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1961 Volvo PV544 in Holland

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Old Jul 11th, 2018, 14:47   #301
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Originally Posted by arcturus View Post
Hi, a long shot but worth trying. I need a replacement choke pull lever with choke cable with inner wire. Mine broke whilst trying to replace inner after fire. Was wondering if you could put me in touch with the Dutch PV group. i already have feelers out with Swedish group. No scrap yards near where I live. Only need the pull with inner cable, not outer or bezel.
That looks repairable to me - but - I'll have a look for you on the Dutch club's website to see if they've got what you need. I'll have to do this later as it seems to be experiencing problems at the moment.

Have you got the part number for the bit you need - it is always best to have that - then we'll know exactly what we're getting.
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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
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Old Jul 11th, 2018, 16:22   #302
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That looks repairable to me - but - I'll have a look for you on the Dutch club's website to see if they've got what you need. I'll have to do this later as it seems to be experiencing problems at the moment.

Have you got the part number for the bit you need - it is always best to have that - then we'll know exactly what we're getting.
The cable is available, I have one. Its the shaft that I need.whilst trying to drill out the old broken cable the shaft broke,now it's too short to allow full choke when pulled out. It would need to be the pull shaft/handle with the cable already attached. Probably only available from a scraped PV
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File Type: jpg 20180617_01.JPG (237.9 KB, 2 views)
File Type: jpg choke cable 1.jpg (81.7 KB, 2 views)
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Last edited by arcturus; Jul 11th, 2018 at 16:44.
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Old Jul 11th, 2018, 16:42   #303
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The cable is available, I have one. Its the shaft that I need.whilst trying to drill out the old broken cable the shaft broke,now it's too short to allow full choke when pulled out. It would need to be the pull shaft/handle with the cable already attached. Probably only available from a scraped PV
Their website is still playing up. At this rate I'll have to send them an email!

I'm not sure if these will help but on the bay of ee =>

https://www.ebay.co.uk/itm/Volvo-Jen...YAAOSwdA5bOYoc

Or a universal solution

https://www.ebay.co.uk/itm/Volvo-CKU...gAAOSwTM5YvtAO
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Old Jul 11th, 2018, 18:56   #304
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Default Repair to RH sill

Tricky repair started today

From the upper side it didn't look too bad





Under the two layers, however, quite a bit of rust damage to the floor pan part that runs up the inner side of the sill was evident



I needed to remove more of the upper section



Made a bit of repair section from 1mm thick Zincor





Cutting out the rusty bit on the floor pan



Hoovering out the muck in the sill (now or never)



Welded in the repair bit on the floor pan



Upper section going in =>



Trimming the top =>



Most of the job done =>



The inner side of the floor pan welding is really difficult - access is dreadful. I've spot welded it so it is a solid repair but I need to figure out some way of finishing the job.

To make a perfect solution it would have been necessary to cut away the whole sill then repair a massive chunk of the floor pan / inner section of the sill - then refit / replace the outer sill. This would have been a bit of a nightmare so I've gone for the solution shown above. The difficulty in doing it this way is getting access to the join between the floor pan and the U shaped repair section...

...to be continued
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Old Jul 11th, 2018, 22:38   #305
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The cable is available, I have one. Its the shaft that I need.whilst trying to drill out the old broken cable the shaft broke,now it's too short to allow full choke when pulled out. It would need to be the pull shaft/handle with the cable already attached. Probably only available from a scraped PV
I've looked on the Dutch club's website (which now seems to be up and running) and they don't have what you need for sale.

