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-   -   1961 Volvo PV544 in Holland (https://www.volvoforums.org.uk/showthread.php?t=277319)

Derek UK Sep 10th, 2018 12:31

Stop messing about and put your best efforts into getting the best finish in 72 that you can. It's quite a rare colour and will always stand out in a crowd. I like it. :regular_smile:

norustplease Sep 10th, 2018 15:23

I agree, all that effort and work, then to end up with a battered looking bare metal finish with a quick spray of clear lacquer. Very disappointing.

Army Sep 10th, 2018 16:27

Quote:

Originally Posted by Derek UK (Post 2446392)
Stop messing about...

Is that you mum?

Quote:

Originally Posted by Derek UK (Post 2446392)
...put your best efforts into getting the best finish in 72 that you can. It's quite a rare colour and will always stand out in a crowd. I like it. :regular_smile:

Quote:

Originally Posted by norustplease (Post 2446444)
I agree, all that effort and work, then to end up with a battered looking bare metal finish with a quick spray of clear lacquer. Very disappointing.

I appreciate your opinions but I don't think you understand how nice this PV could look in bare metal.

First I think it is best to point out that going for a bare metal look (or the way I'm doing this) is not an easy way out. Any time saved in sanding filler is more than lost by the number of times I've been masking areas (!)

I realise that I might not like the end product and have to roll my sleeves back up and get busy with original 72 colour. For this reason I'm painting the inside and the parts of the underside in that colour just in case I need to get rid of the bare metal look.

I will have everything set up to just remove the removable body panels and repaint - the wheels can stay on - by comparison with what I'm doing now it'll be a doddle.

In practice this PV will be a three colour car => I've got chassis black on the underside for practical easy to repair reasons - I've got 72 fawn brown on the inside and parts of the underside like the wheel arches spare wheel hump and lower edges of the sills - and I've got "no colour" on top at the moment...

...trust me this is not being lazy.

#########

The pictures I've taken so far don't demonstrate how nice this car could look (in a delightfully dreadful way).

I'm not going for something like this =>

http://3.bp.blogspot.com/-XIkvgOsLJ3...0/DSC_0237.JPG

(See http://justacarguy.blogspot.com/2013...etal-2000.html)

The body work on that charger is absolutely insane - anybody who has even done even a little bit of body work has got to appreciate how fantastically straight it is. But - and it is a big but - I don't like it on that vehicle shape. I reckon a bare metal look looks much better on something from the 1940s / 1950s (like the PV design) =>

https://s.hswstatic.com/gif/bare-metal-hot-rods-1.jpg

(See https://auto.howstuffworks.com/bare-metal-hot-rods.htm)

Something a bit grungy can be nice - this for example =>

http://www.gibbsbrand.info/blog/wp-c...-Metal-KG3.jpg

(See http://www.gibbsbrand.info/blog/cate...are-metal-car/)

Bit too glossy and too much muck under the clear coat for my liking but even so I kind of like it.

#########

So bear with me chaps! Or should I say "bare" with me... (?!)

If it all goes tits up and I don't like what I've done I've got a solution up my sleeve.

Army Sep 11th, 2018 16:13

2 Attachment(s)
Seeing the most recent discussion direction I thought I'd show a few pictures of the masking (!)

The final chassis black has now been applied to the underside and after a bit of playing tomorrow with a new paint product (I can't wait - so exciting) I'll be tipping the car back upright.

https://www.volvoforums.org.uk/attac...1&d=1536678575

https://www.volvoforums.org.uk/attac...1&d=1536678575

The chassis black will be dry enough tomorrow to allow some masking of the holes in the floor pan (holes that are meant to be there - such as drain holes!). The underside will then be covered / masked before I flip it back upright to protect it whilst I carry on with the epoxy and painting of the inside of the car.

Oh yeah - forgot to say - Dauboline - didn't try it after all - after cleaning out the transmission tunnel are I just went for Eastwood rust encapsulator...

Army Sep 13th, 2018 08:20

Just in case you ever drive your PV into a lake...
 
