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I've not updated this in a while, as progress has been slow thanks to the very cold weather.
So with the lower hinge repaired I wanted to test fit the door just to make sure the gaps were OK before going further. I made an extra reinforcing bracket under the hinge just to make sure. https://wolfnomad.files.wordpress.co...e_55.jpg&w=900 Access to the top hinge is basically impossible with the dash in place so I pulled it out which was surprisingly straightforward. Then continued to strip the rest of the interior. https://wolfnomad.files.wordpress.co...8815519356.jpg https://wolfnomad.files.wordpress.co...8815519415.jpg With a bit of help and a lot of adjusting to the hinge and striker and adding some shims to the hinge, the door was closing nicely and the door gaps seemed pretty good. https://wolfnomad.files.wordpress.co...9458.jpg&w=900 I then celebrated by taking the door right back off again. I marked the hinge positions first though. https://wolfnomad.files.wordpress.co...8815519535.jpg Rather than finish off and close up the A-pillar I thought I would start dealing with the sills, floor and outrigger as the access to them would be better from above while it's all open. Every job here is dependent on another. The outer sill attaches to the rotten inner sill, which is attached to the outrigger, which is attached to the floor. The outrigger is also held on by the transmission mount, and the floor and outrigger are also very near the fuel lines which I don't want to be cutting and welding near. So before any further repairs take place it's time to start stripping things off the car. Fuel tank off. https://wolfnomad.files.wordpress.co..._resize_90.jpg Pump and lines off. https://wolfnomad.files.wordpress.co...e_79.jpg&w=900 https://wolfnomad.files.wordpress.co..._resize_71.jpg With the explosive bits out of the way it's time to take stock of what needs done. The part on the sill where everything meets. https://wolfnomad.files.wordpress.co..._resize_45.jpg The floor above that. https://wolfnomad.files.wordpress.co...2721.jpg&w=900 And with some prodding. https://wolfnomad.files.wordpress.co..._resize_45.jpg The other end of the outrigger is also bad. https://wolfnomad.files.wordpress.co..._resize_95.jpg In general the floor needs patching. https://wolfnomad.files.wordpress.co...e_31.jpg&w=900 Thought I best build myself a garage! https://wolfnomad.files.wordpress.co...5542.jpg&w=900 |
Excellent work there, thanks for posting all the photos.
Since you have the dash apart already and are therefore most of the way, whilst you’re there I suggest you pull the heater box out and clean the fan and lubricate it’s bearings- you could replace it, but if it’s working well there’s no particular need to. It’s also worth flushing the heater matrix- I left mine overnight full of anti limescale stuff which shifted a lot of gunk from within it, alternatively if you know someone with an ultra-sonic tank that will work well too. Cheers |
Your doing a fantastic job on it. Enjoy seeing you save the Volvo:thumbs_up: I have never tried welding and don't have access to power where I live. My 240 Outrigger was the same and got welded for £50.
Your job is so much better. Had it re-welded 2 years later as rusted through on welds! Sold car around 2 years ago. Now have a 1996 940. James. |
Fantastic - you are a braver man than I am Gunga Din.
That is a marvellous refurbishment job, well done, I’m really looking forward to seeing the finished car. Alan |
Wow! This is incredible.
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Chapeau! to Juular for doing all this in the colder conditions of Northern Britain as well. Alan |
More bits repaired.
Inner and outer sill finished at the front. https://wolfnomad.files.wordpress.co...8433444630.jpg It may look a bit tatty or ragged but everything will be ground flush and tidy. Important drain hole kept in place. https://wolfnomad.files.wordpress.co...8433444635.jpg https://wolfnomad.files.wordpress.co...4334446314.jpg Passenger floor finished off. https://wolfnomad.files.wordpress.co...8433444636.jpg https://wolfnomad.files.wordpress.co...8433444637.jpg Which allows me to fit the home made outrigger. https://wolfnomad.files.wordpress.co...8433444638.jpg Plug welded from above. https://wolfnomad.files.wordpress.co...8433444639.jpg Fits millimetre perfect, very happy. https://wolfnomad.files.wordpress.co...4334446311.jpg https://wolfnomad.files.wordpress.co...4334446310.jpg Coat of zinc. It will all get cavity wax and a final coat of something durable. https://wolfnomad.files.wordpress.co...4334446318.jpg The passenger floor is now finished and totally sound. Just needs paint and soundproofing etc. https://wolfnomad.files.wordpress.co...4334446317.jpg Next job.. dealing with the rot at the outer sill/ step area and joining it all up with the A pillar. |
Fabulous - well done.
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What Alan said! ^^^^^ :thumbs_up:
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