Intro from Malaysia - WR7002 - C304

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: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Saturday 31 March 2018

I'm back on deck after 2 weeks of complete rest. Lets see how I go.

Up early eventually leave the house 5.25am - what the heck the highway is crowded and it's pouring down. It's impossible to even stay on 120kph the idiots are all over the road.

Eventually after 100k the rain stops but the idiots down't and I eventually arrive IPOH 190k away at 7.30am for a nice breakfast and a rest before the workshop opens 8.30am,

Wife informs me it's Chinese ancentor Grave Clearing next 2 weekends evryone is coming back to clear the elders graves.

The 8.30am meeting shows they hAave been busy. The rear of the cabin is all soundproofed and 2 layers of insulation added. Its all bolted down and looks really ace. The batteries have had an inspection hatch cut into the floor

My job today is parts collection first while Ranjit does the making of the air intake, starts to mount mudflaps and also bend the leading edge of the service hatch covers deg to make them nice. My job is to mount the panels and the watertank and paint the new battery box hatch and the parts run and work on the clutch.

Afternoon for something different we mount the wheel studs on the tire carriers and then a test load and unload one of the studs on each carrier spins - DAMN we now have to remove and find bolts and weld them in. Damn more wasted time.
Image

The rear panel and roof look really ace.
Image

The new 80 litre Stainless steel water tank is washed and prepared ready to mount tomorrow and test fitted
Image

I have the clutch starting to work it no longer leaks and pressure is building in the clutch line.
Last edited by geckoadventure on Sun Nov 11, 2018 5:02 am, edited 1 time in total.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Sunday 31 March 2018

8am start. I do the Sump 2.5 hours later the sump is bolted in after complete preparation of the sump and the engine block.
Image

The air intake is completed and the connecting pipes made up.
Image

By early evening we have the water tank mounted and 3 panels bolted in and sealed
Image

One mudflap mounted with more to do to stop early wear etc
Image

Ranjit has bent the leading edges of the service hatches inwards 45deg to make it look tidy.
Image

The water tank looks ok
Image

The air intake is completed on the left or the birds nest as it's been named after the tiny finches who made a home in a fluro light in the workshop.
Image

home time 6.30pm. Little did I know it was going to take me 5 hours to get home.

Next morning is the hospital checkup - I fail I'm grounded indefinately until the heart recovers. The workshop has agreed to finish the Volvo to registration passing and also to transport it to KL.
Heinkeljb
Great Britain
Posts: 391
Joined: Wed Feb 27, 2013 1:09 pm
Location: Lewes,Southern England

Re: Intro from Malaysia - WR7002 - C304

Post by Heinkeljb »

What a bad bit of luck for you, when it is so close to being finished. Get better soon, so you can at least drive it once it is finished. This is probably the longest thread with the most views I have come across on the formus.
Just goes to show, do something that interests others and put it on line!

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

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Heinkeljb wrote: Thu Apr 05, 2018 1:43 am What a bad bit of luck for you, when it is so close to being finished. Get better soon, so you can at least drive it once it is finished. This is probably the longest thread with the most views I have come across on the formus.
Just goes to show, do something that interests others and put it on line!

John

I'm lucky to still be here and also lucky the new guy "Ranjit" in the workshop is very very talented and is doing a great job of the finishing Volvo 1 if only I could put him on Volvo 2. It's in good hands while I wait for the healing to continue.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Volvo 1 is coming home to Kuala Lumpur will be sometime after 1st September as I am away the next 2 weekends with the kids kayaking adventure. So Volvo 1/2/4 will all be in the same workshop. and I will finish 1 first then 2 and then 4.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Tuesday 28 August 2018

Got 3 pictures sent to me.

The wiper arms and brackets are finally installed

Image

Image

And the dash is starting to look completed
Image

What's left before it's sent the 190k to Kuala Lumpur on the flatbed:
Bleed clutch again
Brakes redo the rear piping
Fill/check all oil levels in everything
Finish air conditioning (KL job)
Wiring is almost finished so internal panels can be installed
Windows installed
Wiper arms/blades
Install doors.

They say 1-2 weeks before is ready to come home finally.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Thursday 20 August 2018

Got a set of pictures sent to me of progress.

Headlights back in.
Image

It's up on the hoist so they are working on it.
Image

Work on the wiring continues.
Image

Image

Image

The maze of wiring looks not so much of a maze and now looks connected up.
Image

The interior lights etc and batteries are connected.
Image

The dash panel is now almost completed and the water temp etc all connected and working.
Image

Tacho and Speedo connected and warning lights etc connected.
Image

Progress is being made. Today the wiper arms etc are supposed to be connected I guess then the windows can be installed.

I hope to collect it on 29 September and bring it to KL.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Saturday 29 September 2018

Quick trip to IPOH 190k away to drop the kids home kayak trailer in for surgery after someone got the gap between the racks wrong and also fit 4 wheel disc brakes to it.