2 Attachment(s)
...and wonder why the car fills up with water so quickly, here's a couple of pictures of the underside of the car with every (intentional) drain hole masked off for painting the other side

https://www.volvoforums.org.uk/attac...1&d=1536823128

https://www.volvoforums.org.uk/attac...1&d=1536823128

Quite a lot of holes there really isn't there

(Car's now back upright ready for the last stages of paint on the inside - race against the colder weather is on)

arcturus Sep 13th, 2018 09:14

Not sure that all the holes are drain holes. I think that they are holes for the mat/carpet, clips/buttons.

Army Sep 18th, 2018 15:54

Quote:

Originally Posted by arcturus (Post 2447203)
Not sure that all the holes are drain holes. I think that they are holes for the mat/carpet, clips/buttons.

There are indeed a few holes there for the mats and a couple of holes for things that get screwed to the underside but most of the holes are intentional drain holes

Army Sep 18th, 2018 16:00

I haven't been posting much...
 
5 Attachment(s)
...because it has been busy busy getting the benefits of the last warm days - under 17 degrees C you may as well forget about spraying (most) car paint.

The epoxy primer has been applied on parts that weren't already done - amazing to realise how much work was needed when I kind of had it in the back of my mind that I was "nearly there" - not at all.

Anyway the epoxy primer (as I'm sure I've mentioned before) needs to have a connecting coat of this stuff called "Pantsercoating" which I chose to be a light grey to help with sanding and spraying. This is the first layer on the inside =>

https://www.volvoforums.org.uk/attac...1&d=1537282574

https://www.volvoforums.org.uk/attac...1&d=1537282574

https://www.volvoforums.org.uk/attac...1&d=1537282574

https://www.volvoforums.org.uk/attac...1&d=1537282574

https://www.volvoforums.org.uk/attac...1&d=1537282574

The repaired parcel shelf came out OK - if you remember there were some ugly holes cut in it for speakers.

Army Sep 19th, 2018 17:26

Celcover on the sides today
 
3 Attachment(s)
https://www.volvoforums.org.uk/attac...1&d=1537374267

https://www.volvoforums.org.uk/attac...1&d=1537374267

https://www.volvoforums.org.uk/attac...1&d=1537374267

Tomorrow it will hopefully be colour on most of the inside - I need to leave space for the chap spraying (me) on part of the floor pan so that will have to be done on another day

arcturus Sep 19th, 2018 20:06

I'm surprised to see that you have left the glass in!

Army Sep 20th, 2018 08:25

Quote:

Originally Posted by arcturus (Post 2449296)
I'm surprised to see that you have left the glass in!

Me no understand.

That masking took hours!

arcturus Sep 20th, 2018 09:16

Quote:

Originally Posted by Army (Post 2449399)
Me no understand.

That masking took hours!

The one give away of a repainted car is paint on window seals. There may even be corrosion on the lip supporting the front windshield. OK so far I have been very impressed with the quality of your work. I hope that this part doesn't let you down. Not a criticism, merely a personal observation. (I am right in believing that the glass is still in and it's not an illusion?) The masking is excellent!

Army Sep 20th, 2018 17:55

8 Attachment(s)
Quote:

Originally Posted by arcturus (Post 2449416)
The one give away of a repainted car is paint on window seals. There may even be corrosion on the lip supporting the front windshield. OK so far I have been very impressed with the quality of your work. I hope that this part doesn't let you down. Not a criticism, merely a personal observation. (I am right in believing that the glass is still in and it's not an illusion?) The masking is excellent!

It must be my super tight masking giving an optical illusion (!)

Everything - and i mean everything - has been removed from the shell and every body part.

