1966 Volvo Amazon engine transplant!

[Melody121]

Small update from this morning.
I've re fitted the steering box and column and replaced a split ball joint gaitor, there wasn't any play in the ball joint so I gave it a clean and re packed it with grease.

I'll keep plugging away

[Melody121]

Another small update.
I've been doing bits and bobs. I've had the inlet manifold flange made, I just need to buy some pipe and some silicone hose so I can finish it.


Yesterday I also repaired all the studs on the rear hubs, you may remember I replaced the front ones. It was a ballache and I'd recently bought a tap and die set as I'd messed up the threads on one of the steering joints (I couldn't be bothered to replace it). So as the rear hubs apparently need a special puller to get them off and I don't want jobs to take longer than they have to, I had a go at cutting new threads in them instead. A couple were really bad and they're not like new but I can now torque the wheels up which is a good safety feature

This was the worst stud;


You can see which one I've done already;


Then this is finished complete with copper grease to stop them drying out again and repeating the process of stripping themselves!


I can't recommend a tap and die set more, It has saved me so much time and money already and I've only used it twice

Then this morning I've been measuring up for the new bulkhead. I've got some 1" by 1" box section to make the frame from then it'll get plated either side to make a nice strong double skinned bulkhead.

Here is my diagram, I hope to hell I'm good at measuring. The plan is to make a kit of parts tomorrow with my friend and tack it together, then my other half will tack it into the car on Sunday.

This is looking down on the two cross pieces, the centre part is to clear the back of the engine and bellhousing.


From this the transmission tunnel should be pretty easy as it won't have to narrow too much coming back through the car.

Does anyone know where I can get some of that dense foam stuff, the kind that is hard but it's foam so its easy to cut in to any shape? I'd like a cylindrical transmission tunnel so I thought I might make a rectangle one, as I don't have an english wheel, then make a round foam piece for on top which I could also insert cubby holes into for storage.

[Underdrive]

Is that 'weld' round the bearing housing in the centre of the hub? If so, that combined with the unavoidable compromise of strength in the stud threads looks like disaster waiting to happen. Hope I'm wrong.

[nonhog]

if I'm following correctly, you do want a "cone" shaped tunnel?
here is a link to a good idea. http://www.jalopyjournal.com/forum/t.../#post-6183578

Also heard of rolling a small wheel and a large wheel linked together and rolling them to get your cone shape w/o doing the math. (my preference) Make each wheel the same size as your ends of the cone shape. May take a bit of trial and error but you shouldn't need a English wheel. Maybe your knee and a section of pipe to bend around.

[Derek UK]

If you need a rounded off tunnel you could bend it round an oxy bottle or even a local telegraph pole.

As for the weld on the drum, that does look very dubious. The nut looks odd too as it normally tightens down on a washer and I can't see the washer........

[Melody121]

Some good ideas for a cone. Thanks

I feel really dumb for not noticing the hub! That definitely needs a second look! I'll get my other half to have a closer look in the next few days. If thats weld thats a hell of a bodge and it definitely wants a washer too.

[nonhog]

Found the link but you have to sign up to view anything there,
"Allmetalshaping"

picture tells the story.

[Melody121]

Yesterday my friend and I turned my diagram in to these!



They actually fit too! I was so sure they would be miles out!

And seeing as they didn't take too long, we made a gearbox mount too . It's not quite finished, it will be solid mounted to the gearbox with the plate that's seperate in the photo, and the engine mounts will bolt to the floor with reaction plates.
We ran out of time to test fit it and figure out where the third plate should sit.

I'm really chuffed we got this much done though yay

[old fart]

You'd be better off bolting a steel mount to the floor and having the rubber mounting between that and the gearbox,otherwise you've got the gearbox hanging on the 2 rubbers,and I can't see those holding up for long,and if they do go there's nothing for the gearbox to drop onto.

[Melody121]

That's a good point and I'm aware it might fail however it is a very light weight gearbox, the engine mounts and propshaft mount will be taking some of the strain so it should be ok. It was just the simplest way to make the mount with what i had to hand. I can always make another if it's no good