RustV40 Project

[Hoggy32]

Info: This car is a scarp heap and will probably be scrapped within a year or two... if it lasts lol. There are rust all over the car and dents everywhere because of idiots driving in it while it's parked without even leaving a note

All I want to accomplish with this "project" is to restore the most of the body and keep it clean and nice to drive it from point A to point B, and yes you're allowed to laugh at this rust pile lol.

Feel free to suggest things!

Volvo V40 1.8i GDI 2001

TODO List: X = Done / = Ordered parts
Fix rust on car []
Change position lights [X]
Fix electric window power lift on driver side [X]
Respray car []
Paint the grill black []
Fix bushings on gearbox [/]
Change indicator light on left side [X]
Add LED to plate number on back of car [X]
Add LED to interior lights [X]
Change spark plugs [X]
Change air filter []
Change fuel filter []
Solder my own interface for HU-605 Radio and add Bluetooth and AUX [/]
And more...

1. From start:
http://imgur.com/a/sASix

2. Some respray and I bought new position lights (http://imgur.com/a/GuzwZ)
http://imgur.com/a/WGNU4

3. Me fixing window powerlift on driver side
http://imgur.com/a/ZWcr0


Updates:
- New position lights (rear) fitted.
- New dent on driver side, makes the window not go down all the way
- New spark plugs installed (Brisk Premium Plus)
- Some interior LEDs installed http://imgur.com/a/AfDuz
- Dashboard, ECC panel LED installed: http://imgur.com/a/x5WpU https://youtu.be/wMDOSP7Omiw https://youtu.be/56JRtMciRZ0 (The ECC unit has custom built bulbs so I used others and that's why it barely lights up)

Thanks to leftfootleashed for sending me a rear position light

[druid]

My dented rear 1/4 was nasty like yours, the rusty bits i see are wing not body so not so bad.

[Hoggy32]

Originally Posted by druid

My dented rear 1/4 was nasty like yours, the rusty bits i see are wing not body so not so bad.

Update 2017-07-02:
-The new dent I got on the driver door got fixed today. Took a hammer and hit it from the inside a few times and it pop back out. Good as new except some white paint from the other car which can easily be fixed. http://imgur.com/a/5NrY9
-New tailgate bulbs since two bulbs had stopped working.
-Driver window noise fixed.
-Blew out some dust out of the air filter and cleaned the box where it's placed. (I might purchase a new air filter later)

[Hoggy32]

Update 2017-07-12:

-New brake pads ordered both front and rear
-Air filter ordered
-Fuel filter ordered
-Changed headlight bulb since one of them was broken and MOT is coming soon
-Oil filter and oil bought, doing a full service on the car soon.

-Worked on the dent on the back of the car, took me hours to hammer the dent out and then been on the sander for hours. Bondo all over and sand it down again, then primer and wet sand it and then.....
I sprayed the color (Atlantic Blue metallic), when I had a bit left on the front where I removed some rust there was no spray paint left.. and it started to rain so much so it f**ked the paint bad.

Regarding the dent: It looks way better than before but I have to spray some more paint for sure, so I'll have to order some more spray paint from the UK.

Pics will come later

[skyship007]

Originally Posted by Hoggy32

Update 2017-07-02:
-The new dent I got on the driver door got fixed today. Took a hammer and hit it from the inside a few times and it pop back out. Good as new except some white paint from the other car which can easily be fixed. http://imgur.com/a/5NrY9
-New tailgate bulbs since two bulbs had stopped working.
-Driver window noise fixed.
-Blew out some dust out of the air filter and cleaned the box where it's placed. (I might purchase a new air filter later)

It's worth getting an MOT inspection done to see what really does need doing. Otherwise you can spend time with rust or dents that might not matter whilst overlooking something much more important like defective rear calipers.

Good you cleaned out the air filter housing as a lot of folks forget to do that. It's very important to clean it if the engine has a turbo in particular.

The R5W blulbs in the rear lights are a PITA, as they fail on a regular basis. I did try some cheap LED's, but they did not last much longer.

