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Holey water pipes batman! 16 April 2010

Posted by elfringham in volvo.
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I gave up on getting a later exhaust bracket as no one wanted to sell me one. Instead I just bent my original bracket back how it was and refitted it. I removed the freeze plug that was not fitted properly. It cracked very easily and so must have been rotten with rust. The replacement went home so easily that I decided to do the other three as well, they were all quite crusty as well so I was glad that I decided to remove them. Now I have one new fitted freeze plug and three empty holes waiting to have theirs fitted. I am going to try and flush out some of the crud that fell off the freeze plugs as they were removed before I fit the new ones though.

It looks like the Motorola alternator I bought 2nd hand late last year will actually fit OK with just a shorter bolt, no need for a spacer. At least that’s what the measurements I took tonight suggest. So now I have a plan to move forward with which is a big relief. Apart from actually fitting it I also need to source the correct voltage regulator. There are differing opinions about whether or not a Bosch regulator will work with a Motorola alternator but I think I’d like to have it correct.

Unfortunately while cleaning up the water pipe that goes from the head to the oil cooler, I found that it had a rust hole in it. As these are NLA new I asked Brookhouse Volvo to get me a good used one. Apparently they went through 5 pipes before they found me a good one.

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Tin worm 21 February 2010

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I pulled the bracket off the gearbox that is for supporting the exhaust, it had obviously been crudely bent. I straightened it up, repainted it and then refitted it. It is now orientated so that I can attach a bracket to the Simonz exhaust which will secure to this bracket. The only problem with it is that now it interferes with the cross member to support the gear box which will no longer fit in place. After some more intensive research I think the bracket was actually correct as it was, before I ‘straightened’ it. So now I need to source a bracket for a later car that should work for me. While I was under the car pondering on the bracket I removed some of the flaky underseal from the main frame rail that runs from the cross member that is under the drivers feet and on up the firewall into the engine bay. This revealed the true sorry state of it all, a patchwork of poorly done repairs that are all now rotten with tin worm. This will have to be sorted before the car can be driven again. I did refit the oil cooler with a new O ring to seal against the block but I seem to have lost the nut to secure it in place. For the moment I have another in its place, but it is too thick to be a permanent replacement. I also noticed a leak from where the smaller pipe enters the water pump, fortunately this should be easy to fix with the manifold currently removed and the coolant drained.

Popped right off 12 December 2009

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25th May 2008

I removed the rubber bump stops from the top spring mounts by the simple expedient of simply pushing on them with a foot, they popped right off. I then cut the securing bolt off with the angle grinder. I bought a range of brushes for my drill and grinder to tackle the rust and have been doing so on and off, even so the spring mounts are not easy to do at all. It occured to me today that I could simply (!) remove the exhaust for the moment as with the axle out the whole system can be removed as one piece without the need to spearate the constituent parts which woould be nigh on impossible due to age and rust issues. So I started trying to undo the nuts joining the manifold to the down pipe. I soon realised that this is not an easy job at all. I decided to remove the generator to get more access. I could either remove the bracket from the block or remove the generator from the bracket. The first way seemed easiest but when I undid one of the bolts I started to get a coolant leak so I then moved to the second method. I now had enough room to get some decent leverage on the two front nuts and so I promptly sheered them both off. The rear nut has been rounded off and I think is going to need a nut splitter to remove. It looks like there is some welding to be done on the chassis member here at the front despite (because of?) it being a patchwork of previous repairs.

Heat gun 12 December 2009

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13th April 2008

Lots more rust and underseal flakes have gone down my arms and neck over the past month. I have now removed the majority of the underseal from the axle area, that is all that I could chip off with a putty knife with a bit of help from a heat gun now and then. I made a start on removing the rust with an angle grinder fitted with a cup shaped wire brush. I am going to need to buy some more different shaped brushes for this as there are a lot of tricky areas that I can’t reach at the moment. Most of the rust is just light surface rust but there are some areas such as the top spring mounts that are quite heavily corroded and of course they are a complicated shape and are going to be the hardest to remove the rust from. Nothing seems to need welding up though which is good news.

