Volvo Owners Club Forum

Volvo Owners Club Forum (https://www.volvoforums.org.uk/index.php)
-   PV, 120 (Amazon), 1800 General (https://www.volvoforums.org.uk/forumdisplay.php?f=9)
-   -   1961 Volvo PV544 in Holland (https://www.volvoforums.org.uk/showthread.php?t=277319)

Army Apr 19th, 2019 15:17

Still winging it
 
6 Attachment(s)
Getting there slowly =>

https://www.volvoforums.org.uk/attac...1&d=1555679046

^^^I've decided to fill in the holes for the grill mounting bolts on this left hand wing as they were rather oval and needed extra wide washers to provide some sort of support^^^

The plan is to fit the wings and figure out the position of new holes

Other holes have also been filled and the ropy state of the wing is now approaching "not so ropy as it was"!

https://www.volvoforums.org.uk/attac...1&d=1555679046

The repairs (as I have mentioned a few times before) are OK for the next expected stage of applying body filler and also for my more controversial crappy bare metal look. I've added "character"...

...another form of unwanted character is the pock marked underside of the wing. Loads of tiny little rust craters =>

https://www.volvoforums.org.uk/attac...1&d=1555679046

These little craters are a pain in the backside - very difficult to get the rust out of them. Speedblast (fine blasting sand) doesn't really help as the grains of sand are about the same size as the craters and although there's a fair amount of dust mixed in with the Speedblast which could potentially reach inside the craters those grains don't have the mass to be effective enough to shift the rust (I feel).

If only I had (access to) a three hundred thousand euro water jet media blaster (!)

My DIY solution at the moment for problems like this is to use chemical rust eating stuff - like the Rustyco - then apply Eastwood's rust encapsulator.

https://www.volvoforums.org.uk/attac...1&d=1555679046

This can be applied roughly with a paint brush - no care needed as the next stage will be to sand it back so the encapsulator is in the craters but the upper surface bare metal, ready for the next stage => poxy epoxy

https://www.volvoforums.org.uk/attac...1&d=1555679046

With the warmer weather on the way I hope to get a few bits done before I move house - there's a lull in the house buying progress where my attention isn't needed so I can crack on with the Volvo.

I even moved the position of the cars in the workshop - Volvo up front!

https://www.volvoforums.org.uk/attac...1&d=1555679811

So I'm almost ready for potential progress

Army Apr 21st, 2019 19:49

Got the epoxy coat on the...
 
3 Attachment(s)
...inner part of the front left hand wing today.

A second coat of the Eastwood rust encapsulator was applied yesterday - today I took most of it off!

https://www.volvoforums.org.uk/attac...1&d=1555868736

Most effective way is (of course) to use an angle grinder with a wire brush. Final smoothing was done with sanders

https://www.volvoforums.org.uk/attac...1&d=1555868736

^^^The result is shown above - the lower craters are filled with the encapsulator - the upper surfaces are clean and ready for the epoxy primer^^^

https://www.volvoforums.org.uk/attac...1&d=1555868736

Second coat of epoxy tomorrow (with any luck)

Army Apr 22nd, 2019 15:08

I'm hpoing this will be the last of the engine bay paint
 
2 Attachment(s)
Towards the end of the year in 2018 I was still painting in the uncommonly warm autumn weather but to be honest I was feeling the pressure and ended up making too many mistakes when painting the engine bay.

I decided back then it wasn't good enough and needed to be sanded back again

Painting - spray painting - large flat(ish) surfaces is way way easier than spraying complicated shapes like this bulkhead. This time with the pressure off I think I've come up with an acceptable finish...

https://www.volvoforums.org.uk/attac...1&d=1555938322

...as you can see I've masked a large area of the bulkhead as one third of it was good. The lines where the paint meet might be a bit of a problem but I'm hoping I can sand them smooth after the paint has hardened...

https://www.volvoforums.org.uk/attac...1&d=1555938322

...tomorrow I'm going back to the workshop for a better look once the paint has dried.

Fingers crossed eh? I don't want to be doing that again in a hurry.

Army Apr 25th, 2019 16:18

King pin update
 
3 Attachment(s)
Well it has been a while since I posted about the king pin replacement.

It hasn't gone very well - it hasn't gone well at all.

I've reached the conclusion that the only way to do this job successfully is to have the special tool SVO1171

With out SVO 1171 the chances of success are slim - very slim.

In the spirit of education and owning up I'll show the disaster =>

https://www.volvoforums.org.uk/attac...1&d=1556200719

I bought a 1990s vintage adjustable hand reamer on the bay of ee that will adjust between 18mm and about 20mm (I think). It is an OK bit of kit but isn't of the same quality as a normal fixed size hand reamer.

It did work but as you can see it isn't long enough to go through both of the bushes on the spindle assembly...

https://www.volvoforums.org.uk/attac...1&d=1556200719

...I wasn't hopeful but thought it was worth a try - the adjustable reamer had been bought - so I reamed out the hole to fit the 19mm king pin.

As you can see in the next picture the alignment with the other bush was a world away from where it should be =>

https://www.volvoforums.org.uk/attac...1&d=1556200719

Hashtag **** up!

Oh well ten euro's wasted - newly reamed bush was pressed out and replaced with another new one.

########

So what to do - what to do?