So what's been done to the Volvo quite a lot:
-Window washer 15litre made and ready to fit sits where the radiator used to go.
-Fuel pump wiring relaid to avoid andthing trouching them.
-Both forward winch cables are not enclosed in a tube for most of the underneath to stop any cable drag and protect all engine underneath delicate areas.
-All wiring is completed and we tested everything yesterday
-New fanbelt tensioner made and fitted
-Compressors etc work.
-Engine starts and runs nicely but very noisy I will assume that will change once its outside and all covers are on.
-Fan being installed to haul air over the turbo when its idling to stop radiant heat
-All the cabin panels are installed
-Window wipers work
-Rear camera up and running
-lockers work etc

What's left to do before it returns to Kuala Lumpur:
-CLutch test
-Brakes test
-PTO to be made running with new vaccum switches
-WARN winch to be tested
-Cable for Factory PTO to fitted
-Bolt down the dash
-Prime the aircond
-Check the radiator cycles properly
-Fit the rear internal lights
-Install the turbo fan
-Test the odometer
-Test the tacho
-Install the seats
-Fit the doors
-Fit the front windows
-Fit the rear seats

Whats to do when its back in Kuala Lumpur:
-Inspection and re-Registration
-Get interior panels made up for the centre console
-Fix 18500lb winch
-Road test
-Repaint to the new colour since the current colour holds oil stains/dirt etc.
-Get it ready for it's income making role.

They think it will be finished 5 Oct 2018 but we may leave it there for another week of testing.

Side views not much to see
Image

The 2 colour interior lights work
Image

Slowly its getting complete - right view
Image

Front view
Image

It's so close its quite exciting.

[MEDIA=youtube]6cjkZtuBvvY[/MEDIA]

[youtube]6cjkZtuBvvY[/youtube]
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Friday 5 October 2018

Late night pics I guess they were working on the lights.

Next weeks work:
-CLutch test
-Brakes test
-Install the seats
-Fit the doors
-Prime the aircond

What's left to do before it returns to Kuala Lumpur:
-PTO to be made running with new vaccum switches
-WARN winch to be tested
-Check the radiator cycles properly
-Install the turbo cooling fan
-Test the odometer
-Test the tacho
-Fit the front windows
-Fit the rear seats

Whats to do when its back in Kuala Lumpur:
-Cable for Factory PTO to be fitted
-Cable for Warn Winch to be fitted
-Inspection and re-Registration
-Get interior panels made up for the centre console
-Fix 18500lb winch
-Road test
-Repaint to the new colour since the current colour holds oil stains/dirt etc.
-Get it ready for it's income making role.

Lights all done.
Image

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

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Friday 9 October 2018

A fleeting visit to have a discussion on progress and what's left to do before I take it home. Home date is agreed now 17th October 2018. The Tow truck is booked and confirmed.

It rained the whole 190k up to Ipoh and the whole way back to KL. The drive back listening to Sting, Pink Floyd and Fleetwood Mac made the drive easier.

So progress since my last visit such a long time ago. They have finished the mods to the Orphanage's Kayak Trailer it's also ready to come home next week also.

A lot of little fixes and mods have been done, Fuel pressure issue has been resolved and the fuel filter moved to give more room for access. Air Tank moved also for more access to the engine bay.

The tube made and fitted under the chassis to allow the winch cable to not catch on anything is made and installed.
Image

The rear side view and the new quick release tow bar for the kayak trailer all fitted
Image

Brett smiling as he tells me it can go next weekend and holding the remote for the interior coloured lights. The rear tire carriers have also had the studs welded on now and not pressed in.
Image

The front view and yes the doors are on for the first time in 7 years. Only the top halves to be fitted now.
Image

Grills fitted on top of the rollcage to protect the radiator and air conditioning.
Image

Everything almost fitted in the interior one seat and the gearbox cover to go. Leaving only the covering of the tunnel to be done and some minor painting of black around the window.
Image

Image

I hear I'm going to have a big issue at road transport inspection as I have changed the interior layout and also lined the cabin sigh! We will find out on the day.
Image

The interior looks pretty good. The steering column cover is still to be found else they will have to fabricate an alloy one.
Image

I can see all the instruments from my seating position.
Image

The console looks good. Everything works except the 18500lb winch and the 2 air cond switches need to be fitted.
Image

Right side view. The issue with the bottom of the poor gap at the bottom of the drivers door to be fixed in KL.
Image

The lights in the rear 2 colours and the new black handles for climbing into the rear.
Image

Green lights
Image

Still one side panel to fit and the tree deflector is fitted to the top of the rear cabin.
Image

View as the CIA satellite will see it lol.
Image

View as the monkeys in trees will see it in Malaysia.
Image

Yes it drives. Clutch pedal had the pivot point changed to make it work. Apparently it's a very heavy clutch, I will need to install the Toyota spring assist kit to fix this. They drove it out in the workshop but there is no brakes they ned to replace the vaccum pump as it's leaking and the air conditioning the shop needs a "new" fitting to prime the air cond.

So 8 days and it's home couldn't be happier. We have a small water leak to deal with at the water pump. Then I try and get inspection done the following week since everything that's needed to work for inspection works.

