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Old 05-04-2018, 06:35 AM   #51 (permalink)
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wow
my FC-150 cab doesnt look that bad after all

nice work on everything
too bad the body shop dropped ball
but that seams typical with every body shop to try and screw you
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Old 05-05-2018, 06:03 PM   #52 (permalink)
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Damn ISUZU is delayed by 2 days coming back from 200k away in IPOH and is only back on Tuesday with 67HP gain (to 177) and 38% increase in torque from 360nm to about 496nm.

Up call taxi to Nice breakfast. Call taxi to take me to auto store. Buy a dolly hammer set. Then another taxi to boat shop and collect the new HELLA waterproof tail lights for Volvo 2. Then the same taxi back to the workshop. Crikey $170rm in taxi fares gone.

Go to lunch very hungry then back about 1.15 ready for action.

I decide before pictures of the white circles is needed there are 31 of them to repair. I'm given the bangladeshi worker to do the welding and I can do the dolly work.

Left side


Roof top


Right side


Only takes me 10 minutes to knock out 5 dents with the dolly hammer and the curved dolly.






Then I see several dents and issues I missed. They are marked for repair also.

Rapidly we make progress each window has 8 bolt holes to be welded up. The TIG welder makes quick work as I prepare the holes for welding tap and sand etc.

All the smiley faces are repaired ares 2 holes filled or one. We find several pinholes and they are drilled until no more rust and a circle cut out and repaired also.

Then we decide to remove the spare tire carrier off the roof. Man i'm so happy I did its a rust haven. Now I need to get the IPOH shop to do same to Volvo 1.



One hour laster I have it cut out in about 12 sections and wire brushed down. More work is needd to pull out the dent and fill the holes. I have also saved myself cutting a 8" plate and welding it in double bonus.
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Old 05-05-2018, 06:04 PM   #53 (permalink)
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Then it's time to wander around the cabin and view the days work.










At hometime what do we have 31 dents or bolt/rust holes filled and 11 to go. So why could the "professional body shop" take 8 months and not achieve what I did in one afternoon with a dicky heart and working very slowly.


I still have the rear and the front to look at and once I lift the cabin off we know there is rust on the bottom ledge to be cut off and replaced.

Roll on 2 weeks time - they are cutting out the engine mounts and gearbox mounts once they get rid of the

PINZgauer which is taking forever to get the owner to get the last part to put the dash back on and drive it away.

Taxi home and the wife has cooked a meal for us - so nice.

Today we also found another victim of the "professional body shop" who also lost his huge deposit with no work done. I'm so glad the cabin is back in my hands even though I have lost 8 months.

My health is improving the goal of me and Volvo 2 competing in RFC2018 is still in sight.

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Old 05-05-2018, 09:22 PM   #54 (permalink)
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I am a pretty stubborn cus, but you take the prize. How you do not just throw this project in the crusher and go fishing the rest of your life is beyond me. All those rust throughs and gazillion dents would have killed me. And I'm healthy.

Really enjoying your post and seeing the pictures. Make me feel so much better about my projects that piss me off from time to time.

I'll bet your local petrol station owner loves you! And now a taxi! Crap! I'll bet you're the kind of guy that could have survived the Bataan Death March. You just never give up.....
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Old 05-06-2018, 02:50 AM   #55 (permalink)
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I am a pretty stubborn cus, but you take the prize. How you do not just throw this project in the crusher and go fishing the rest of your life is beyond me. All those rust throughs and gazillion dents would have killed me. And I'm healthy.

Really enjoying your post and seeing the pictures. Make me feel so much better about my projects that piss me off from time to time.

I'll bet your local petrol station owner loves you! And now a taxi! Crap! I'll bet you're the kind of guy that could have survived the Bataan Death March. You just never give up.....
They only made 8713 of these vehicles so saving 2 from the boneyard makes me happy and I know another 2 currently being saved here.

http://https://en.wikipedia.org/wiki/Volvo_C303

All the Malaysia 6x6's were destroyed buy being cut in half except for about 5. The axles sold for comp trucks etc.

Only the Police FRU (Riot) squad ones were sold to the public.

400mm of ground clearance is very hard to beat.

I'm pretty stubborn you have to be to paddle 400k trips solo.

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Old 05-06-2018, 10:12 AM   #56 (permalink)
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Old 05-10-2018, 05:29 PM   #57 (permalink)
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Well some good news. The pictures I posted about 2 months ago of the Volvo 2 cabin caught the eye of the Volvo wrecking yard TATANKA.

They contacted me on FB and said we have one bottom RHD cabin in stock do you want it.

We have gone back and forth waiting for a price of shipping.

I recontacted him 10 days ago and said do you srtill have it I really need it.

