1961 Volvo PV544 in Holland

[Army]

...but I'm only ready to show the first coat of the engine paint



The coverage is kind of OK but it will need at least another two coats before I am happy.

This first coat is a bit darker than it will be because the iron is still shining through (!)

[Army]

Originally Posted by Army

I got some more pictures (eventually I´ll get there you see)



The last few numbers are indeed 4.10 so I reckon the chance is good that that´s the final drive ratio.

However - outside on the casting of the axle I have found some patent numbers and these two =>



031480

And a 27 =>



Looking at the vp automotive site for spares (I want new bearings) before I bother trying to adjust the backlash and pinion and crown wheel positions it seems like the 27 might mean M27...

...thing is I get the impression that M27 wasn´t produced with the 4.10 final drive ratio.

It could be that I have a bitsa situation as there is evidence of the orange rust preservative paint that I assume was applied in the 1980s (found on other parts of the car too)

Whilst I am in the process of banging off another email to vp automotive to ask them if someone here can also help that would be great as it is always nice to have additional confirmation.

^^^^^^^ Can anyone shed light on this differential question please? ^^^^^^^^^^^^

[Army]

I'm slowly piecing this together. I (now) think the M27 rear axle came with the following final drive ratios

4.55
4.3
4.1
3.9

According to Skandix =>

Spicer type M27: The axle tubes have an outer diameter of 57mm, type M30 has 63,5 mm.

I have no idea if the M27 and M30 axles are of the same width. (Brake backing plate to brake backing plate)

The M27 is described in the service manual as "semi floating" so that must mean the Panhard rod attachment needs to be there with the coil springs - I assume this differentiates the M27 from the M23 which I guess is the cart horse leaf sprung version fitted to the Duett. Thing is, I can't find a picture of a M30 to see if the differences between that and the others.

[Army]

Here are some rough calculations of maximum wheel speeds (all theoretical no real world losses included) for a PV544



The overdrive ratio in a M41 makes one heck of a difference - it is a serious step - which I guess is why they are known to cause a B18 engine to struggle somewhat in a PV

[Army]

...the engine is slowly getting to look a bit less patchy.





I'm bound to have missed some bits so when it is dry I will tip it upside down / alarmingly on its side so I can get the sump removed and see if more of the red is needed.

[Army]

...before I run out of argon (again)

The lip for the boot seal is a little bit moth eaten on the lower edge



Shame really but I have seen pictures of worse (!)

Using a bit of 1mm thick Zincor (coating removed before welding remember) it was an easy job just to tack an extra wide piece in place from the "middle side" of the car towards the outer edge bending a bit has I went





(Low amps on the TIG welder and the magnetic welding clamp isn't a great combination but it'll do)


Tacked =>



Bit too much splodge but I wanted to make sure I had enough penetration - I don't want it cracking off when something heavy gets loaded into the boot and bumps its way in



Splodge ground / B&D powerfiled away



Using a bit of masking tape as a guide for where to cut away the excess of the new metal =>



(The idea behind the extra large bit of metal is threefold

1: The extra metal helps with heat dissipation during welding
2: The extra metal makes it bigger and easier to hold with welding gloves (!)
3: Trimming the extra metal at the end of the welding process means you don't have to bother / worry about exact pieces not quite fitting as well as you cut them because they moved due to shrinkage whilst welding)

Cutting with snips (note difference between LH and RH snips!) on the whole gives a nicer edge than a cutting wheel.

[Christerart]

Great thread!..

Brings back memories - I had a friend who had one of these and I vividly remember him driving the s%^t out of it.

Great cars for the time (and still)!

Looking forward to more..

[Army]

Originally Posted by Christerart

Great thread!..

Brings back memories - I had a friend who had one of these and I vividly remember him driving the s%^t out of it.

Great cars for the time (and still)!

Looking forward to more..

Thanks

This Volvo is certainly throwing up a lot less problems than the shed of a Series 2a Land Rover I've also got on the go...

...though some days you do wish you'd never started with some things!

Good example was the sump

(I was really tempted to buy a new one and be done)



^^^^^^^It was in a very grotty state^^^^^^

I wire brushed and wire brushed and wire brushed...



...and still it wouldn't come clean with out several coats of the more expensive engine cleaner.

After more wire brushing (all angle grinder + wire brush attachment - I'd still be doing it now if I'd tried to do it by hand) it seemed like the oil was finally separating from the rust.



^^^^

Stripping disc got rid of most of it

Then I treated with a rust killer and finally reached the stage where I can try out that can of VHT barrel paint I bought



I'm hoping it will be gucci gucci after all that

[Army]

...that were cut into the under back seat step for the seat belt inertia reels.

This is how the holes looked =>



(All a bit gash really - As said before I'm not leaving it like that)

Starting with a bit of Zincor



Bending into a stepped Z form



Trimming to size



Cutting out bits to make 90 degree bends



(Top tip) To help with the bending it is best to cut away a circle at the root of the bends so the sides don't distort / make the bends wander



Cutting the holes straight in the body (they are also the same size on both sides of the car now! 10cm wide X 12 cm high)



Trial fit =>



What the boxes look like when done =>





The inner sides of the boxes have been painted (drying as I type). I plan to use a combination of riv-nuts if the pliers will fit and spot welds to fix these boxes in place.

This isn't quite done yet - I also need to make some edge trim pieces (these will be screwed into place with self tapping screws) that will hold the under seat trim piece in place

To be continued

[kishor]

Originally Posted by old fart

'Tis a '64, I know that, cos it's mine!

Your PV is extremely wonderful

Ta
Kassie