More masking =>


With the window masking removed for spraying the special on bare metal clear coat it was time to mask over the new applied clear coat to get nice straight lines on the insides of the window holes.

https://www.volvoforums.org.uk/attac...1&d=1537461868

To get nice straight lines / clean edges I'm using super duper orange 3M masking tape - it costs a fortune so only gets used on special occasions...

https://www.volvoforums.org.uk/attac...1&d=1537461868

https://www.volvoforums.org.uk/attac...1&d=1537461868

...I quickly switch back to the cheaper stuff (costs 1.50 euros a roll) for fitting up the newspaper (which also only gets used to cover parts that are going to be sanded - just in case there's a bit of print transfer)

https://www.volvoforums.org.uk/attac...1&d=1537461868

https://www.volvoforums.org.uk/attac...1&d=1537461868

If you look inside the car I've masked an area on the floor so I can spray - this will have to be painted at a later date

https://www.volvoforums.org.uk/attac...1&d=1537461868

######

The inside has now been sprayed in the base coat and two coats of Car System anti-scratch gloss clear coat.

https://www.volvoforums.org.uk/attac...1&d=1537461868

https://www.volvoforums.org.uk/attac...1&d=1537461868

Spraying inside a car - any car - is a nightmare. Difficult to spray in confined spaces - difficult to get decent coverage - difficult to stop drips and runs...

...I think I did OK today but there are several places that will need to be rectified.

######

Note I've painted all the way round all of the window openings in epoxy - pantsercoating binding layer - base coat and gloss clear to make sure that rust has a very hard time forming under the window rubbers. I'm hoping the window rubbers cover all of the fawn brown paint - if some of it is visible I'll have to invoke plan B...

...to be continued

arcturus Sep 20th, 2018 19:16

Apologies, It looked to me that the glass was still in. Excellent work

Army Sep 23rd, 2018 13:32

Well I'm anbout as glum as the grotty weather today
 
4 Attachment(s)
Can't paint car paint today - too cold - 16 degrees C in the workshop - not worth the hassle

Glum

Glum

Glum

Still 'ere's some progress pictures made in the last few days =>

Inside of the floor pan is finally covered in top coat original Fawn Brown (Might start to think about the wiring loom!)

https://www.volvoforums.org.uk/attac...1&d=1537705594

^^^^ Here's the masking removed that I was standing on to paint the rest of the inside

And of course the negative image of masking around the bit I've just painted so I can paint the last bit

https://www.volvoforums.org.uk/attac...1&d=1537705594

I'll be glad when all of this masking is done and the paint is done

https://www.volvoforums.org.uk/attac...1&d=1537705594

#####

The reinforcing strips on the bonnet are a nightmare. I could feel surface rust under some parts but wasn't able to get all the way under to scrape it off.

After paint stripping and degreasing I used the liquid form of rustyco to attack the bits I couldn't reach - I swilled it about for a few days

Then had to wait ages to get the stuff to dry out (left it for a week)

Finally once dry I used thinned Eastwood Rust Encapsulator...

https://www.volvoforums.org.uk/attac...1&d=1537705798

...that too got swilled about in the cavities and the parts where no beer / man will reach

arcturus Sep 23rd, 2018 14:21

Didn't have that problem. Whoops, pic' upload failed.
my bonnet doesn't have the ribs

arcturus Sep 23rd, 2018 17:59

1 Attachment(s)
Quote:

Originally Posted by arcturus (Post 2450418)
Didn't have that problem. Whoops, pic' upload failed.
my bonnet doesn't have the ribs

Probably less stiff. It happens with age

old fart Sep 23rd, 2018 18:25

1 Attachment(s)
Saw a car the clour yours should be this morning, looked bloody gorgeous!

Army Sep 24th, 2018 09:35

Quote:

Originally Posted by arcturus (Post 2450476)
Probably less stiff. It happens with age

Thanks - I have seen several different designs in pictures on the interweb - I'm not sure if the version I have makes anything stiffer it is a pretty wobbly part of the vehicle that was chafing at the bulkhead - I'll have to find a solution for that at some point or other...

Army Sep 24th, 2018 09:37

Quote:

Originally Posted by old fart (Post 2450481)
Saw a car the clour yours should be this morning, looked bloody gorgeous!

