Jump to content

Juular's scandi dramas. Ovlov 240 / C70. Bolting the 240 back together.


juular

Recommended Posts

  • 2 weeks later...

There's not a huge amount to do to get the 240 back on the road. The rear suspension needs cleaned up, derusted and re-bushed.

I had a massive clearout as my garden was starting to look like a scrappy.

Brushing under this car was the most cathartic thing ever.

resizer_163274154353718.jpg

resizer_163274154353717.jpg

Found a leak on my new welding regulator, which means £40 of Argon got pissed into the wind.

resizer_163274154353716.jpg

Emptied a tin of dynax seam sealer into every cavity, rail, sills etc.

resizer_163274154353715.jpg

Painted the floors.

resizer_163274154353711.jpg

Painted then undersealed all the repairs - another coat is going to be necessary.

resizer_163274154353710.jpg

resizer_16327415435379.jpg

Started stripping the suspension parts.

resizer_163274154353713.jpg

This is a really shit job. In the future I'm simply going to pull the front and rear off, stick it into a big bin and send it off to be blasted.

De-bushed everything. Another really shit job.

resizer_16327415435375.jpg

 

The big bushes on the axle are really stubborn.

resizer_163274154353712.jpg

I resorted to a combination of fire, spinning sharp things and a hacksaw.

resizer_16327415435378.jpg

resizer_16327415435377.jpg

resizer_16327415435376.jpg

More time consuming stripping.

resizer_16327415435374.jpg

resizer_16327415435373.jpg

No point in trying to fix this spring top mount, it's fit for the bin.

resizer_16327415435371.jpg

Rust treatment.

resizer_163274154353714.jpg

 

resizer_16327415435370.jpg

resizer_16327415435372.jpg

 

At this point things have stalled as I need to either make or buy a bush press.

Link to comment
Share on other sites

  • juular changed the title to Juular's scandi dramas. Ovlov 240 / C70. Welding complete. Rebuild begins.

How did Juular die?

49 times we fought that beast
Your old man and me
It had a chicken head with duck feet
With woman's face too
(Oh, that's rad!)

resizer_16333415580871.jpg

 

And it was waiting in the bushes for us
Then ripped off your dad's face
He was screaming something awful
In fact it was this huge mess
I had to change the floors
(The floors?)
You see his blood it drained into the boards
And I had to change them
But we all got a chicken duck woman thing
Waiting for us

resizer_16333420875680.jpg

resizer_16333420875681.jpg

resizer_16333420875682.jpg

resizer_16333415580870.jpg

M12 threaded bar bush press : 0

Shonky home made trolley jack bush press : 0

Volvo trailing arm bushes : 1

These are getting flung at a garage, they can deal with them!

Link to comment
Share on other sites

  • juular changed the title to Juular's scandi dramas. Ovlov 240 / C70. Something's waiting in the bushes of love.

A lot of waiting around at the moment. Have flung those suspension arms at a friendly garage to sort the bushes out. I'm also still waiting on windscreen quotes from a lot of places. 

Rebuilt the rear brake calipers.

resizer_16339429026136.jpg

resizer_16339429026137.jpg

Made a start on stripping all the gunk off the axle.

resizer_16339429026135.jpg

The underseal is really horrible stuff. Most rotating tools just smear it about. Attacked with a blow torch, it burns for ages before settling into a hard ceramic like barrier that is really difficult to remove.

The best way so far is to use the knotted wire wheel to cut it down as much as possible, then go over it with the power file and a 40 grit belt. It's very, very slow work.

You might wonder why I'm bothering but half of the axle is very rusty and I'd like to treat and paint it, but the underseal reacts with and blocks paint from sticking. It's best to start with a clean slate since the axle is off.

The big bushes were surprisingly easy to reinstall using a big hammer. I used a woodworking vice opened out as a spreader to stop the ears bending.

resizer_16339429026134.jpg

 

resizer_16339429026132.jpg

resizer_16339429026133.jpg

Then some rust treatment.

resizer_16339429026131.jpg

I'll paint that midweek when the weather looks dry.

I also made a start on fixing the ongoing oil leak on the c70. I haven't driven it since August.

resizer_16339429026138.jpg

As suspected the sump sealant was pretty useless. When I dropped the pan there was hardly any left on it. 

I've got the anaerobic stuff ready to put on, when I find the energy to get on with it.

Link to comment
Share on other sites

  • 2 weeks later...

The C70 has been sitting having a word with itself for a couple of months now. There's nothing actually wrong with it, but I feel a bit anti-social driving something that dribbles itself everywhere. 

I think the leak is coming from a few places. The spark plug O-rings are evidently shot.

resizer_163515099165329.jpg

resizer_163515099165328.jpg

 

The cam cover doesn't seem to visibly be leaking but the sealant I used doesn't seem up to the job so I may as well change it while taking the seals out.

