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Loads of other stuff happened...
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...but I'm only ready to show the first coat of the engine paint
https://www.volvoforums.org.uk/attac...1&d=1523979158 The coverage is kind of OK but it will need at least another two coats before I am happy. This first coat is a bit darker than it will be because the iron is still shining through (!) |
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Axle / Differentials
I'm slowly piecing this together. I (now) think the M27 rear axle came with the following final drive ratios
4.55 4.3 4.1 3.9 According to Skandix => Quote:
The M27 is described in the service manual as "semi floating" so that must mean the Panhard rod attachment needs to be there with the coil springs - I assume this differentiates the M27 from the M23 which I guess is the cart horse leaf sprung version fitted to the Duett. Thing is, I can't find a picture of a M30 to see if the differences between that and the others. |
Bit of data
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Here are some rough calculations of maximum wheel speeds (all theoretical no real world losses included) for a PV544
https://www.volvoforums.org.uk/attac...1&d=1524125794 The overdrive ratio in a M41 makes one heck of a difference - it is a serious step - which I guess is why they are known to cause a B18 engine to struggle somewhat in a PV |
After three coats...
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...the engine is slowly getting to look a bit less patchy.
https://www.volvoforums.org.uk/attac...1&d=1524146204 https://www.volvoforums.org.uk/attac...1&d=1524146204 I'm bound to have missed some bits so when it is dry I will tip it upside down / alarmingly on its side so I can get the sump removed and see if more of the red is needed. |
Had time for a quick little welding job today...
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...before I run out of argon (again)
The lip for the boot seal is a little bit moth eaten on the lower edge https://www.volvoforums.org.uk/attac...1&d=1524146397 Shame really but I have seen pictures of worse (!) Using a bit of 1mm thick Zincor (coating removed before welding remember) it was an easy job just to tack an extra wide piece in place from the "middle side" of the car towards the outer edge bending a bit has I went https://www.volvoforums.org.uk/attac...1&d=1524146397 https://www.volvoforums.org.uk/attac...1&d=1524146397 (Low amps on the TIG welder and the magnetic welding clamp isn't a great combination but it'll do) Tacked => https://www.volvoforums.org.uk/attac...1&d=1524146397 Bit too much splodge but I wanted to make sure I had enough penetration - I don't want it cracking off when something heavy gets loaded into the boot and bumps its way in https://www.volvoforums.org.uk/attac...1&d=1524146397 Splodge ground / B&D powerfiled away https://www.volvoforums.org.uk/attac...1&d=1524146397 Using a bit of masking tape as a guide for where to cut away the excess of the new metal => https://www.volvoforums.org.uk/attac...1&d=1524146397 (The idea behind the extra large bit of metal is threefold 1: The extra metal helps with heat dissipation during welding 2: The extra metal makes it bigger and easier to hold with welding gloves (!) 3: Trimming the extra metal at the end of the welding process means you don't have to bother / worry about exact pieces not quite fitting as well as you cut them because they moved due to shrinkage whilst welding) Cutting with snips (note difference between LH and RH snips!) on the whole gives a nicer edge than a cutting wheel. https://www.volvoforums.org.uk/attac...1&d=1524146397 |
Great thread!..:)
Brings back memories - I had a friend who had one of these and I vividly remember him driving the s%^t out of it. Great cars for the time (and still)! Looking forward to more..:) |
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This Volvo is certainly throwing up a lot less problems than the shed of a Series 2a Land Rover I've also got on the go... ...though some days you do wish you'd never started with some things! Good example was the sump (I was really tempted to buy a new one and be done) https://www.volvoforums.org.uk/attac...1&d=1524322757 ^^^^^^^It was in a very grotty state^^^^^^ I wire brushed and wire brushed and wire brushed... https://www.volvoforums.org.uk/attac...1&d=1524322757 ...and still it wouldn't come clean with out several coats of the more expensive engine cleaner. After more wire brushing (all angle grinder + wire brush attachment - I'd still be doing it now if I'd tried to do it by hand) it seemed like the oil was finally separating from the rust. https://www.volvoforums.org.uk/attac...1&d=1524322757 ^^^^ Stripping disc got rid of most of it Then I treated with a rust killer and finally reached the stage where I can try out that can of VHT barrel paint I bought https://www.volvoforums.org.uk/attac...1&d=1524322757 I'm hoping it will be gucci gucci after all that |
Started to tidy up the holes...
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...that were cut into the under back seat step for the seat belt inertia reels.
This is how the holes looked => https://www.volvoforums.org.uk/attac...1&d=1524328788 (All a bit gash really - As said before I'm not leaving it like that) Starting with a bit of Zincor https://www.volvoforums.org.uk/attac...1&d=1524328788 Bending into a stepped Z form https://www.volvoforums.org.uk/attac...1&d=1524328788 Trimming to size https://www.volvoforums.org.uk/attac...1&d=1524328788 Cutting out bits to make 90 degree bends https://www.volvoforums.org.uk/attac...1&d=1524328788 (Top tip) To help with the bending it is best to cut away a circle at the root of the bends so the sides don't distort / make the bends wander https://www.volvoforums.org.uk/attac...1&d=1524328788 Cutting the holes straight in the body (they are also the same size on both sides of the car now! 10cm wide X 12 cm high) https://www.volvoforums.org.uk/attac...5&d=1524328786 Trial fit => https://www.volvoforums.org.uk/attac...1&d=1524328788 What the boxes look like when done => https://www.volvoforums.org.uk/attac...1&d=1524328788 https://www.volvoforums.org.uk/attac...1&d=1524328788 The inner sides of the boxes have been painted (drying as I type). I plan to use a combination of riv-nuts if the pliers will fit and spot welds to fix these boxes in place. This isn't quite done yet - I also need to make some edge trim pieces (these will be screwed into place with self tapping screws) that will hold the under seat trim piece in place To be continued |
Pv544
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Ta Kassie |
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