Here's a link for their site if you want to see for yourself - their contact details are there too but I'm not sure how it goes for non members

https://www.volvokv.nl/
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Old Jul 12th, 2018, 09:00   #306
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Thanks, having a look at all the options. Found a bunch on ebay.de
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Last edited by arcturus; Jul 12th, 2018 at 09:15.
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Old Jul 12th, 2018, 14:05   #307
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Default After a vague bit of interest in the paint stripper PORstrip

I thought I'd do a series of pictures showing how effective the POR-Strip stuff is

Like I say it isn't in the same league of 1980s Nitromors that used to try and rip your eye balls out of their sockets

POR-strip fumes are quite low. In a well ventilated area they are almost unnoticeable (but wearing a mask is best)

The series of pictures show a progress of the LH rear quarter panel over a period of approximately 90 minutes



For the first pictures all I have done is to brush on the stuff

The thinnest paint reacts the quickest (of course)



^^^ That happened after about 15 minutes

Here's an example of how thickly I'm coating the paintwork



This is about as thick as it will go on a vertical side - much thicker and it starts dripping off which, considering the price of the stuff, is the last thing you want to happen

About 30 mins in =>



Still just with brushwork (so to speak) - brushing the flakes off and applying more of the stripper



After about an hour of watching the paint peel I got the scraper out and gave it a bit of a stab



As you can see anything with a filler thickness of about 1mm or greater and the POR strip struggles



Here's what it looked like after about 90 minutes of soaking



The thinnest paint has gone.

The thinnest filler and paint has also gone

The other stuff where the filler is thicker than 1mm is still quite solid. The stripper doesn't seem to want to soak in.

At this point my patience has been used up and I will be getting the sanding discs out after a bit of a stab with the new multitool and scraper combo

I might test some of the last parts of the filler after the sanding to see if the POR strip can still cope with it when it is thinner.
Attached Images
File Type: jpg 1961 Volvo pv544 porstrip1.JPG (139.2 KB, 41 views)
File Type: jpg 1961 Volvo pv544 porstrip2.JPG (180.1 KB, 41 views)
File Type: jpg 1961 Volvo pv544 porstrip3.JPG (165.6 KB, 42 views)
File Type: jpg 1961 Volvo pv544 porstrip4.JPG (167.4 KB, 42 views)
File Type: jpg 1961 Volvo pv544 porstrip5.JPG (154.3 KB, 42 views)
File Type: jpg 1961 Volvo pv544 porstrip6.JPG (157.4 KB, 43 views)
File Type: jpg 1961 Volvo pv544 porstrip7.JPG (178.9 KB, 42 views)
File Type: jpg 1961 Volvo pv544 porstrip8.JPG (154.1 KB, 41 views)
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1981 Mercedes 300D <=> 230 diesel to petrol conversion project
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Old Jul 13th, 2018, 19:35   #308
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I found wrapping panels in cling film on top of the stripping chemicals, then leaving overnight, almost makes this sort of thing pleasant. Come back the next morning and you can almost blow off all the paint and filler.
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Old Jul 13th, 2018, 23:12   #309
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I found wrapping panels in cling film on top of the stripping chemicals, then leaving overnight, almost makes this sort of thing pleasant. Come back the next morning and you can almost blow off all the paint and filler.
I'm game - I'll try that on the roof - off to the supermarket I go...
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1981 Mercedes 300D <=> 230 diesel to petrol conversion project
1965 Series 2a Station Wagon mega build
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Old Jul 14th, 2018, 13:36   #310
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Default So following the advice above...

...made me remember reading the tin where it also says wrap if possible.

Strange isn't it? I did RTFM but then forgot about it. Oh well we'll see tomorrow if it makes a difference.

I couldn't face going to the supermarket on a Saturday morning so I've improvised with super thin plastic sheeting you can buy these days instead of decent dust sheets and some left over plastic bag packing.





Note the gucci new white party tents - now in use to help keep the sun off drying paint and epoxy and paint stripper. A glass roof is a really nice thing to work under for most of the year in Northern Europe - light is always welcome - when I was in a different part of the building in a space under a solid concrete floor it was like being a mole...

...still direct sunlight even with glass between does have its problems (that have now been solved thanks to the Lidl - 15 euros a tent! Cheap cheap - matches the quality too - one fart and they're done for)
Attached Images
File Type: jpg 1961 Volvo pv544 porstrip9.JPG (139.3 KB, 31 views)
File Type: jpg 1961 Volvo pv544 porstrip10.JPG (139.8 KB, 31 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!

Last edited by Army; Jul 14th, 2018 at 13:38.
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