I now have a shipping price for the cabin bottom and 4 doors from Sweden to Kuala Lumpur

Just waiting for the invoice to send the money which cannot be done till next Monday due to the 3 days of holidays after our dramatic election here.

The good I expect to be here in 4-6 weeks. Now I can just concentrate on the cabin top and the rear panel.

So many thanks from Claes at Tatanka for friending me on FB and the Volvo TGB forum on FB also.

We can quietly restore the bad cabin bottom over the coming months and it may be able to be used in another Volvo restoration you never know whats around the corner (Adams Volvo 3 etc).

When I have a pic of the shipping crate I will post it.

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Old 05-19-2018, 08:37 PM   #58 (permalink)
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ISuzu is returned Friday 11 May from IPOH. Saturday fancy breakfast is ruined by seeing a water leak from the ISUZU. So instead of working on the Volvo I have to head 30k the other way and spend 4 hours in the workshop repairing the cooling split hoses the Turbo shop caused. We had fixed one and reattached everything when we realised there was 2 leaks sign. Take everything off and fix leak no 2.

Hence I missed working on Volvo 2 by the time I finished it was time to head home and get ready for the family dinner outing.

Friday I paid for the Volvo Cabin and doors to come from Sweden - to Malaysia I guess they will arrive in the next 5 weeks.

I Have been told by the heart surgeon to start exercising by walking etc as I'm slowly improving so he has agreed I can work on Volvo 2 (1 I'm still banned from driving that long) but no heavy ligting etc.

Breakfast cheese on toast with tomato and hot cross buns - a rarity in Malaysia


I sleep in today due to an icident with the CATS waking me up to go in and out from 3am onwards and because we are looking after a bitch cat for a week I cannot leave the outside door open - damn.

Hence breakfast is at 12.00pm. Then it's down to Volv0 2 workshop 10 mins away.

I have no news on Volvo 1 progress.

They help me split the cabin, remove the rear panel and leave me the top hanging on the car lift. Then it's all mine andI work my way around identifying more little rust holes to drill out and repair. I cut out sections of the front of which need replacing THey are going to make new pieces and weld up during the week. I am getting my Toyota mechanic to come assist us in reassembling the Volvo axles on the chassis so we can move the Volvo around the shop.

I wear a wire brush out cleaning the paint off. However, The damage caused by the "expert restoration" shop using a scrapper and a heat gun is immense deep gouges everywhere in the steel sigh.

Splitting the cabin was an engineering feat lol using the car lift.


The rear of the cabin needs a little work before its ready to paint.


The front not as bad as I thought only 2 areas cut out.


The rear panel I will tackle next trip it has about 4 areas needing cutting and replacing.


6pm my 5 hours are up. I left the shop with over 30 new areas to TIG weld up by next Saturday.

Time for cranberry juice and a meal at the pub since I can no longer drink beer.
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Old 05-20-2018, 06:22 PM   #59 (permalink)
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good to see you're up and about.
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Old 05-21-2018, 01:30 PM   #60 (permalink)
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gecko adventure,

Glad to see your are getting back on your feet. I watched your Volvo 1 build and began to worry when the updates stopped but I see now that you have been sneaking in work on Volvo 2 in the background. It's good to hear your doing better even though it is slow. One step at a time.

I have a question:
Why did you choose the seats for your Volvo 1 rebuild and what is the model number of those seats.

Keep up the good work and keep getting better!

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Old 05-22-2018, 12:03 PM   #61 (permalink)
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gecko adventure,

Glad to see your are getting back on your feet. I watched your Volvo 1 build and began to worry when the updates stopped but I see now that you have been sneaking in work on Volvo 2 in the background. It's good to hear your doing better even though it is slow. One step at a time.

I have a question:
Why did you choose the seats for your Volvo 1 rebuild and what is the model number of those seats.

Keep up the good work and keep getting better!

ballencd
The seats were chosen for Volvo 1 because it had RECARO 25 year anniversay seats installed in it when I purchased it. The seat base was too high and being 6'2" my head was very close to the roof - too close. So I hunted down locally made SCCUS seats which sit a lot lower, which I also have in my hoon truck but they cause me to sweat a lot so I revovered them in cloth for Volvo 1.

Volvo 2 will probably have pure race seats or Mazda RX8 seats if I can find them they are getting very hard and expensive to find at chop shops.

I'm slowly getting better heart beats more regular now but is still way higher than it used to be.

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Old 05-26-2018, 06:47 PM   #62 (permalink)
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Since I'm still banned from driving long distance I'm only working on Volvo 2. Volvo 1 has made no progress since the last set of pics I posted for it.

The cabin bottom for Volvo 2 is all paid up and leaves Gotenburg on 30 May and is due about 4 weeks later in Malaysia.

