Malaysian Police Volvo C304 (4x4) Restore

[cicak]

ok sorry about that all fixed

otak rosak

[cicak]

23 February 2014

Ok time for a wrap up of the design and the intention.

1. Restore the truck to a factory new level - rust removal etc.
2. Add DAKAR truck look.
3. Add a Diesel Engine (14B-T) and make it JUNGLE and long distance touring capable. Added HIGH Ratio Crown and pinions. Still looking for a T230 Xfer case and RR gearing
4. Add Rollcages (roofracks for purposes of registration.
5. Remove rear doors and seal up
6. Extend the rear cabin roof line back up 8"
7. Cockpit add gauges (14 including water temp, boost, ET, 12 and 24v gauges, air pressure, vaccume gaugeand stereo and airconditioning and harness seatbelts and seats power steering and rebuild the cabinn to remove the rust.
8. Add console for the extending all the controls to be in range of the arms when strapped into the harness
9. Add 12v and 24v 12v for lights and rear cabin lighting.
10. Relocate radiator, air cond, intercooler, air filter, exhaust and recovery gear all to a middle 18" utilities area. All of them out of water and mud randge.
11. Toss off the rear cabin (440kg +30kg) and replace with a new gullwing cabin with alloy skinning and 2 rolling out slides and hammock hooks etc and also optional drop in sides (remove the 4 doors first) and 6 seats and harnesses
12. New fuel tank of 187liters.
13. two spare tires mounted at rear of truck
14. Add LED lights front and sides etc
15. Add a WARN 12,000 rear mounted winch and a T-MAX 18,500lb winch to sit beside the factory PTO winch
16. Brake Disc conversion been done
17. Rewire the complete truck
18. New Maxxis 35" Bighorm 762
19. GPS Speedo (still finding out about VDO speedo connected to a GPS sender)
20. Reverse camera
21. Fridges etc connected
22. JUngle camping gear not camper setup its too heavy for our environment.

[cicak]

5 March 2014

yes there is no updates.

No progress for past 6 weeks. Waiting for the workshops new employee to start (last Thursday) to finish the welding up of the water tank and the rear seat frames and the side rails then the rear frame can be removed, sandblasted and painted so the alloy panels can be attached finally.

I have had delivered the new VDO speedo which is driven by a GPS and a VDO tacho (max revs 4000 ) it will sit with the Digital Tiny Tach. I also picked up a few bits for the VHF radio triple ariel switch and cables so they can be installed when the overhead console is made.

Speedo


Speedo cable - GPS


Tacho


The cat ("Trouble") is not impressed with the Volvo progress and is lying on the keyboard in protest lol.


I await the next update from the workshop

[cicak]

7 March 2014

Got a call from Brett - how many type of seat belts you sending me. So far I have 3 types - oops. Looks like the last set I sent up were 3 point and he does not want them in the rear so he selected a SPARCO 4 point which I had spare. Now I have to go buy 5 more oops at a cost of $150usd each lol. So the rear seat frames are now finished and all the harness mount points set for SPARCO harnesses only. and he received the TAcho and Speedo. The TACHO looks so good im going to put one in both my other DIESEL trucks.

Still no pics I will push him for pics next week maybe by end of next week the rear frame will be ready for sand blasting and painting.

[cicak]

14 March 2014

The steering column is being done this week they have not worked on the Volvo Monday-Wednesday

They are fitting it and then fitting a alloy casing around it and the power steering part.

I await pictures of this.

More pre-occupied with what has happened to MH370 this week.

21 March 2014

Quick call to the workshop progress.

• Rear Floor finished
• Seat belt connections all done for the 6 rear passenger bucket seats.
• 100litre water tank contstruction started today.
• Air intake/snorkle being built and is 1/2 completed once this and the water tank completed it will be sandblasted (late next week)
• Wiring clips all added this week ready for the wiring loom to be laid through the truck next week
• INstrument panels and overhead console will be laser cut and weleded up in the coming 1-2 weeks
• Wiper motors and wiper arm lengths yet to be worked out
• Steering column still being worked on.

Pictures to be sent to me next week when they reinstall the seats to drill the holes into the floor to mount the seat frame retaining bolts.

New Maxxis 37" Trepadors ordered for it collection in April

[cicak]

26 March 2014

Got some pictures today from someone who was collecting the rims from the workshop for me.

Looks like its very close to sandblasting and painting time the wiring is being laid out.

Wires sticking out of the headlights as the loom gets laid.





Workers working on the wiring


Stripped down no seat belts nothing left inside.

[cicak]

28 March 2014

Got these pics sent to me while I was preparing for a 3 day 4x4 trip so no time to upload.

Wiring loom layout is about 70% complete

Water tank (80 liters) is complete.

