06:06 PM   #44 (permalink)
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A quick trip down to the cabin shop after work to see if they are in fact working nights like they said - no they are not. This has become a common sight from the other in the group who are watching out for their vehicles being worked on. Some have been here 2 years or more with little progress.



Friday 30 March 2018

I run down to the chassis shop after work and collect Volvo 1's water tank and pay the bill, it looks ace work.

Then the bonus - they have got the engine and gearbox hanging there in position with just the 4x4 lever to remove so it can be positioned properly in the chassis and the new mounting points made up.





We discuss me bringing the cabin from the cabin shop if no progress is made in next 2 weeks so I can work on it.

Meantime the new crown and pinions are being delivered tomorrow for the Toyota professor to install then the axle tubes can be brought back to the chassis shop and re-installed.
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Old 04-04-2018, 06:25 PM   #45 (permalink)
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Went down to the cabin shop and surprise he was open and not one bit of progress has been made on the cabin except they say the cabin cross member is ready for collection from the laster cutting shop - so why have the not collected it - oh we were closed all last week. Crikey!!!!!!!. Another customer was there pulling his kit out he is in our watch this workshop group.

Due to my current health state I have left the cabin there to be worked on with the threat no weekly visible progrss via pictures it comes out, including him not sending pictures as that means no progress. Next update due is this Saturday.

Another member of our watch this workshop group is on the warpath on FB and letting loose with his opinions lol.

This panel restoration shop is putting itself out of business the biggest customer just left with his huge deposit spent by the workshop with no work performed and others are spreading the bad service word. He is the only one who can take court action as our amounts are not considered courtable *^* sigh - Mine is the last paying cutomer left and that is only on a week by week basis.

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Old 04-27-2018, 08:18 PM   #46 (permalink)
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Thursday 26 April 2018

Finally after weeks of trying to get hold of the cabin workshop and several visits to see if they were open along with others dropping in to see if he was open he finally answered a message - he did not ring etc.

I made an appointment for a progress update. Thursday 12.30pm

YES - he is open

I look at progress and realise he has done not one thing since we last inspected the cabin on 17 March. I make a decision - it's coming out. A frantic set of phone calls and i finally got a flatbed tow truck. They offer me the cardboard templates but in the end I saw they were not loaded up into my trusty Isuzu.



I contact the Chassis shop tell them it's coming in soon.

Meantime we load it into the tow truck and the last paying customer leaves the workshop. WIth no workers and all 4 current paying customers gone (still owed their deposits etc) and future customers being wanred off on FB the future looks bleak.


Finally 3.30pm its unloaded at the Chassis shop

A quick walkaround reveals the amount of panel work I have decided to do myself to do once I'm back on my feet. Meantime I can comedown and start identifying all the issues and prepare new templates and draw up the final plan for this monster. In all honesty I do not know when I will be back on my feet I have failed another hospital heart checkup.

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Old 04-28-2018, 05:07 PM   #47 (permalink)
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that's a drag that guy is having a rough time and you got hosed.

good luck.
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Old 04-28-2018, 11:12 PM   #48 (permalink)
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There's no other body shops around that can fix that cab?

Hope you get better and can get this thing done, it's a cool project.
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Old 05-03-2018, 06:58 PM   #49 (permalink)
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There's no other body shops around that can fix that cab?

Hope you get better and can get this thing done, it's a cool project.
There is but I have stopped trusting people I don't know. This shop was recommended by a friend.
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Old 05-03-2018, 06:59 PM   #50 (permalink)
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Saturday 29 April 2018

Visit to the Chassis/Cabin workshop to draw up a detailed chassis plan.

I have been doodling away on the design of Volvo 2 and its looking like this, now I need to get this onto a proper scale drawing.


Crikey it's a struggle just to walk back and forth to the desk to write down the measurements the heart goes nuts.

Once the measurements are taken it's time for a really close inspection of the cabin in the bright light.

There are 31 separate areas on the top half which need attention either a dolly hammer or just welding up holes all of which can be fixed up quite easily just time will be 3-4 days.A couple of area need cutting out and new pieces welded in,, We can get these laser cut before hand and just weld them in.

Then there is the cabin bottom. its a lot worse than I thought we go through marking issues areas. Andrew asks how much for a cabin from Sweden I tell him. He says buy it this will be constant draw up laser cut trial fit/bend then recut and oh more to cut and the wages cost will be huge.

So I contact Tatanka on FB they reply in less than 30 minutes. yes we still have the cabin we will get a shipping cost for you to Malaysia.

Left side of cabin areas marked for repair.


Middle of cabin areas marked for repair.


Right side of cabin areas marked for repair.


Then its time for home once the rain stops and Zing the ever growing puppy will not sit still for a picture


During the week I went for the Heart check but not as I expected I was sitting in the hospital peeing blood when I got the heart check lol. However, the heart is improving and now sits in the 70's which is much better than 150 range and is becoming more rythmical again.It's still got a way to go to get back to the 52 resting range which it was for about 30 years. A change of dosage and the blood stops and i'm released. Lol they call this good news.
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