Some of the engines don't like non Volvo plugs, as there is no real equivalent.

[Hoggy32]

Originally Posted by skyship007

It's worth getting an MOT inspection done to see what really does need doing. Otherwise you can spend time with rust or dents that might not matter whilst overlooking something much more important like defective rear calipers.

Good you cleaned out the air filter housing as a lot of folks forget to do that. It's very important to clean it if the engine has a turbo in particular.

The R5W blulbs in the rear lights are a PITA, as they fail on a regular basis. I did try some cheap LED's, but they did not last much longer.

Some of the engines don't like non Volvo plugs, as there is no real equivalent.

New plugs are doing great.

One thing that failed MOT last time was "Missing sideposition light", either you remove both or have both side working. I did a ghetto fix: http://i.imgur.com/iClsBKf.jpg
However, I've got a new light and replaced it, it's looking good.

Also another thing that failed MOT was high emissions, but it went through because the guy was nice enough. The catalytic converter is bad and I have to try to find another one for it.

[skyship007]

Originally Posted by Hoggy32

New plugs are doing great.

One thing that failed MOT last time was "Missing sideposition light", either you remove both or have both side working. I did a ghetto fix: http://i.imgur.com/iClsBKf.jpg
However, I've got a new light and replaced it, it's looking good.

Also another thing that failed MOT was high emissions, but it went through because the guy was nice enough. The catalytic converter is bad and I have to try to find another one for it.

Oddly enough we have not had any owner report a failed CAT yet. Some CAT's can cause MOT issues when they rust through and are expensive to replace if you buy a new one, although you can try using a good looking low mileage used unit. The pre CAT section might also need replacing if it's badly corroded.

If a CAT does get blocked up with Zinc ash it can't be cleaned out (Unless you like playing around with very corrosive acids). That ash results from engine oil anti wear additives, so if you can keep the oil consumption down and avoid using oils with high levels of Zinc based anti wear additives they last longer. Alas the only alternative to Zinc based anti wear additives is one of the new generation Ceramic oil additives and they are too expensive to be included in any normal engine oil at present.

If you do buy a used CAT, make sure it does not rattle when given a good shake, as that means the internal matrix has broken up and it might not work as intended.
My previous car was a Renault 19RT and the CAT had to be replaced (700 Euros plus fitting) after it failed a TUV inspection. The chap thumped it with his fist and it sure rattled. He then pointed to a few small holes in the seams and it was game over, as he gave me a full failure notice which gets entered into their data base, so no point trying to get another place to pass it after bodging up the rust holes.


A TUV inspector made me change both reversing bulbs for standard 10w jobs as they were too bright. 20 quid wasted as some muppet binned one of them (They were top of the range Corus LED's).
Alas my partner demonstrated why she really does need good reversing light by backing into another car a few months ago!

[Hoggy32]

Update 2017-07-23:

-Some goodies has arrived: http://i.imgur.com/9RAnKLP.jpg
-New Air filter installed: http://imgur.com/a/yCOmP
-Interior LED for makeup mirror installd, check the difference between the old and the LEDs: http://imgur.com/a/rz8gv
-Some pictures of the dent that I "fixed". It looks better than before tho http://imgur.com/a/I3K01
-I've soldered the new bluetooth aux arduino chip and tried to install it on the car, it works perfectly good you can change songs through the HU radios next/previous buttons however the audio is hacking so I have to go though and see what's lose and fix it. http://imgur.com/a/vonUP

I hate this car because the body is so messed up

[druid]

Nice job on the dent!

[Hoggy32]

Update 2017-08-02:

- New brake pads installed (Front and Rear)
- Brakes are bleeded and new Brak fluid is in now.
- Led installed in the glove box and in the trunk, I must say... LED IS A MUST for better light in the dark, it's a HUGE difference between LED and those old bulbs.
- Handbrake wire snapped of and I've ordered new left and right handbrake cables to install when they arrive.