Sunday, August 16, 2015

Engine - Volvo T6 Hybridz: Part IV

New tools acquired so off with the head!

Still need a counter hold tool to keep the crank shaft from rotating when taking the damper and pulleys off, but that I can whip up next weekend when welding continues.

This side is cleaned up and only one sensor remains... Did not have a large enough wrench or socket so I will need to get that off before parts washer.

Friday, August 14, 2015

Engine - Volvo T6 Hybridz: Part III

The dismantling has advanced a bit, but screeched to a halt as the tools did not endure the torture.

Onwards with the pictures!

Monday, August 10, 2015

Engine - Volvo T6 Hybridz: Part II

New motor has arrived and dismantling has started.

Slight change in venue, but at least the garage is warm in winter and also really close to our home. No need to drive 1.5 hours to the garage to tinker with the motor.

Motor in question is a Volvo B6284T that came from a Volvo S80 MY. 2003. The car was driven only 115k kilometres (according to the seller) so here is to hoping that everything is in order and checks out!

I'm not going to ramble very much this time and I will just dump the pictures as this is reasonably straight forward deal.

On to the pictures:

Sunday, August 2, 2015

Fabrication - Engine: Part I and Patch Panels: Part II ½

This update is going to be a bit mixed due to work being done with new driveline, patch panels and a little bit of garage alterations.

So "lets get to work", as Tom says on his videos!

First up, the driveline components and engine along with some garage "remodelling":

I spent a weekend at the garage and first thing I did was to go and pick up some parts. So I drove on Friday to the garage and left to get parts on Saturday morning and drove over 400 kilometres total on that day!

First stop was in Tampere to pick up this; a busted aw30-43.

Sunday, July 19, 2015

Supporting tasks for the project - Garage III

Saturday did not go as planned with the project... My goal was to wake up early, drive to the garage (1 hour drive) and make some new patch panels. Almost all of this happened, but not the patch panels!

Sometime last week, I had an epiphany: Why don't I use my now vacant Ikea Jerker as a welding table and make a "machining center" to the garage? I thought that I would do that and still have time for some patch panel fabrication, but as always I got a bit carried away!

On to the pictorial review of the work day!

Some readers (if I have any) may remember, that the garage looked something like this... the tool carts were easily available and there was ample table space.
Unfortunately there was no room for a column drill and grinder and the space below the other pallet shelf was full of "stuff".

Sunday, July 12, 2015

Fabrication - Patch panels: Part II

Summer holiday has been dealt with and some progress has been made!

I have made few patch panels and now there is more new sheet metal in the left front fender well than old metal and even the lower part of the suspension tower got rebuilt.

Also my friend shot blasted some parts for me again. Should be easier to weld new coil-over tubes to the hub assemblies and paint the parts when the time comes. Might be that my friend will have to shot blast them again before paint if rust gets to the parts.

Let the picture avalanche commence!

Suspension parts loaded in a container and going to my friends house to be shot blasted along with some "bribes" for his hard work.

Saturday, May 30, 2015

Fabrication - Patch panels: Part I

It has been a bit quiet on the "Eastern front", but now there has finally been some progress with the project.

During the last two weekends I have cut the car even more, but I have even made some new panels to compensate!

Without further ado, lets get the show going...

The form of the first patch panel taped and outlined with a marker.

Monday, April 6, 2015

Fabrication - Frame rails: Part I

During the Easter I toiled away with the drivers side frame rails.

Material used is 60x40x3 mm RHS profile and it should be more than adequate for this task... might be even a slight overkill!
I managed to spend two days building one lousy frame rail, but I hope that the next one will happen a bit faster.

At least now I have a sample frame rail, as now I just had to guess/measure what should be the correct angles and lengths.

Onwards to the pictures... First the Mark I and also what I had to cut away during this stage:

Area marked that needs to be cut away... Among other areas.

Sunday, March 8, 2015

Fabrication - Flooring: Part II

The cutting has continued during few previous weekends.

I have cut off half of the drivers inside rocker panel and unearthed some "vintage" quality rust. Almost all of the original sheet metal had vanished and only the more resent repairs remained.

Wednesday, February 25, 2015

Fabrication - Flooring: Part I

Fabrication has started!

Well not really, I just have made the first cuts and taken the drivers floor off.

Here is the starting point for the removal process. Damage is quite extensive and the previous repairs have been done very poorly. Thus the whole floor has to go!

Thursday, February 19, 2015

Tool sourcing - Tools for repairs

No new developments apart from few "part sourcing" trips.

As the day comes nearer when I start the real restoration of the car, I noticed that some tools will be needed... Well they are not necessary, but I would like to think that they will help my job and I'm a "gear nut". This means that I think that: "the better the gear, the easier the work".
Also because I'm a full fledged novice in sheet metal work, I will need all the help I can get.

First additions to the tooling of the garage are needed when cutting the floors and frame rails off the car.

These I bought from Finland, as I will need them come the next weekend. At least I hope so!

Monday, February 16, 2015

Fabrication - Rotisserie/Sled is finished

During the last weekend I finally have "completed" the rotisserie or as I have started to refer to it: "the Sled". Also I managed to lift Zeta on top of it and make "adapters" on which Zeta rests on the Sled.
This only took few months to achieve so the project is on track... I wish!

The outcome of this toiling away in the garage.
It doesn't look much, but it's sturdy, it's designed for this car and I have made it so it must be very good. Jokes aside, the Sled is rather sturdy and the spacing between the longer sides is 130 cm from center to center. This means that the seam on the car runs nicely in the center of the beams as one can see from the following pictures... sort of.

Wednesday, February 4, 2015

Fabrication - Rotisserie II

After the last update I have made the feet for the rotisserie, cleaned up the garage and made an auxiliary tank for the air-system. Also a lot of time has passed since last update!

Here is a start for my auxiliary tank for the air-system (all installed now, but no picture)
This way the capacity is doubled to 100 litres and the compressor need not to run as frequent as before when using air tools. These tanks will be connected with a hose and therefore will run in parallel. After the tear-down, I also have parts for the running compressor as the units are identical.