Volvo 2 - What not another one - WR6973

Volvo TGB and 30X (303/304/306) mods and resto work, news, resources and non-technical stuff
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

Yes I should but the Volvo 1 workshop not done anything since my last visit some 6+ weeks ago. Previous weekend was long weekend so I gave myself a compulsory rest in KL and last weekend was also a public holiday saturday and I had an evening appointment with wifes play performance in KL so not going to IPOh for 1/22 a day. SUnday workshop was not going to be open as he is back racing motocross again.

I also made a huge commitment to the kids home charity kayaking event for the past 8 weeks as being the event organiser I had to ensure training done and everything organised and all logistics done etc. Thats completed and I have until march before the next one is due to be run. Volvo 1 had to take a backseat for this as it was meant oto be finished by 1 August 2017. Thats gone by sigh.

So I took the free time to work on Volvo 2. The workshop is doing most of the work with Cabin repair and the other new KL workshop is doing the rollcage etc and is in process of moviing to a workshop about 20 times larger and is only 6k from home.

Volvo 1 work is currently wiring only left which i'm not good at as im colour blind on red and green. So the workshop wants exclusive work on the wiring only. Leaving me the doors only to complete. THis coming weekend im in IPOH Friday (public holiday again) and SUnday and Saturday to relocate the Volvo 2 chassis to the new workshop lockable paint shop until the workshop opens. Wife is away this weekend also so I need to drive to IPOH and back each day so I can feed the 4 cats. 400k a day gets a bit tiring with Malaysian traffic.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

21 October 2017

The Cabin and chassis have been separated after some difficulties with pulling the steering wheel off.
Image

The chassis is ready to go to the rollcage workshop.
Image

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

The tow truck eventually arrives and is loaded up.
Image

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

Image

Image

Work starts next week on the rollcage after a design discussion.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

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
Image

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

The puppy is really happy to see me.
Image

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.
Image

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.
Image

Front view of the cabin.
Image

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.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

23 November 2017

Work on VOlvo 2 continues. The steel for the rollcage is being ordered.

The engine and gearbox is to be lifted out.

Even better news is I had little choices for engine and gearbox combo's.

I cannot obtain and ISUZU engine and gearbox so went the other extreme since I hate the remaining alternatve of Mitsubishi engine/gearbox or toyota 1KZ/auto.

A 2JZ Toyota Supra VVTI 1/2 cut has been obtained and will be mated to a 4x4 auto gearbox.
Image

Then it's going to a wireman to recover the loom and give me a turnkey engine and gearbox.

A lot of the other parts from the Supra can be used - DASH etc Radiator and all the overflow bottles and the headlights and indicators etc.
User avatar
VinceAtReal4x4s
Admin
United States of America
Posts: 2035
Joined: Mon Apr 12, 2004 10:36 pm
Location: Ca. or lost in South West USA
Contact:

Re: Volvo 2 - What not another one

Post by VinceAtReal4x4s »

That seems like an extreme amount of work to make it operate correctly.

I have to ask... where do you get your energy from? :)
"For those who risk, life has a flavor the protected shall never enjoy"

Your donation makes this site possible!

Image
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

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.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

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.

Image

Image

Image

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.
Image
Heinkeljb
Great Britain
Posts: 391
Joined: Wed Feb 27, 2013 1:09 pm
Location: Lewes,Southern England

Re: Volvo 2 - What not another one

Post by Heinkeljb »

Glutton for punishment aren't you!

Must be difficult to decide which Volvo to deal with first!

John
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

Heinkeljb wrote:Glutton for punishment aren't you!

Must be difficult to decide which Volvo to deal with first!

John

There is a priority list:
Volvo 1
Volvo 2
Boat rebuild
Volvo 3 my friends one).
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

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.

Image
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

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.
Image

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.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

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.

Image

Image
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

15 February 2018

Unbelieveable Andrew managed to get a auto tranny workshop on CNY eve to come and join the autogearbox to the engine.
Image

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.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Volvo 2 - What not another one

Post by geckoadventure »

17 March 2018

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.
Image

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

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

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

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.
User avatar
VinceAtReal4x4s
Admin
United States of America
Posts: 2035
Joined: Mon Apr 12, 2004 10:36 pm
Location: Ca. or lost in South West USA
Contact:

Re: Volvo 2 - What not another one

Post by VinceAtReal4x4s »

You are moving mountains! You need to take it easy though man. Do some fishing and smell some roses... you can't mess with that stuff!
"For those who risk, life has a flavor the protected shall never enjoy"

Your donation makes this site possible!

Image
Post Reply