Yeah - I know - we'll see half of the car is going to be treated with the original colour for now. I do fancy the cruddy salt flat racer bare metal look for the outside at the moment. The jury is still out - I'm going to see how it looks once I put it together again

arcturus Sep 24th, 2018 13:22

What are your intentions with this PV when it's all finished. will you be keeping it or selling it on?

Army Sep 24th, 2018 14:49

Quote:

Originally Posted by arcturus (Post 2450670)
What are your intentions with this PV when it's all finished. will you be keeping it or selling it on?

Oh I'm not going through all that silliness with that bloody underseal just to sell it on!

This car will be a "daily driver" in so much as it will be something I intend to drive once in a while. I don't go far may be 3000km a year if that (recently I've been too ill to drive so I've imposed a self inflicted ban).

For me the PV is something with a bit of character that I won't get too worried about if I leave it in a car park (benefit of a pre-bashed body!) that is road tax free (big deal in Holland) fairly cheap to insure as an only car with an agreed value arrangement. For me the biggest PV plus is the head room - even in a large Mercedes (my favourite make so far - I have two) my head is really close to the headlining - blinking irritating being a normal sized person in a world designed for midgets...

Army Sep 25th, 2018 14:11

Bit of a shame...
 
2 Attachment(s)
...the penny has dropped - I've more or less run out of painting time.

Tomorrow and Thursday look like the last warm days of the year. To take advantage of the last days I'm going to get the bulkhead / engine bay finished at last - I had trouble with the nasty paint reaction remember and for that (emotional / ****ed off) reason it got delayed and delayed.

Today I "popped a wheelie" with some help from some brake drums and a few blocks of wood to hold the body in a more upright position so I can spray tomorrow if it is warm enough. It will probably have to be Thursday of course but with any luck that part will be done so I can start with the (front) suspension and the engine + gearbox etc

https://www.volvoforums.org.uk/attac...1&d=1537880930

https://www.volvoforums.org.uk/attac...1&d=1537880930

The oncoming colder weather does mean there will be a massive delay with finishing this project. I am kicking myself for not getting it all done sooner - but as always life gets in the way.

I am (of course) investigating other options such as hiring a spray booth or getting someone else to finish off the paint for me but so far I've not found anyone locally who I trust...

(Saying no more - could get rather rude!)

Army Sep 27th, 2018 14:45

Right that's probably it...
 
1 Attachment(s)
...that's probably the last bit of top coat paint I can apply to the car for the next six months..

Flipping 'eck! Epic fail - didn't win the race with the warm weather.

Still once these parts are dry I can tidy up - clean up - take all the junk I've got kicking about down the tip and have a good re-group and re-assess of this daft project I've started.

https://www.volvoforums.org.uk/attac...1&d=1538055849

As you can see I'm running out of space again - pain in the backside - no matter how much space you have it is never enough. I'm sure I could fill two football pitches with junk given half the chance...

arcturus Sep 27th, 2018 15:56

Send some of your "cool" weather here. It's been 30c in Sagres.And perhaps some rain whilst you are at it :)

Army Sep 28th, 2018 07:41

Quote:

Originally Posted by arcturus (Post 2451760)
Send some of your "cool" weather here. It's been 30c in Sagres.And perhaps some rain whilst you are at it :)

As far as I am concerned you are welcome to as much cold and rain you can take back with you - come and get it!

Army Sep 29th, 2018 16:21

This arrived in the post today
 
1 Attachment(s)
I'm hoping it will help with painting a few smaller parts during these colder days

https://www.volvoforums.org.uk/attac...1&d=1538234386

Can't be used to help epoxy along as epoxy doesn't get on well with UV but for real car paint it should be good - it is only 1kW but it kicks out an impressive amount of heat...

