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1961 Volvo PV544 in Holland

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Old Mar 16th, 2019, 15:42   #641
Army
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Quote:
Originally Posted by blueosprey90 View Post
...

Also what are those red circular "terminal blocks" called (A, B, C & D) and what was your source for them?
More on the terminal blocks - I said I'd find the manufacturer - I did (!)



^^^RIPCA^^^

As you can see I also bought the terminal cover kit.

I'm not especially impressed. There's a circular piece of perspex that goes over the cross head screw terminals and a very very loose rubber johnny thing over the main wire that would normally be used on a battery cable.

So the terminal cover kit is a bit of an afterbirth thought after the decent post had been designed. Shame really - it is just about functional - but not very neat =>





I'm not sure if I'll even bother fitting the cover kits for the right hand side terminals...

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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 18th, 2019, 14:52   #642
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Default New tangent today (!)

Blower motor needs a bit of help.

The fan cage floats about a bit too much on the end of the motor shaft. You can pull / push the cage about 5mm backwards and forwards on the motor so something needs to be fixed...



The grub screw on the cage (fits into armature / motor shaft) came out nicely - I was surprised.

After a fair amount of rust eating penetrating had been left to work its wonders super hero dexterity was needed to hold the cage and a parallel pin punch in one hand and then hammer the motor's shaft free from the fan cage =>



The rubber mounting parts were a bit stuck to the mounting flange but came away with a bit of careful encouragement. These resilient bits must be added to reduce motor noise in the cabin.



Long - through body bolts - undone to remove the mounting flange and to separate the motor casing



The end cap at the end where the brushes are fixed had a broken fixing spring on the bearing which actually helped remove the shaft from the end cap...



...but could very well be part of the trouble - part of the reason why the shaft / armature floats about so much within the casing



And there we have it - one motor in as many bits as I feel is necessary / prudent



It seems like the brushes have been replaced...



...I get the feeling that whoever did that job didn't shim the armature nicely in the casing.

The commutator is pretty worn out on the armature (whereas the brushes have lots of meat on them) which is a shame as there may not be enough meat to let me get away with machining them smooth again.

To be continued (at my usual leisurely pace)
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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 Mar 18th, 2019, 16:58   #643
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You were lucky to get the fan off that easy. With luck, the comm can be skimmed. As long as the separator grooves can be recut a bit so the brushes actually switch things on and off as they pass you should be OK.
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Old Mar 18th, 2019, 21:04   #644
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Derek;

Removing the all-metal impeller of the 544 ventilator motor is a lot simpler than the same job on the 122 ventilator with plastic impeller...

If I didn't know any better, I'd like to suggest that the brushes might have been replaced with a narrower set...it looks like the set in there have really dug into the commutator, because they are narrow and only in contact with about 40% of it! Are you seeing what I'm seeing?

Cheers
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Old Mar 24th, 2019, 15:53   #645
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Sorry for the delay in replying - I'm busy buying a house at the moment - trying to find one with a decent workshop solution isn't easy. It seems that "normal" people think a single garage is reasonable...


Quote:
Originally Posted by Derek UK View Post
You were lucky to get the fan off that easy. With luck, the comm can be skimmed. As long as the separator grooves can be recut a bit so the brushes actually switch things on and off as they pass you should be OK.
I think the existing part is more or less toast - the gouges are a bit deep

Quote:
Originally Posted by Ron Kwas View Post
Derek;

Removing the all-metal impeller of the 544 ventilator motor is a lot simpler than the same job on the 122 ventilator with plastic impeller...

If I didn't know any better, I'd like to suggest that the brushes might have been replaced with a narrower set...it looks like the set in there have really dug into the commutator, because they are narrow and only in contact with about 40% of it! Are you seeing what I'm seeing?

Cheers
I thought the brushes were a bit narrow too when I took it to bits. The holders do look like they should be there though...





The only identifying mark on the plastic holders I can find is a "VR14" - I've done an internet search but haven't come up trumps just yet.
Attached Images
File Type: jpg 1961 Volvo pv544 blower motor in bits9.JPG (158.2 KB, 100 views)
File Type: jpg 1961 Volvo pv544 blower motor in bits10.JPG (154.2 KB, 96 views)
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Old Mar 29th, 2019, 14:44   #646
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Default Unfortunately...

...I'm far too busy with estate agents, banks and surveyors to get much done on any of my numerous projects. The Volvo is suffering.

However, after the fun and games with the left hand part of the suspension (King Pin etc) I decided I'd try and see how just cleaning and painting the right hand side would go. There's nothing wrong with the king pin on the right hand side so I thought I'd save a bit of time and money by not going full on anal and just replace it "cos I'm already there".



Getting the grease and dirt off was pretty time intensive. Gaps are too small for most rotary wire brushes (be it on an angle grinder or in a drill). I didn't fancy dunking the whole assembly in the parts cleaner because removal of solvents from grease tends not to be as straightforward as you might hope.



So a slow process was adopted (as therapy for having to deal with middle men - all very well and good middle men but I prefer to deal with people who actually do stuff!)



After rust treatment I got it to a stage of having a first coat of Eastwood Rust Encapsulator today. Tomorrow I'll be checking to see if it will stick.
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Old Apr 10th, 2019, 14:49   #647
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Default Busy busy with housing requirements...

...only had a few nano seconds to get on with a bit of welding that should have been done long before now.

It is getting close to be warm enough for paint again (!)



(Seem to be having trouble adding more pictures - I'll try again some other time)
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File Type: jpg 1961 Volvo pv544 front lh wing repairs and derusting2.JPG (134.9 KB, 67 views)
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Old Apr 18th, 2019, 13:07   #648
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Default Nothing wrong with the site...

...everything wrong with me!

I forgot to resize the pictures so they wouldn't upload (!)



Back to a bit of de-rusting and welding on the front left hand wing. If I could have found a decent metal replacement for reasonable cash I would have considered it



It is pretty ropy bit of mush in several places



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Old Apr 18th, 2019, 13:37   #649
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Nice job. Looks like you have a few more similar "inserts" to do but the price of a decent wing means that if you can do repairs to that standard you will be saving yourself quite a lot of money. In fact, buying a few similar wings and repairing them could make you money.
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Old Apr 19th, 2019, 04:15   #650
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Nice job. Looks like you have a few more similar "inserts" to do but the price of a decent wing means that if you can do repairs to that standard you will be saving yourself quite a lot of money. In fact, buying a few similar wings and repairing them could make you money.
I'm not sure if there's a market for repaired stuff

It is pretty time intensive and fairly consumable intensive too. Despite my best efforts there always seems to be a bit of old bitumen somewhere that catches on fire and messes up my TIG electrodes. I spend a lot of time re-grinding and cleaning weld areas...

...here's making an oval hole for the indicator slightly less oval









All of these repairs are only made to a "will need a smidge of filler" standard. I haven't got the patience to make them really good.
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