Still to do before next Saturday mooring. Steering Column cover. Fit floor. Fit PTO winch vaccum switches and panel. fit the door tops. fit the front window and the window wipers and washers. Fit door handles.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

Saturday 27 October 2018

5.55AM my chauffer arrives and I give him the keys to the 80 Series Landcruiser I'm borrowing/buying while

my Isuzu is in the workshop for new master cylinder for the past 2 weeks. The aircond dies lol its a hot

trip up.

Biggest day in the life of the Volvo it's coming home the tow truck is due to arrive in IPOH 9am, The 190k

cruises past as my chauffer wheels his way north.

I say hello and goodbye to the all restaurant staff whom I've eaten breakfast at for the past 2.5 years.


Inspection time Brett and myself inspect whats done whats good and whats left to do.
Image

Bolted all up for the first time its starting to take shape with only the transmission tunnel and the

repaint the obvious stuff to complete.
Image

Pensive as I look it all over will it make the 24th November deadline.
Image

The roof console and the reverse camera.
Image

The harness seatbelts remain to be bolted in and the engine cover is finally bolted down.
Image

The fuel pump and furl tank filler area is cleaner with the fuel filter and compressor tankl moved tight to

the cabin. The fuel feed issue fixed with the minor leak repaired.
Image

Planning the next vehicle? Or discussing RFC next event they are both going to attend.
Image

Number plates now attached and the Kayak trailer tow bar is fitted. The rear panels all bolted in we found a

water leak at the end of the journey.
Image

Spare tires all mounted we need to mount a anti vibration rack later and a wheel mounting slide/guide pin.
Image

The newly powdercoated grill and the tool kit is now bolted down behind the drill. The new front windows

were only fitted Friday afternoon.
Image

The moment for it to be squeezed onto the flatbed it fitted by inches.
Image

The journey home uneventful apart from the tow truck struggling up every hill.

Pic of it in it's new home tonight. I took it for a drive before parking it in its new bay while we finish

it. Very night drives quite well apart from the shuddering steering which we think we know whats causing

this.


20181027_WA0028.tour.mp4

20181027_WA0029.tow.mp4

The Volvo starts it's slow journey home the tow truck can barely pull it.
Image

It cruises past the next door powdercoating factory who have done a great job of the tasks we have given

them.
Image

Saying goodbye to Mr Brown was a little harder he didn't want to say goodbye and kept mucking around.
Image
Last edited by geckoadventure on Wed Oct 31, 2018 7:27 pm, edited 1 time in total.
geckoadventure
New Zealand
Posts: 481
Joined: Sat Aug 21, 2010 8:48 pm
Location: Malaysia
Contact:

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

28 October 2018

They took pics on Friday night. It looks pretty cool with it's green and red lights.

Underneath from the rear
Image

Roof and grill. Still need to make a air scoop for the radiator.
Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

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

Re: Intro from Malaysia - WR7002 - C304

Post by Heinkeljb »

Looking good - now just the snagging to do and outfit the rear.

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

Re: Intro from Malaysia - WR7002 - C304

Post by geckoadventure »

10 November 2018

Trying to work on the Volvo at the workshop. We finally got a cleaup run at the raditor testing and flushing last weekend. 1 hour idling away watching the temp run up and down and the fan cutting in etc. Did about 5k in High Range and then low range then it got permanently stuck in LOW) and tested the radiator at high revs low speed etc. All worked fine. Now have to pull the leaking waterpump sigh. Installed the second window wiper arm so finally it has 2 complete window wipers next is window washers. Tested the wipers in the usual afternoon rain.

The front wheels shaking with the power steering is still not solved. We have aligned some parts better and then discovered water in the fluid. We are now removing the power steering hoses etc to flush it all out and try again. This and a return brake pedal spring are needed then it can go for inspection.

Hunting down parts is totally frustrating in KL's horrific traffic everything is so far apart lost 4 hours yesterday chasing parts all over town. Left the 24 bolts for the rear seats sitting in the bolt shop and it was too late to go back when I realised. Still trying to find a upholstery shop (Kussen shop here) locally to get the gearlever cover made and get them to come and try and cover the tunnel.

Still have the lack of power issue to sort out the turbo cuts in then you can feel the power drop away. A boost gauge needs to be fitted to see what happens.

The gecko footprints are to be continued down and along onto the battery box and along the fuel tank with 2 new panels to be cut and bent up in the coming weeks. I have a air intake shroud to make also to force air into the radiator.

Progress is slow and frustrating.

When I compare Volvo 1 and VOlvo 4 one realises how far Volvo 1 has progressed.
Image

It looks good just needs a coat of paint.
Image

We went for coffee and went in the UBER Pinz. Very nice very smooth very noisy lol just like a Volvo.
Image

The previous harness seat belts plastic covers broke in our humidity and so bought a new set but the thread on the eye bolts down not match damn IMPERIAL vs METRIC. ANother visit to the bolt shop is needed.
Image

Finally 2 wipers are on the Volvo. Window washers to go.
Image

After going home early due to a very unhappy stomach the big 8kg cat decides to sit on my chest and asks how was my day. Crappy I say.
Image
Post Reply