Early start at Volvo 2 workshop. First job finish cutting of the engine mount and make the 2 vaccum brackets welds I had cutof the chassis look like they had never been there no marks nothing to be seen by the vehicle inspectors.

3 hours later 2 of the 3 weld cleaning operations are done then I have to make way for the Volvo axle asssembler to start weaving his magic one of my friends offers to help him while I go play with the cabin top.

Allen turned up to work on his Pinz so he can take it off to get the air conditioning installed.

Meantime I have a little fun while doing the cabin. Idiot driver


and idiot passenger


Then a saw Andrew with a mini horse I asked him who's horse is that he said mine. This Doberman was huge he came up to almost my belt loop and is one imposing dog/horse. He has a great personality and lets you know he needs to be patted with one swipe of his head lol. He is constantly on guard never stops watching people.


Then Allen got his Pinz started and even with wiring still to complete a quick road test it was ready to be taken down to the AiR COnd shop next week. He has beaten me in the race between his Pinz and Volvo 1.


After 3 hours I finally have a lot of progress on the 4 dents/awful creases on the roof and it's starting to look factory again.


By 6;20pm and packup time it's really improved I still have one crease line to remove and then just concentrate on removing all the dents and finish putting the proper curve into the roofline. Next weekends work.


The Volvo portal assembly area we ended up not completing as we could not find the 2 locker cogs they have gone missing sigh.


The cleaned up vaccum brackets on the chassis.


Roll on next Saturday.

Last edited by geckoadventure; 05-27-2018 at 05:15 AM.
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Old 05-29-2018, 10:24 AM   #63 (permalink)
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Public holiday so I worked in the morning and then head off to the workshop 10 minutes away.

Allen was there working on his Pinz. Only one thing to do tap the roof dents more. Then it was lunchtime at restaurant "Silly Billys" how apt.After lunch they started welding up the holes in the cabin but the welds were not sticking on the back panel due to the rust content. So we marked the strip covered by the channel and I cut it out. We are going to weld a new complete rear panel on after I clean the rust up with PYE.

Then it was back to the roof tapping until 5.30pm its starting to look ok 3-4 more hours and the roof might be finished and shaped and smooth.

We discussed how to fix the rear panel I might have to make pieces by hand to weld in.

The rear panel after I perform the surgeons cut.


The roof damage is slowly being pushed back to the factory standard.


Jim your next challenge is to remove all the rust from the bolt on rear panel by 30 JUne else it will rust away. This tape will self desctruct in 5 seconds lol.


More rear bolt on panel damage.


Good news is the Cabin bottom is being loaded onto the boat tomorrow.
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Old 06-02-2018, 08:29 PM   #64 (permalink)
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The cabin is on the way from Sweden to Malaysia roughly 4 weeks before it arrives in Kuala Lumpur.



It looks pretty good
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Old 06-02-2018, 08:31 PM   #65 (permalink)
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I have been given during the week 3 months freedom to drive and travel etc then if my heart does not improve I'm under the knife if the heart does not return to normal rythmical level i'm having an operation of some sort. I had a long chat with the Cardio and he believes firmly that the cause of my heart issues is my extreme cycling adventures over the years.

Volvo 1 had 2 days work done on it this week also and it's alnost ready to start.

Cabin day, first I go out and hunt down a brandnew engine oil cooler and fan it's put in the storage box in the workshop. The ATF cooler I collect during the week.

I tap away on the cabin for over 2 hours and it's pretty straight now by the bit I have tapped out is out 1mm more than I need for it to be flush all the way along. The right side is flush. I will try and fix it next weekend some more with a small amount of heat.


The right side I have fixed the old wound which also got welded by previous offenders and is difficult to tap out. The rest can be body filled.


After a hour sleep due to the heart saying enough and giving me cronic fatigue in the opressive heat I'm refreshed and ready to go.

Then I tip the cabin over and applied the PYE rust converted 2 layers into the cut made last week and cleanup all the welds by flapper wheeling them flush.


Every other old rust scars are PYE treated the same to prevent the rust coming back. I'm told the new rear panels will be here next week to weld on.
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Old 06-13-2018, 08:46 AM   #66 (permalink)
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I have help today little Joe from the kids home wants to spend the day with Grandpa and he is good help. His job wire brush the rest of the roof for me while I tap more of the big roof dent then start on the rear panel repairs.

Mark then cut and make a new piece


Wire brush


Weld in and wait and repeat the exercise 8 times more. 4 done 4 to go.


A corner piece is really quite trickey to do so it needs a second go.
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Old 07-17-2018, 04:35 PM   #67 (permalink)
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14 July 2018

LIfe been busy 5 days with the orphanage kids on a kayaking training camp then working last 3 weekends and next 2 sigh.

However meantime the freight company contacts me 12th July the Container arrives and delivery will be around 17th July.