...to be continued - should get to try it out in anger next week

arcturus Sep 30th, 2018 10:43

Could you not rent a free standing patio gas heater? That would warm the garage and let you finish the job

Army Sep 30th, 2018 14:46

1 Attachment(s)
Quote:

Originally Posted by arcturus (Post 2452613)
Could you not rent a free standing patio gas heater? That would warm the garage and let you finish the job

Have you ever been in a caravan with a gas heater? The amount of moisture / condensation produced is dreadful - that would mess up the paint (big time)

I'm hoping lady luck will stay on my side. The end of this week the forecast is reckoning on a few days where the night time temperature won't go below 10 degrees and the day time approaches 20! Yeah! Under the glass roof in the workshop I might get more than 20 degrees which would be ideal.

If I'm lucky I can get some more done.

At the moment it is full steam ahead with the epoxy primer and preparation for the doors =>

https://www.volvoforums.org.uk/attac...1&d=1538315068

Despite several sanding and air blasting attempts that double skinned bonnet is still seeping out muck that gets stuck in the primer. Pain in the backside. Spray - sand - hoover - air blast - hoover - spray - sand - repeat - repeat - repeat...

Army Oct 1st, 2018 15:22

Finally getting somewhere with another problem part
 
3 Attachment(s)
That blinking front got left to one side because at the time I was still trying to figure out a decent way of getting rid of stupid underseal.

The thinner and the decent paint stripper combination is finally making progress =>

https://www.volvoforums.org.uk/attac...1&d=1538403631

The internal corners on the sides are especially frustrating

https://www.volvoforums.org.uk/attac...1&d=1538403631

https://www.volvoforums.org.uk/attac...1&d=1538403631

Having removed the caked on muck, however, I've found a few (tiny) holes that need attention - so more welding tomorrow I guess...

Army Oct 2nd, 2018 14:49

Whilst the cleaning and repairs to the front section...
 
3 Attachment(s)
...continue and the inside of the doors get coated in epoxy primer and that blinking bonnet with the seeping crud gets coated in pantsercoating (ready for colour tomorrow with any luck) - I've started masking again!

I'm getting ready for the off chance the weather / workshop will be warm enough for a protective layer of Car System anti-scratch over the top of the Cellcover

(Too many product names? Go back and read again!)

https://www.volvoforums.org.uk/attac...1&d=1538487914

You can see how I've painted round the windows from the inside to the outer edges that will be covered by window rubbers.

I did this for a bit of extra protection in the never ending fight against rust

https://www.volvoforums.org.uk/attac...1&d=1538487914

(Thought I'd better show a masking in progress picture just in case folks feel I've left the glass in!)

https://www.volvoforums.org.uk/attac...1&d=1538487914

Once the holes have been covered I'll be sanding with 600 / perhaps 800 grit paper so the next clearcoat will stick - it is also an opportunity to correct a few drips (!)

adarvasi Oct 2nd, 2018 22:06

Army,
I spent most of the morning and all afternoon going trough your restoration. Fascinating, entertaining and very, very useful. Thank you very much for sharing.
Andres

Army Oct 3rd, 2018 17:09

Quote:

Originally Posted by adarvasi (Post 2453548)
Army,
I spent most of the morning and all afternoon going trough your restoration...

Well that's dedication!

I suspect I've got a way to go - they'll probably be more posts to come

Army Oct 3rd, 2018 17:15

Swanning about getting nowhere today
 
2 Attachment(s)
Still masking and sanding getting ready for the warmer weather that should be arriving tomorrow

Disaster struck =>

On removing some masking tape paint pulled away from the edge

https://www.volvoforums.org.uk/attac...1&d=1538583127

Pain in the backside - means a fair amount of messing about - but I suppose it is better to have the problem now rather than later

Flipping bonnet is still giving me trouble - combined hoover and air line method seems to be producing mass (defying the laws of physics I'm sure)

https://www.volvoforums.org.uk/attac...1&d=1538583127

Tomorrow I hope to have the outside of the cellcover sanded and ready - perhaps there'll be some bald PV pictures for you all...

Army Oct 4th, 2018 17:19

Update for today
 
2 Attachment(s)
The underside of the bonnet has been painted as best as possible with base coat. Problem is the edges / shadows / sides on the stiffeners make it a very difficult piece to paint - tomorrow I need to get the paint brush out - tis the only way I'll get to all the parts...