Wiring loom down through the engine bay


Water tank in place


Rear underfloor wiring loom



Rear roof wiring loom


Water tank

[cicak]

5 April 2014

Quick visit took another Volvo owner up also to see the restoration process - yup he fell in love with it and wants the same lol.

Power steering mounted on top right of the underneath.


The new console ready for the Tacho and Speedo only rest of the gauges will be at head height.


Side view of the inside doors off ready to be painted


The central locking locks in place for the rear.


Skeleton side view


Skeleton view from the top wiring loom visible


Wiring diagram is now complicated


3-6 months for completion I'm told.

[CRUZAAMAD]

Any updates ?

This would be the only reason id ever leave my country to do this sort of stuff.

a real offroad adventure

when you get it all up and running
take some videos of your trips and upload to youtube

im sure a few here would like to see the trails and stuff you get up too..

[cicak]

Any updates ?

This would be the only reason id ever leave my country to do this sort of stuff.

a real offroad adventure

when you get it all up and running
take some videos of your trips and upload to youtube

im sure a few here would like to see the trails and stuff you get up too..

You can come over here and do an adventure with us lol.

I have regular customers from OZ they just went back Friday and now want a 7 day adventure next year.

[cicak]

Wahooo progress - Builder has stated next friday will be sent off for sandblasting and painting so I have 1 week to sort out the final colour scheme.

The steering column is getting final shroud and mount finished this week.

new Window wipers all fitted


Pics tomorrow - I hope with new sneakers on also.

It will probably not make the Orphanage trip on 13-16 September damn but I estimate end of september it will be finished.

[cicak]

1 August 2014

Progress pics of the Volvo power steering setup.

New steering wheel grafted in and power steering unit grafted into the steering shaft by an engineering shop.













My new assistants

"Fury"


"Fury" the 12 week old kitten thanks to my employees for giving it to us and being "hugged" by "Cheshire" the 11month old wild kitten yes the measuring tape stealing cat.

[cicak]

3 September 2014

Ok so have a few spare days after breaking down in the jungle about 20 days ago and had to wait 2 days for parts and got back to work on the wednesday so immediately went on 2 weeks compulsory leave due to our leave policy.

Today popped up to work on the Volvo before its stripped.

Cut out the 12mm round bar for the tie down points and some loops have 3-4 to cut out tomorrow and then we will weld them in. 13 done 3 to go in the morning.

Last item to do is to fit the step release whichis inside the cabin where yellow line is where the internal step release will be placed tomorrow.


Details - side bars all fitted now can remove panels and have it 1/2 opened at the rear or completely paneled up. Front two uprights on the bull bar fitted. New rollcage rules might make my external cage legal here now


Tool box in the front grill is visible. Some holes to fill the painter will advise how to fill weld or braise or hole sealant.


Top view looks cool only exhaust exit bit to do.


Seats all sitting in place nothing to do except bolt down.





37" Trepadors are going to cause an issue we need to fit them tomorrow and look at the offset they are going to touch the front guards.

KInda happy - more reporting later on Friday.

[cicak]

4 September 2014

Finished up the top hatch locking tabs. Welded in the tie downs points and finished the fold down steps locking pins.

Then it was the time for the strip. All the bolts are undone 8 to go in the morning to lift the rear out.

The doors have an internal rust issue to be dealt with






Front cage off and the wiring loom stripped and labelled.


All the doors frames etc removed


Side view






Tomorrow the LIFT off.

[cicak]

5 September 2014

Continuing the stripping today all stripped and all touchup welding done and then we discovered that 2 braces had been missed on the rear body and the 6 contact points with the cabin needed more work.


















Damn fit the cage back on and redo the welds took us an hour to fit it properly to effect the repair.






Time for home to repair the busted CV joint on the mighty troopy they had one set of welds left to do.


Monday finish the remaining touchups on the body

Tuesday off to the paint shop for the sandblasting and undercoat.

[cicak]

For those who like my stories this is the 22-26 August

Here is an adventure and charity work all in one. I got home 2 days late from this one. The picstorial im still doing.

[video]http://youtu.be/NTF7qnxLIyI[/video]

[youtube]NTF7qnxLIyI[/youtube]

http://youtu.be/NTF7qnxLIyI

Roll on the Volvo being finished. We are going back on 5th October to put what will be our standard turnkey generator holding bench in which is currently being built and galvanised.

[cicak]

11 December 2014

Quick visit to collect my new boat trailer and then check on the Volvo at the same time.

Progress has been made.

Chassis has been painted black
Rear cabin frame has been sandblasted and undercoated
Front Cabin is to be split and sent to a sandblaster who uses softer blasting material not steel pellets like was used for the Rear Frame.

Chassis painted - sorry about the pellet etc on top but no time to move it.


The Cabin with more touchup brazing done.


