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1961 Volvo PV544 in Holland

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Old Mar 5th, 2018, 17:14   #101
Army
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Er OK thanks chaps - bit of a conflict on the seat tube at the moment then?

Other than that the Mitsuba wiper control documentation looks pretty scarce on ye olde interwebe...

...I´ll keep looking - there might even be a schematic on the other side of the box...
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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!
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Old Mar 6th, 2018, 17:06   #102
Army
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Default Forgot the camera today...

...so just one from the clever phone

Doing more than expected but as it is getting warmer I´m getting ready for paint

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File Type: jpg 1961 Volvo pv544 heater fan box being stripped.jpg (136.3 KB, 125 views)
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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!
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Old Mar 7th, 2018, 16:18   #103
Army
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Default Ending up doing way more than I hoped

Still I guess the only way to fix something is to take it to bits...



The wiring loom and the dash has been removed so I can merrily wire brush away the paint in the engine bay and bulkhead.

The windscreen has been leaking and the interior floor needs a bit of a going over too.

That´s a bit of a bugger.

######

Even so other parts that I was planning to have a go at are coming along nicely

Subframe - stripped



Other parts that will be getting multi layered coatings have been stripped and treated to Brunox.



Next layer will be ferpox epoxy primer - then probably Eastwood chassis black.

For other parts that will probably get scratched such as tie rods and this heater box get treated to Hammerite satin black - super easy to spray on - super easy to fix at a later date if they do indeed get scratched

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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!
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Old Mar 7th, 2018, 19:19   #104
Army
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Default Chassis number position

I forgot to say - I found a chassis number stamped into the bulkhead

Previously I had been lead to believe that Volvo didn´t start doing this until later 1966 (information found in a spares book)

However - my 1961 PV does have it



The chassis number plate is as many have said on the RHS of the vehicle (left hand arrow in the picture) - But this can be removed (!)

I found the chassis number and the model number stamped into the bulkhead between the hole for the heater ducting and the hole for the wiring loom on the LHS of the vehicle (right hand arrow in the picture)
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File Type: jpg 1961 Volvo pv544 chassis number positions.jpg (232.6 KB, 120 views)
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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!
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Old Mar 8th, 2018, 14:55   #105
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Default Red Letter Day!

That sodding rear suspension has been removed.

It put up a good fight and had to be done the wrong way

I wanted to remove the trailing arms from their front mounting points but struggled to get the bolts loose. This was mainly because the car wasn´t / isn´t up on a lift - working lower down to the ground restricts the length of grolly bars in tight spaces.

I removed the Panhard bar and the upper differential mount from the underside of the car - well Panhard rod only comes off at the lower end - was trapped by exhaust at top mount...

...then I removed brake lines and parking brake / hand brake cable from the centre (only to find that too is wrapped around the exhaust!)...

...propshaft was easily removed but needs to come out towards the rear so can potentially get caught up in the rear axle gubbins too.

Shocks came off easily and the lower spring mounts weren´t too too difficult to get loose. The upper spring mounts not so easy when rusty! I waited until the axle was lowered before removing them.

The (fabric) straps stopping the rear axle from dropping were left until the last minute. U-clamps on the trailing arms were undone - that was hard going - U-clamps removed - strap on one side removed - axle pings down a bit under a tiny amount of spring compression...

...then just do the other side. Phew =>



The trailing arms mounts at the front were ¨easy¨ to remove with more space once the axle and exhaust was out of the way

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File Type: jpg 1961 Volvo pv544 rear suspension struggles1.JPG (236.1 KB, 115 views)
File Type: jpg 1961 Volvo pv544 rear suspension struggles2.JPG (224.3 KB, 115 views)
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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!
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Old Mar 8th, 2018, 17:06   #106
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Default Propshaft also in bits

Easy to do with a hydraulic press - not necessary because these things are especially stiff / hard to shift but because of the controllability



Note the dangerous use of sockets! Don´t damage tools when doing this - if your needle moves more than a blip on your hydraulic gauge then you´re doing it wrong - virtually zero force is needed...

Shove the UJ cross one way (after removing circlips!)

Then back the other way =>



Pick out the seal and wriggle the needle bearings out of the caps



Then use a hammer and punch to knock the caps out of the way so you can remove the UJ crosses



Next up a good degrease...



...and some paint
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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!
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Old Mar 10th, 2018, 15:47   #107
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Default Tiny steps...

...found out how the front seats were modified.

The hoops do indeed look like they came from an Amazon - see Amazon spares book. They seem to have been welded onto the PV lower seat rails. Access to the cross head screws is made via the holes in the tube (not sure if that´s how they are on the Amazon) =>



Nicely modified (in my humble opinion) as they´ve seam welded all along the two joining surfaces on both sides of the hoop - mega strong.

####

I´m glad I ripped up the floor mats and removed the old sound insulation - water ingress was starting to take hold. I think I´ve caught it in the nick of time.



Finally finding evidence of the original body colour too!



That and the discovery of the stamped chassis number has removed all concern about inadvertently picking up a ringer of yore...

######

In other news - reason for strangely aligned trim piece between front door and bonnet has been found =>



It was poorly put back together again with a screw instead of a proper clip!
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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!
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Old Mar 10th, 2018, 19:03   #108
old fart
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I'd put the Amazon seats back if I were you. I've just done a 150 mile trip in my 544 today, and my bum hurts much more than in my Amazon!
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Old Mar 10th, 2018, 22:56   #109
norustplease
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Quote:
Originally Posted by Army View Post
It looks like the windscreen rubber has been leaking a bit on the car

I managed to remove the trim really easily (which seemed strange)



Evidence of water pooling on the dash top is shown by rusty screws on the outer edge



I have never been able to pull out a windscreen with just my fingers before!

#####

I´m guessing the seal used is not meant for a PV. Is it perhaps possible to get the seals mixed up with Amazon ones / another vehicle?

Or are they all made badly ¨these days¨?
There should be some sealant in there, injected after the rubber/glass is in place.
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Old Mar 11th, 2018, 14:17   #110
Army
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Quote:
Originally Posted by norustplease View Post
There should be some sealant in there, injected after the rubber/glass is in place.
Thanks - I thought as much.

Bit of a shame it wasn´t done when the paint job was completed - the up side of course is that it was a lot easier to remove!

Quote:
Originally Posted by old fart View Post
I'd put the Amazon seats back if I were you. I've just done a 150 mile trip in my 544 today, and my bum hurts much more than in my Amazon!
Good to hear that bit of confirmation - thanks. According to the Dutch PV club the Amazon seats are considered to be an upgrade.

I´m waiting for some cloth from VP Automotive in Sweden so I can re-do these Amazon seats in the style of the original interior code for this car (40-197). I´m hoping the original back seat coverings are going to come good - they are very grotty - but it would be a substantial saving if they don´t need to be replaced...
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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!
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