Volvo Community Forum. The Forums of the Volvo Owners Club

Forum Rules Volvo Owners Club About VOC Volvo Gallery Links Volvo History Volvo Press
Go Back   Volvo Owners Club Forum > "Technical Topics" > PV, 120 (Amazon), 1800 General

Notices

PV, 120 (Amazon), 1800 General Forum for the Volvo PV, 120 and 1800 cars

Information
  • VOC Members: There is no login facility using your VOC membership number or the details from page 3 of the club magazine. You need to register in the normal way
  • AOL Customers: Make sure you check the 'Remember me' check box otherwise the AOL system may log you out during the session. This is a known issue with AOL.
  • AOL, Yahoo and Plus.net users. Forum owners such as us are finding that AOL, Yahoo and Plus.net are blocking a lot of email generated from forums. This may mean your registration activation and other emails will not get to you, or they may appear in your spam mailbox

Thread Informations

1961 Volvo PV544 in Holland

Views : 83211

Replies : 750

Users Viewing This Thread :  

Reply
 
Thread Tools Display Modes
Old Apr 19th, 2019, 15:17   #651
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default Still winging it

Getting there slowly =>



^^^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"!



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 =>



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.



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



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!



So I'm almost ready for potential progress
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
Old Apr 21st, 2019, 19:49   #652
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default Got the epoxy coat on the...

...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!



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



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



Second coat of epoxy tomorrow (with any luck)
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
Old Apr 22nd, 2019, 15:08   #653
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default I'm hpoing this will be the last of the engine bay paint

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...



...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...



...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.
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
Old Apr 25th, 2019, 16:18   #654
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default King pin update

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 =>



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...



...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 =>



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)
Attached Images
File Type: jpg 1961 Volvo pv544 king pin problems1.JPG (191.4 KB, 81 views)
File Type: jpg 1961 Volvo pv544 king pin problems2.JPG (139.1 KB, 74 views)
File Type: jpg 1961 Volvo pv544 king pin problems3.JPG (241.2 KB, 79 views)
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!

Last edited by Army; Apr 25th, 2019 at 16:24.
Army is offline   Reply With Quote
Old Apr 25th, 2019, 23:40   #655
Derek UK
VOC Member
 
Derek UK's Avatar
 

Last Online: Today 17:01
Join Date: Jul 2006
Location: Chatham
Default

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.
Derek UK is offline   Reply With Quote
Old Apr 26th, 2019, 05:37   #656
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default

Quote:
Originally Posted by Derek UK View Post
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.
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
The Following User Says Thank You to Army For This Useful Post:
Old Apr 26th, 2019, 15:58   #657
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default Back with the painting...

...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.



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



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!)
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
Old Apr 26th, 2019, 17:19   #658
adarvasi
Member
 
adarvasi's Avatar
 

Last Online: Mar 1st, 2022 01:17
Join Date: Sep 2018
Location: Mexico City
Default

Great info Army, thank you
Andres
adarvasi is offline   Reply With Quote
Old Apr 27th, 2019, 18:25   #659
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default

Quote:
Originally Posted by adarvasi View Post
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 =>



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







Tomorrow I'll return with lists of what I bought - and some paper so I can make up a list of what I need...
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
Old Apr 27th, 2019, 18:31   #660
Army
marches on his stomach
 

Last Online: Feb 11th, 2022 04:15
Join Date: Jan 2018
Location: Somewhere in the Netherlands
Default Despite the head scratching...

...I at least got the fuse box fitted

(So mission control is now in place)



^^^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 =>

Attached Images
File Type: jpg 1961 Volvo pv544 custom fusebox fitted1.JPG (145.8 KB, 62 views)
File Type: jpg 1961 Volvo pv544 custom fusebox fitted2.JPG (162.1 KB, 60 views)
__________________
1961 Volvo PV544 the quick and easy in between project(!)
1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
1992 Mercedes 190E The car that works!
Army is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT +1. The time now is 19:09.


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