1966 Volvo Amazon engine transplant!

[Underdrive]

I can't lay my hands on my copy of the testers manual at the moment but basically if a fundamental part of the vehicle's construction has been altered from original spec then it is up to the testers discretion to assess, and should then pass/fail or to cover their backsides request written assurance of suitability from a qualified engineer. This is a common problem faced by builders of custom cars and a look round some forums may help with possible alternatives to what you are trying to do and maybe some tips on how to keep your MOT man happy.

[Melody121]

So yesterday I did some more cutting, I removed the rot from the passenger side and run a flap wheel over the drivers side to assess the condition.
Straight away there is a hole that was covered by the accelerator pedal mount but other than that some messy but acceptable previous repairs is all I found.
That night after Phil finished work he confirmed just the section up to the hole would need removing, so a little less than the passenger side.

Here are photos of the bulkhead from the inside once I'd done for the day...





So the plan today was to cut out the last little bit and get some bars in there.
Then my friend's beady eye spotted a serious problem....
The panel gap between the top of the wing and the door had closed... Sh!t!!

The pic probably looks worse than it is as the panel gaps on this car are horrendous to start with but it's closed up about a mil.



On Phil's instruction I have jacked under the edge of the wings to support it and open the gaps back up a bit, checked the opening and closing of each door in turn and now she sits with all doors firmly closed until Phil can get home from work and cast an expert eye over it. Then, if it's not FUBAR, weld some structural ridigity back in before any more work is done.

The doors operation is unchanged however, although that's a good sign, I now sit holding my breath and praying this isn't curtains for poor Olga

[Melody121]

My little panic is over, it's not moving too much and although it still got a little flex, were heading the right way now.

Today with my friend we welded in some of the new bulkhead, it was a bugger cause we happened to get smashed last night playing shot Jenga, so imagine welding and grinding in a cramped uncomfortable place with a headache and feeling a bit sick.... Oh well

We left the second vertical brace out as the hole behind the pedals needs to be cut out and new metal put in first, but I think the next job will be finishing the passengerside to make it strong again anyway.



Then we pretty much finished off the gearbox mount. The centre plate is welded on and it just needs a lick of paint and some threaded bar to link it to the casting on the gearbox. For now it is doing a fine job of holding up the box.... I was too hungry to make more of an effort with the photo I'm afraid so this will have to do till I take it off again for paint

[Melody121]

Yesterday i had a busy afternoon. I made a patch for the outside of the bulkhead and tacked it in place. I've started making the inner and side too but ran out of time before I had to go and meet our wedding photographer... But thats booked so yay

Here are some piccies.... Apologies for the rubbish welding. I rarely get a go and this was the first time I tried anything on my own so I forgot to turn the gas on, hence the burnt look, HaHa! Dummy!









This bit will plate the inside where the box section is.



Now I just need to make sure this rains gone for the afternoon before I drag all the electricals back outside, the forecast is looking ok I think.

[Burdekin]

Just weld clean metal to clean metal and you'll find it much easier to weld. Weld through primer is only needed at the back of parts that you can't get to after welding to paint properly. Also just put a V prep in when butt welding and you'll get 100% penetration and not have to have the amps up as high so less distortion.

[Melody121]

Thanks for the tips, I'll only put the weld through on the back of stuff then. It'll save me money too cause that stuff is expensive!
I won't be doing the welding though. My other half has been welding for 10 years, he just doesn't have a lot of time so I'm doing everything up to tacking the panels in place. I've got about half an hours welding under my belt and can't reliably do strong welds yet!

[Melody121]

Did some welding today.. Not me so the gas got turned on this time two patches down 6 to go!

[Melody121]

Just a little welding vid cause i could

https://youtu.be/70BVB5Zpf7Y

[Derek UK]

Wear a hat? a stray spark would really make you jump. Try making a small circle with the gun to do the plug in one go. Other welders might care to comment on that. Well done, you look confident, and that's what matters.

[V70 Geoff]

Originally Posted by Melody121

Just a little welding vid cause i could

https://youtu.be/70BVB5Zpf7Y

Reading through your reports does make me feel a little better about my own Amazon project, currently about two years and £5k down the road with more to do. Every time I have taken something apart it has required replacing so almost all the mechanicals are now new and the structure is stronger than when it was manufactured. Rebuilt gearbox, axle, brakes and suspension so far and a B20 engine with new clutch, alternator, fuel pump, fuel tank etc. Now why do we do these things when I have a perfectly lovely trio of more modern Volvos outside to choose from?????