Rust flakes 12 December 2009

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14th March 2008

Since my last update of these pages I have removed the old axle and painted the new axle and lower spring mounting cups. I have bought a set of new springs which will be fitted on reassembly. I also started to attack the rusty top spring mounts. While under the car I could not help but notice all the rusty bits that have crept under the under seal. So while the axle is out of the way I resolved to tackle that as well, at least the bit of it that will be difficult to reach once the axle is refitted. So far all I have managed to do though is to shower myself in rust flakes that went down my arms and neck. This is going to be quite a job, I just hope I can get it done before next winter rolls around again.

Out of line 29 November 2009

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5th November 2007

I drove the car a bit more over the summer which was good although it still sounds a bit rough and I noticed noise coming from the drivetrain as well. I now have the car up on jack stands. The new impact wrench undid the pinion flange with no bother at all. When I removed the old oil seal I felt that the pinion had a bit too much movement in it which I thought might be the cause of the drivetrain noise. So I now have a spare rear axle on hand and I will see what the movement of the pinion is like on that one. I also intend to replace all the universal joints and centre bearing and carrier on the propshaft so that came out as well. I undid the big nut on the propshaft before removing it but I had to remove the starter and jam a screwdriver into the ring gear to do it. The centre bearing carrier was rotten and had torn through almost half way round. The rubbber gaiter protecting the sliding joint was missing and to cap it all the sliding joint had been put back together 90 degrees out of line which may have been the cause of the drivetrain noise. Some serious rust found in the front chassis members which may well need sorting before the next MOT. Maybe I’ll save up for a MIG welder.

Splashes 23 November 2009

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8th May 2006

Well it rained on Saturday but I did manage to get the car out for a short ride on Sunday. The fixed seats are great; I am no longer straining my neck to see over the front of the bonnet. More rust removed and replaced with splashes of grey primer. I am going to have to get a full respray done I think as I am realizing that all the paint is in fact beyond salvage. I am just a bit reluctant to do it yet as that will mean taking it off the road while I remove the exterior trim and lights, bumpers etc. There is plenty of evidence of a respray being done in the past and I think something went wrong with it. I may try and get it done over next winter.

Splotches 23 November 2009

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5th May 2006

I have not been able to do very much recently. I had another session of rust removal so there are more splotches of grey primer now. I also managed to uncover some body filler which maybe the sign of lurking horrors. I also have some new screws and nuts to hold the grill surround on with although that took some trial and error. The screws are stainless steel so I hope they will last a while. I’m hoping to be able to get out for a drive tomorrow.

Defeated, at least for the moment 23 November 2009

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10th April 2006

The seat support kits that I ordered from the states arrived on Friday and I tried to fit them on Sunday. Unfortunately they have defeated me so far. All the wires that attach to the side are the same length and as the seat narrows from the front to the back, they end up being too tight at the front and too loose at the back. I’m checking with the supplier to see if I’m doing something wrong or if my seats are unusual. In the meantime the seats are stuck by the radiator in the sitting room. I also removed the grill and surround in preparation for some rust removal and repainting. There is a patch there that had some generic white paint slapped on and it is showing rust coming through. Some more tools came up on eBay from an 1800 toolkit but they sold for ridiculous amounts of money.

Film 23 November 2009

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18th March 2006

I managed to find an excuse to take the car out for a little spin last weekend as well as today. I’ll have to get new front tyres soon as the ones on there are cracking a bit from age and sun I think. For the insurance to get agreed value cover I have to provide some photos taken on a 35mm camera as digital ones are not acceptable. So I bought some T-cut and today I removed the worst of the rust stains from the driver’s side where rusty water from the doors had left tracks on the paintwork. I also dug the hub caps out of the garage and put them on. Then I had to dig out my old SLR and put a film in it. I finished the whole film on the car so I could send it off for developing. Unfortunately as it is real film I can’t put the photos up here yet to show it in its present state. Most of the paintwork is still a mess, rust bubbles, chips and assorted marks and the bumpers are still rusty. Speaking of bumpers I got a set from eBay that are actually correct for the year. They need a fair amount of work to sort them out before fitting though as they are also pretty rusty and they had to use a gas torch to cut the bolts off to get them apart. I also bought a pair of door mirrors and fog lamps from eBay. I know I should finish off sorting out the paintwork and the engine before I do anything else but I’m a sucker for a bargain.