THe rear cabin frame all undercoated


Wiring loom is all tubes up ready to install

Next is top coat for frame and cabin after blasting this week, I have to pass the paint code to paint shop also asap.

2 months they say drive away from workshop.

Heart is ok now sort of. On Cardio's orders no more whitewater activities. No more 4x4 Competition driving or wenching, no more endurance kayaking or cycling. Tablets keeping the heart stable.

[cicak]

25 Feb 2015

Quick update

After the efforts required for the massive flood relief and now subsequent food drops and the latest supplying clean water I have not had much time to look at the Volvo.

I heard it was sandblasted and then in paint I sent them the paint code for RESCUE ORANGE as I have offered the Volvo to be a main squad vehicle for the Malaysian Emergency Disaster Rescue Force - Elite 4x4 Search & Rescue Squad hence it now has to be orange.

I will get an update this week and post some pics of the rescue stuff and a link to our rescue story from an outsider.

[BJ73]

Totally awesome thread mate, in fact one of my favorites across all of the forums I visit.

Earlier on you were saying you take customers on tours, do you still do this ? There's something captivating about those Rainforest Jungles.

[cicak]

Hi sorry yes I do still take people to the jungle

have a big corporate trip coming up

sorry been resting a lot to get the heart fixed up properly now back on my feet.

[CRUZAAMAD]

You all ok buddy ?

keep us posted on your recovery
and your build thread as well

[cicak]

after a small cash crisis it was supposed to be painted last week (while I was away fishing) but the paint shop cried saying the paint code I gave them was wrong and could not get to the internet URL I gave them for the colour code SOB so I could go up for the next 5 days this week and work on reassembly. So now its being painted this week instead I hope.


I need the Volvo finished for the upcoming monsoon season as the LOGGING has intensified not reduced and the chances of bigger flooding is even higher this year.

Heart fine stopped taking the tablets no more irregular heartbeat.

[cicak]

11 Sept 2015

Latest update its been undercoated and the top coat is due to be done next week.



More updates when I get a PAinted PIC.

[cicak]

12/12/2015

Well the builder run me Thursday come up and see me I'm sick of the painters quotes.

So Saturday took the trusty Isuzu and attached the boat and trailer, had a swiush breakfast and then headed to the workshop 190K away. Fark me holiday traffic and 3.5 hours later.

Reversed the trailer in for the addidtion of rollers to combat the issues on steep boat ramps and a dry pull out and to make it 3 feet shorter. No the dog is not the trailer tow dog. He is also still deciding whether to rebuild the new fuel tank/seat which has leaked again 3 weeks after the boat shop repaired it looks like the did mig welding and not tig on the fuel tank so its split - YIKES!



Then onto to the real purpose of the trip the Volvo.



The final requote they got was $4800 and oh we will do you a favor we will paint it in the workshop for you. 4800 just for the cabin and the roll cage its laughable. Its already undercoated etc.

So it was decided. In the workshop we will get our own painter and paint it in the same area they paint the trailer axles So sometime in the next 10 days it will be painted and assembled. The winches and all the chassis stuff will be attached in the next 10 days (Winches and wiring etc). I marked all the areas which need a little putty before the top coat is applied.

Before you ask the beast beside the Volvo is a 2WD 400HP Nissan V6 powered Landrover Alison gearbox etc and yes it goes. No its out of scope for this story line lol.


The Build has recommenced the target is before my birthday in March.

[cicak]

24/12/2015

Good news cabin split in two and removed from chassis again to do the touch up welding and putty work.

So next week almost ready for painting.

So merry XMAS to you all from me and my friend Mr Cheshire.

My little friend Cheshire happily sleeping on my chest. So go give your pets a hug for XMAS.


Honest it was me that made this mess it was the black cat at the door "Fury" is his name. Yes the mess was really made by Cheshire.


May all your offroad trips for 2016 be action packed. Laying out the practical course for charity group 4x4 driver training lol what they never saw lol.

[cicak]

2 Feb 2016

I rung for a progress report and got told none so I asked why he said no staff to do the body work. So being years since I prepped a body I volunteered to do my own vehicle.

Monday wa a pub holiday and they offered me the workshop for Sunday and they would help me Monday.

So Sunday morning 9am im 190k away from home at the workshop. I start had a quick look at the Cabin and did a quick plan of attack. All day I played with small amounts of body filler. By the end of the day the cabin wac starting to look close to being ready for paint. Original dents etc were left alone

The frame as Sunday morning



My companion while I did the top of the cabin was the workshop new guarddog the cazy happy 7month old mongrel


The rear panel is a bit of a mess but its been decided its original we leave it.


Filling the repair work from the patches added to the roof.


Oh yeah the pooch likes ICE as its over 34c here at present


Preparing the paint


Inside of the cabin top painted


We sat this here this morning ready to paint then we realised the sealant we added at lunchtime took 24 hours to cure our mistake for not picking it up yesterday


So after 2.5 days work of pure hard work in the heat I have made a lot of progress.
Early this evening we moved stuff around to enable the rear cage to be painted.