...use of paint brushes is not illegal! Some might think you should spray everything but sometimes it is easiest or even best to break out the paint brush =>

https://www.volvoforums.org.uk/attac...1&d=1538669772

^^^^^Here I've just sprayed some etch primer into an old aerosol cap

##########

In other news the body is now more or less ready for the promised warm day tomorrow so I spray on the anti-scratch layer

https://www.volvoforums.org.uk/attac...1&d=1538669772

I'm hoping the dull finish shown in the picture above is close to how the body will finally look when I get the top layer of matt clear coat sprayed (with any luck that'll be Saturday)

blueosprey90 Oct 4th, 2018 18:21

Does you body have a roughly 1" diameter hole in the sill area at the bottom of each B Pillar? If so, do you have any idea of the purpose of these holes. I have them on the 444 and they are a bit distorted outward.

Army Oct 4th, 2018 19:06

Quote:

Originally Posted by blueosprey90 (Post 2454148)
Does you body have a roughly 1" diameter hole in the sill area at the bottom of each B Pillar? If so, do you have any idea of the purpose of these holes. I have them on the 444 and they are a bit distorted outward.

I don't remember anything like that. I'm pretty sure there's nothing like that on my car.

I can check for you in a few days time - I've just masked the windows and doors so I can't get in until the outer spraying is done.

I'll get back to you.

Army Oct 4th, 2018 23:41

Quote:

Originally Posted by blueosprey90 (Post 2454148)
Does you body have a roughly 1" diameter hole in the sill area at the bottom of each B Pillar? If so, do you have any idea of the purpose of these holes. I have them on the 444 and they are a bit distorted outward.

Quote:

Originally Posted by Army (Post 2454165)
I don't remember anything like that. I'm pretty sure there's nothing like that on my car.

I can check for you in a few days time - I've just masked the windows and doors so I can't get in until the outer spraying is done.

I'll get back to you.

Err actually if you look back to a post I made in June it looks like there is a hole in the sill like you describe

https://www.volvoforums.org.uk/showp...&postcount=242

https://www.volvoforums.org.uk/attac...1&d=1527080567

Quite a way from the B pillar

I hope someone didn't use that as a seat belt mounting point - I don't think the inner sill / floor pan is strong enough for it there

I don't know why the hole is there either - it could just be intended as an access place for anti-rust goo.

blueosprey90 Oct 5th, 2018 04:25

Thanks,

Mine look a little bigger and for some reason, both sides are distorted out. I thought maybe something to lift the body.

I want to try to fit inertia 3 point seat belts, and I need something with some meat in that area.

Army Oct 5th, 2018 08:40

Quote:

Originally Posted by blueosprey90 (Post 2454247)
Thanks,

Mine look a little bigger and for some reason, both sides are distorted out. I thought maybe something to lift the body.

I want to try to fit inertia 3 point seat belts, and I need something with some meat in that area.

I don't think they're intended as lifting points. Even with everything stripped out the weight of the body is a bit much for a non reinforced hole in 1mm thick steel sheet.

{I estimate the body weight to be under 150kg when everything has been removed but unfortunately I have no way of checking this}

As you know I have been following your thread - I am aware of your seat belt desire - but I'm not sure of the existing mounts you have in your PV. I assume my car had a factory three point fixing system fitted. I assume that when inertia reels were fitted to the lower part of the B pillar some one cut into the hollow box section under the rear seat so the rear seat passengers didn't have to trip over the reels.

You can see in the picture that I've added in little bits of bent steel to close off the box section and make it a bit more rigid.

I'm sure I've mentioned already that I'm not 100% happy with the way this has been done on my car - all I've done to the current set up is to try and tidy things up a bit.

I think I remember saying if there are no factory fixings on your car then I reckon you're better off getting advice from a classic car company that specialises in fitting seat belts. If not then you need to investigate the strength of rivnuts / nutserts and beefing up the structure to suit => As you can see from the holes in your sills thin metal can be bent easily - you have to fix things to strong things (!)


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