Restoration restoration restoration

[940_Turbo]

Originally Posted by rusty244

All areas of rusted metal cut out:

That is looking nice. For future reference just because the repair panel is that big doesn't mean you have to use it all! It tends to distort less if you weld nearer the arch by cutting the panel down.

[rusty244]

Originally Posted by john h

Well, either really. It certainly is possible to DIY, but on the other hand if you do the cleaning prep underneath the car properly, you'll get mucky and drenched to the skin, and applying the stuff is very messy as well. It's not the most pleasant job, and even less fun doing it in winter!

Send a PM to 'Steve and his 244'. He has half-finished an article about how to rust-proof a 240; sure he'd let you see what he's got even if it's not finished.

There are a few pics of me doing my Merc here - not exactly the same as your 240 obviously but the the basic principles apply to most cars really:http://www.volvoforums.org.uk/showpo...4&postcount=22

Cheers

John

Cheers John.

Good job on the merc. I may have a go at this actually, keep me out of trouble over Christmas if I can make a bit of room in my dad's garage. Would be a nice transferable skill to have for future cars too.

I suspect I may give up part way through and resume over summer but I might surprise myself!!

[rusty244]

Originally Posted by c_lee

Hey Rusty that looks like a great job.

And good to see it done well.

Iv'e been following John's great 160 series restoration thread and had wished there was someone more local who ( I was confident ) would do a similar job for the odd thing I may need doing on one of my 240's.

They are less major than you had done I think - hole in small localised area of offside sill on the doorstep, possibility of hole developing before long in the area where the offside sill joins the rear wing ( door step area again ), and finally the end of the offside outrigger - probably best to replace whole outrigger as the parts are available.

Confidence in the repair is paramount for me.

When I had my 360GLT and it developed two medium sized holes in its offside sill a local garage on Twist Lane in Leigh quoted a total sill replacement for £100 ( that was many years ago ).

I was satisfied with that and booked the job only to find, on collection, they had patch welded the sill with the excuse that a new sill wasn't available.
And the patch welding wasn't that good either - it was obvious to see.
One customer lost to them - never been back since.

I needed the car for work and had to pay for the bodge up to get my car back.

I'm in Greater Manchester too and would be interested to know who did the work for you.

Colin

Thanks Colin.

PM sent.

Having had some pretty poor repairs to sills etc in past I was determined to get a good job done this time, particularly in such critical / visible areas of the car!

Was very impressed with the guys that did the work this time from start to finish - wouldn't hesitate to take anything from a minor repair to a full restoration to them.

[Lesky]

Superb! The restorers did a very nice job with the lines where the trim mounts just behind the door.

[john h]

Originally Posted by rusty244

Cheers John.

Good job on the merc. I may have a go at this actually, keep me out of trouble over Christmas if I can make a bit of room in my dad's garage. Would be a nice transferable skill to have for future cars too.

I suspect I may give up part way through and resume over summer but I might surprise myself!!

I forgot to say, there are hand-pumped rust-proofing kits available, but in my experience they are very frustrating to use and you need access to a compressor and airline to do it properly.

John

[rusty244]

Originally Posted by john h

I forgot to say, there are hand-pumped rust-proofing kits available, but in my experience they are very frustrating to use and you need access to a compressor and airline to do it properly.

John

Cheers John.

The more I think about it the more I think this is a job for summer when I can rent/beg some suitable space&equipment!

In the meantime I will try to go easy on the old thing and use sparingly in these salted conditions!

[rusty244]

Originally Posted by 940_Turbo

That is looking nice. For future reference just because the repair panel is that big doesn't mean you have to use it all! It tends to distort less if you weld nearer the arch by cutting the panel down.

Thanks 940_Turbo.

Caught up with the folks that did the repair and this is their view on the size of panel used:

"Theres several reasons we do this (if the panel allows) one is because its what we call a natural edge, theres a step in the steel there that gives the panel strength so distortion is kept to a minimum, also if you stand beside a car and look at it, you look down, the volvo has a trim there that takes your eye from the repaired edge, any discrepancies are impossible to see, also from a distance your eye takes the same line in, and wont focus on the mm or 2 below it.
Cutting a curve in a flat panel and welding is almost impossible without distortion, the reason being that the movement in the steel isnt caused by heat/expansion, the warping is caused by cooling/contraction. Distortion in a straight cut/weld all pulls in a similar direction whereas a curve pulls in an arc and causes flex"

[john h]

James,

When you can, get a photo of the rust inside the boot and I'll give you my two penneth about how best to repair it.

John

[Paul240480]

Originally Posted by john h

James,

When you can, get a photo of the rust inside the boot and I'll give you my two penneth about how best to repair it.

John

Have just imprinted that in my little brain, for future 'tin worm photo's' of Tank lol

[john h]

Originally Posted by Paul240480

Have just imprinted that in my little brain, for future 'tin worm photo's' of Tank lol

Of course, no problem!

John