Rear cage 2/4 sanded tomorrow they can finish it and paint it


The doors are being taken apart a there is a small rust issue in the top/bottom join area.


3rd coat on the top of the cabin.


So next Monday Chinese new year to be spent in the workshop.

[cicak]

8 February 2016

Chinese new year Holidays

Arrived monday morning to the pleasant sight of the rear cage and all parts painted that I had left the week before.




Brett stuck the engine and gearbox on the forklift and then left for CNY lunch and said you can install and oh yeah learn to drive the forklift lol.

2 hours later I had it all installed but need new gearbox mount bushes.



Then started on the 18,500lb winch install. Success again took me about 2 hours plus searching and cleaning up parts areas to get stuff out.


9 February

Had assistance from the builder all day and we managed to get the cage installed and bolted down after installing the WARN 12,000lb winch and tightening the 18,00 bolts down correctly.




Then dinner time for both of us and we packed up at 5pm after getting the fuel tank reinstalled yet again and the gear change installed and bolted it. A whole pile of parts washed and a list of parts needed to buy.



10 February

Morning starts with washing the dusty parts and yeah playing with the puppy.


And the finl result is washed parts eventually and a half washed puppy


Lunchtime and I have the radiator and the intercooler bolted down everything is connected except hose clamps it all takes time including cleaning out threads etc.


Then late arvo it's all hands on deck to mount the two rear panels while I have been testing that all the front panels are fitting and doing final trimming and I take the second hand 80 Series muffler out for a scrub




At the end of the day what do we have well it's starting to look pretty good. It's time to head off to my chinese mums place and collect wifey for the longg drive home.

[stilivn]

Moving along now. Looks good mate.

[cicak]

19 February 2016

Friday morning dashed up the 190K to the workshop and arrived just after the workshop opened at 8.10am

Idea was to run arround and get parts etc ready for Saturday and Sunday

After much running around and forgetting parts I pulled the wiring loom out after shoving the wire eating pupppy outside we layed it out for the morning.


So a the end of Sunday what do we have apart from my employee ringing me and saying my RED truck as funny noises from the rear after they took it offroad. So we pack up early for the 20k run down the road to check it out then another 175k home. Fark TOW TRUCK back to Kuala Lumpur turns out the rear locker
tore itself apart after it was stripped today (Wednesday).

We have a wiring loom sitting in the truck all cable tied up and a few connections done. Rear taillight has a broken bolt and rsuted insides so I need new ones from sweden first.


All the wires hanging out of it. The cabin is not on as there is still issues with the engine area. The 12 alternator took me a day to get it to fit properly and belts fitted inluding 2 trips to the spare parts shop to get them correct.


Little Joe has some fun with the puppy after spending 2 days stripping paint.


Then we have a pile of parts to paint or electropaint and anodize.


Oh yeah then the 2 weekend helpers the stripper and the wire man.

[cicak]

19 March 2016

Saturday morning finds me and an assistant Rob at the workshop before 8am collect the keys

greet the happy puppy an then go have breakfast and discuss the plan as Rob has to be back in

KL by 4pm.


Rob preparing the dimensions for the cutting out of the service hatch panels and the

surprise. They are to be laser cut and prepare in the coming weeks.


By lunchtime I have quite a bit of the soundproofing done in the cabin.


It's too hot for the workshop puppy he just lies around stealing stuff and breaking it. 39c

is very hot lol.


Then it's time to take Rob back to KL and then dinner refuel and the nite drive back up. End

of the day 570k travelled.

20 March 016 (Sunday)

I also apply paint stripper to the one door I have to work on and commence to get rid of the

body filler. The black is the rust converter.


More soundproofing work continued.


I gotta get rid of these holes. ooks like the welder has to come out and I have one more to

fix and the roof needs a repaint we found a istake which needs fixing.


Even the front of the window is being soundproofed.


The dogs collection of damaged kit.


Then I mounted the doors and checked alignment - opps some bending required.




Then I install the front windows again and try and find the seal rubbers cannot.


21 March 2016 Monday

The overhead instrument console is layed out getting it ready to take to Rob to get measured

up to get laser cut.


Then it's time to do the console instrument layout check with the new steering wheel. The

console will be remade its not right.


I move onto the overhead console and lay it out until im happy with it. It's also to be

laser cut.






Then the afternoons progress is slowed by the arrival of Nazir who has come to collect the
Volvo's old engine for his C303 restore project. Happy restoring Nazir I will come and visit
you in Taiping soon. That is a cool old Chev pickup he has.


Then the final task for the day is to swap the sneakers and empty more junk from the

workshop wow 7 pieces removed in one day.