The 13th 2pm I get a OCS message with pics on it the Cabin bottom has been delivered to the workshop. Wow less than 24 hours in dock and it's delivered.

I pop over after work and spend 90 minutes pulling the crate apart. The cabin looks immaculate.















Then Saturday I popped in and we move the cabin to the newly built Volvo 2 bay in the workshop


Any illussions on whether I should have bought the cabin are squashed by this pic.


Will be 3 weeks before I can do anything to Volvo 2.
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Old 07-21-2018, 08:02 PM   #68 (permalink)
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Working today so morning rush out have nice breakfast then and do shopping errands. Collect the new race seats for the Volvo and deliver them before heading to the office but not after going to the Garmin shop to sort out the continuing insane issues with the crap product the GArmin 585 GPS and its associated software. Then its 12.00am in the office and again at 4am to 8am sigh,

Andrew has been busy measuring up the rear panel to get the template ready to have it laser cut.





After working the last 3 weekends I'm worn out.

It's going to be 3 weeks before I can work on the VOlvo unless I finish the deadline Tuesday So I can have Saturday on the Volvo before I work the night shift sigh.
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Old 07-28-2018, 02:06 PM   #69 (permalink)
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That was good luck finding that other lower cab half that was in such good shape. It looks like you'd have hundreds of hours into fixing the other one.
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Old 08-04-2018, 06:00 PM   #70 (permalink)
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Worked the last 4 weekends I have no idea which day it is. But quitely in the background Andrew has been weaving his magic on Volvo 2.

Since the front panel was 2 piece Andrew replicated it exactly - no I'm not replacing the orignal 1.2mm with a single 2mm front plate. Side view of the two plates joined.


Side view of the two plates joined.


Old front panel was removed from the top panel.


Now it's ready to be welded in.
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Old 08-13-2018, 06:29 AM   #71 (permalink)
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Wife went to screen printing class I went to work on Volvo 2. Axle assembley day.

Too us 4 hours but eventually we got he axles assembled. Now I have to go buy 24 new diff lock nuts and replace every diff nut one at a time. Then every portal bolt - 8 per wheel as some of them are shwoing signs of stretching and wear from the portal bolts not being kept tight or locktighted by the previous abusers used on them they have worked their way loose and are now useless.

Landcruiser II Discs and callipers adorn the portals and all new bearings all round.

Front axle


Rear axle.


Oh I also bought Volvo 3 now affectionately know as Volvo 4. Went half's with my buddy the boat builder. Delivery is Wednesday.
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Old 08-13-2018, 06:56 AM   #72 (permalink)
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Oh I also bought Volvo 3 now affectionately know as Volvo 4. Went half's with my buddy the boat builder. Delivery is Wednesday.
What does one of those axles weigh?

Will there be build thread for Volvo 4?

BTW, looking at your captions, I assume Volvo's steer like forklifts?
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Old 08-13-2018, 08:44 AM   #73 (permalink)
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What does one of those axles weigh?

Will there be build thread for Volvo 4?

BTW, looking at your captions, I assume Volvo's steer like forklifts?
Front axle about 319kg or 700pounds rear is about 10kg lighter.

I'm sacking the editor I got it wrong way round.

Yes there will be a build thread as we are putting a Range Rover V8 in it sigh.
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Old 09-03-2018, 05:23 PM   #74 (permalink)
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Long weekend and I gave myself 3 days complete rest after the long hours at work then the kids home kayaking trip I decided rest was needed.

Went and visted Volvo 2 and 4 while they welded up the mighty Isuzu's exhaust.

They have completed installing the Axles under the chassis and it's standing back on its sneakers.


The cabin front panel is welded in and looks completely factory. Only the "A" piller repair remains/


The engine mounts look like they are getting closer to being completed.
Volvo 4 looks bad in places but definately not as bad as VOlvo 2 was.
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Old 10-08-2018, 03:10 PM   #75 (permalink)
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After collecting new winch cables for Volvo1 and the new fridge from the shop it was time for lunch then work on Volvo 2 for the afternoon.

Work is held up on Volvo 2 engine mounts due to the unexpected Pinzgauer engine rebuild going on on the restored Pinz. 2 people took the engine apart and then got removed from the workshop so the poor workshop owner is trying to put it all together after balncing the pistons and conrods. This truck needs to be finished to give Volvo 1 a bay when it's transported from IPOH to Kuala Lumpur in the coming weeks.

Meantime we decided to work on the new doors and sanded them down ready for primer and tapped all the dents out from the transporting from Sweden to Malaysia.

All was ok until breakfast decided to upset my stomach sigh.


The engine mounts look like they are getting closer to being completed however then the other PINZ decided to spit all its oil out the dipstick on startup in the afternoon. Oops another rebuild needed more delays to Volvo 2.
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