########


I came up with two options

1) Go to a machine shop and ask for help
2) Find the special tool



Option 1:-


Machine reamers are shorter than the hand reamers and they don't have (that much of) a tapered leading edge to help guide the ream through the two holes.

After consulting three machine shops I found someone who was willing to mount the spindle in a dividing head (so it could be flipped accurately through 180 degrees) and then ream the bushes to size from either outer side.

I thought this would probably involve a labour cost of about 60 euros and probably the need to have two more bushes fitted (!) so I decided option two was best



Option 2:-

SVO1171 is as common as rocking horse ****.

I contacted every local Volvo dealership to see if they still had the tool - no dice

I contacted every national classic Volvo specialist to see if they have the tool - no dice

I contacted the VkV club I'm a member of here in Holland and found someone who said they have the tool

?!Success!?

I went to visit the club member today. Really nice chap - very helpful - but it turned out the tools he's got aren't SVO1171 - shame. He's convinced he did the job thirty years ago with the special tool but can no longer find it...

...luckily someone was smiling down on me: He said he felt so bad that I'd come to see him for "no reason" that he was willing to swap my dismantled parts for a whole second hand one that was in good condition.

Like I said - a nice chap.

Whilst I'd rather have had a brand new - made by me assembly - I swallowed my pride and grabbed the offer with both hands!

So the moral of the story is - don't start to replace king pins on a PV with out having SVO1171 - SVO 1171 is in my opinion the best solution for this job - but if you're pushed, a dividing head and several machine reamers ranging from 18 to 19mm might just get the holes suitably aligned for the king pin to fit correctly (but I have a feeling you're going to need a bit of luck for that to work)

If you look at the book - SVO1171 is long enough to go through both holes and that whilst one hole is being reamed it is being guided by the other hole - this is the only way I can see these holes will end up being perfectly aligned (which if you think about it is blinking crucial)

Derek UK Apr 25th, 2019 23:40

Many years ago I visited Nordicar with some Dutch friends. At that time they were offering the kingpin axle unit as an exchange item. It's likely that they still do that. I don't think they did them in house.
VolvoKV (V44) may also do the same scheme through their spares system but I think that is for members only and unless it's changed you have to register the sort of car you have to buy spares for that model only. i.e. A PV owner can't buy Amazon specific spares.

Army Apr 26th, 2019 05:37

Quote:

Originally Posted by Derek UK (Post 2516073)
Many years ago I visited Nordicar with some Dutch friends. At that time they were offering the kingpin axle unit as an exchange item. It's likely that they still do that. I don't think they did them in house.
VolvoKV (V44) may also do the same scheme through their spares system but I think that is for members only and unless it's changed you have to register the sort of car you have to buy spares for that model only. i.e. A PV owner can't buy Amazon specific spares.

Getting a complete replacement assembly isn't a problem (yet). I can get them via the VKV club as I am a paid up member - it is just that I consider buying modular solutions as cheating! I'd rather do the job myself...

...unfortunately in this case the necessity of using a very hard to find special tool makes it very difficult to be as self sufficient as I'd like. I'm going to keep en eye out for SVO1171. Recently there was one for sale in Sweden but I missed the auction.

Army Apr 26th, 2019 15:58

Back with the painting...
 
2 Attachment(s)
...whilst the humidity stays at a reasonable level

The inner side of the front left hand wing has been painted - I think it is best to say the finish is "functional" - not as good as it could have been but as I'm going to be apply a coat of POR-15 hard Urethane anti-chip coating I'm not overly fussed.

https://www.volvoforums.org.uk/attac...1&d=1556286995

Little things like the door hinges have also been painted as well as - drum roll - the glove box door

https://www.volvoforums.org.uk/attac...1&d=1556286995

That has been a right pain to get to a half decent standard (I don't know why it was just one of those bits that always seemed to go wrong!)

adarvasi Apr 26th, 2019 17:19

Great info Army, thank you
Andres

Army Apr 27th, 2019 18:25

4 Attachment(s)
Quote:

Originally Posted by adarvasi (Post 2516221)
Great info Army, thank you
Andres

You're welcome

When you get to the put stuff back on the car stage don't make the mistake I just did - don't expect that the kits of fixings you can buy are easy to understand with out the description of the parts on the seller's website!

I've been scratching my head all afternoon wondering what this kit is for =>

https://www.volvoforums.org.uk/attac...1&d=1556382190

I think it is probably something to do with the front suspension

https://www.volvoforums.org.uk/attac...1&d=1556382190

https://www.volvoforums.org.uk/attac...1&d=1556382190

https://www.volvoforums.org.uk/attac...1&d=1556382190

Tomorrow I'll return with lists of what I bought - and some paper so I can make up a list of what I need...

Army Apr 27th, 2019 18:31

Despite the head scratching...
 
2 Attachment(s)
...I at least got the fuse box fitted

(So mission control is now in place)

https://www.volvoforums.org.uk/attac...1&d=1556382484

^^^I've cut some nylon rod for spacers so the fuse box sits away from the bulkhead - this needs to be done to allow the washer bottle pipe to go through the bulkhead^^^

And here it is in position =>

https://www.volvoforums.org.uk/attac...1&d=1556382484


All times are GMT +1. The time now is 20:16.

Powered by vBulletin
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.