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Discussion Starter #21
12 June 201

Great news the panel shop rung me requesting permission to replace interior panels in Volvo 2 they have commenced work on it.

I will get pics when I can. Maybe this saturday.
 

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Nice that you can work on this one closer to home. I can't imagine all the travel hours wrapped up in your other one
 

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Discussion Starter #23 (Edited)
One day im going to go through my diary and work out how many hours I spent driving. We know iv'e done about 65,000k's driving up and down to IPH and back. That does not include the HILUX (one trip that was bad these things have no power), My red 13/14B-T hybrid jungle monster which you cannot hear the stereo from above 80kph lol and the Blue handbag 1KZ Landcruiser.

Yes the cost has been huge 65,000k at 10k a litre is 6500 litres alone so at $2rm a litre thats 13,000rm or 4,000USD, cheap hotel bills etc also huge cost. 100trips on the highway is $46 per trip. $4600 or $1,000USD. Ooops im going to stop counting money sigh.

However progress on Volvo 2 has slowed a little. The panel shop stopped work for RAYA and took 2 weeks off however now during the tail end of his holiday way up north his wife dropped the baby and it's now in ICU so the Volvo 2 sits there in an unknown state with poor Rahmat not earning any loot while he waits for nature and the doctors to get his new baby out of ICU.

Never mind it will all work out. I still hope to have it completed around XMAS time.

Even better the new workshop it will be getting the Rollcage etc is moving to a new location which even has its own painting booth so I can do everything in the one place.
 

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Discussion Starter #25
7 September 2017

They asked me to go down visit Volvo 2 as they had made progress and cabin not long from being separated from chassis.

Took them lunch also. THis is the first view I got neat Rhamat and crew working on it.


Bracing on the inside some work had been done on the front sides to pull the panels out to make them all flush again.


The rear view nothing to see here.


Inside view then the cheeky workshop cat decided I had food and started to investigate next time I will take him food. YUp the floor is rotten and are some of the interior panels.


Rahmat starts dreaming when its all finished I can go for a ride in it - maybe - lol






Yup its uite messy inside


Drivers floor is non existant. I have given them a plan to follow to make it easy to restore.


I like it.


Now the plan.

Next week late the cabin comes off. I take the chasssis to the workshop and we start work on the rollcage and the new rear tray. Will make a decision in the engine and gearbox. Once all done then the suspension and be done and by that time the cabin should be ready to be reinstalled (XMAS) just like a real car manufacturing production line lol.
 

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Discussion Starter #27 (Edited)
9 September 2017

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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Discussion Starter #28
16 September 2017

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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Discussion Starter #30
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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Discussion Starter #32
21 October 2017

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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Discussion Starter #34
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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Discussion Starter #35 (Edited)
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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Discussion Starter #36 (Edited)
2 January 2018

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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Discussion Starter #37
2 February 2018

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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Discussion Starter #38
9 February 2018

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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Discussion Starter #39
11 February 2018

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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Discussion Starter #40
15 February 2018

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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