Timing belt off - again. This time last year I was hesitant to do the timing belt myself. I think I've had it on and off 5 times since then.

resizer_163515099165330.jpg

Most of the sealant I put on seems to have gone..

resizer_163515099165326.jpg

Scrubbed up and new seals in place.

resizer_163515099165325.jpg

resizer_163515099165324.jpg

Anaerobic sealant rolled on.

resizer_163515099165316.jpg

resizer_163515099165323.jpg

Same job for the other end.

resizer_163515099165318.jpg

resizer_163515099165317.jpg

resizer_163515099165315.jpg

resizer_163515099165314.jpg

Finished this off with a fresh oil and filter.

I had to tap the cam oil seals back into place, so I had to take the distributor rotor and cam sensor off. I broke them both in the process.

resizer_163515099165320.jpg

resizer_163515099165319.jpg

Since the car was going nowhere, I did a couple of other jobs I've been putting off.

New driver's side brake hose.

resizer_163515099165312.jpg

I bought one of those cheap Lidl oil pumps to bleed the 240s brakes, this was a good time to test it out.

resizer_163515099165311.jpg

Seems to work!

resizer_163515099165310.jpg

 

And the last job for a wee while hopefully..

This is the normal GT steering wheel with suede trim.

resizer_16351509916538.jpg

Tinker, bang, unscrew.

resizer_16351509916536.jpg

resizer_16351509916537.jpg

Much better!

Link to comment
Share on other sites

  • juular changed the title to Juular's scandi dramas. Ovlov 240 / C70. Incontinence incompetence

The 240 did get some attention as well.

Rear axle painted.

resizer_163515099165334.jpg

Got the suspension arms back from the garage with the new bushes in. In the future, I'm not messing about trying to do them myself.

resizer_163515099165333.jpg

resizer_163515099165322.jpg

resizer_163515099165321.jpg

resizer_163515099165331.jpg

 

The fuel tank needed a bit of TLC as the seam had started to rust. It wasn't leaking so I used the power file to remove as much rust as possible, then treated what was left.

resizer_16351509916535.jpg

resizer_16351509916534.jpg

 

Finally, this is the state of the lower spring retainers.

resizer_16351509916533.jpg

screenshot_20210605-142818.png

That will be right!

The originals are 1mm, so some flat 2mm should do the job.

resizer_16351509916532.jpg

I've altered the idea a little by welding through a bit of M12 threaded bar and a nut on top.

resizer_16351509916531.jpg

resizer_16351509916530.jpg

That way I won't have to counterhold anything to put them back together, I'll just spin a nut on the ends.

Link to comment
Share on other sites

  • 2 weeks later...

C70 update after doing all the work to fix the oil leaks.

resizer_16361384001240.jpg

Shat itself again. 

More accurately I put the front cam seals in at a jaunty angle and forgot to true them up before I put the belts on and started the engine.

Thankfully all I needed to do was tap them back into place through the holes in the sprockets, so no need to take the belts off again. A ton of degreaser was launched in there so the oil didn't eat the belts.

Took it another drive and it was STILL leaking from pretty much the same place as before.

This ruled out the sump and cam cover so I changed the last thing it could possibly be.

resizer_16361384001242.jpg

That's the turbo oil return pipe and yes, that small o-ring is buggered.

Thankfully I had a stash of gaskets from the engine rebuild.

resizer_16361384001241.jpg

With that replaced I took it a drive.

resizer_16361384001243.jpg

FINALLY no more leaks!

Oh wait, what's that doing at that angle?

resizer_16361384001244.jpg

Fuck.

resizer_16361384001245.jpg

resizer_16361384001246.jpg

Yeah that's utterly shagged. 

Most of that bit of pipe is a temporary repair from the past.

Am I flinging more money at this car? 

Am I fuck!

A bit of bodging required.

resizer_16361384001247.jpg

resizer_16361384001248.jpg

resizer_163613840012410.jpg

resizer_16361384001249.jpg

TOTAL MINT

resizer_163613840012411.jpg

It's a good 20cm shorter now I've cut out the really rotten bits. I am hoping it's enough to see out the winter and by then hopefully this car will have started to be less of an ungrateful cunt. I might treat it to a new bit of exhaust if it behaves.

Took it out a nice autumn run down the back roads.

resizer_163613840012412.jpg

resizer_163613840012413.jpg

.. and FINALLY, I reckon I'm happy with it.

Here's what I've done to the car in a year of ownership.

Timing and drive belts, tensioners and pulleys

Front shocks and top mounts

Track rod ends

Discs and pads all round

Poly ARB bushes

Poly subframe bushes

Poly top engine mount

New OEM lower engine mount

New battery

CV joint

ABS ECU resolder

EBD switch

Transmission fluid swapped

Turbo drain pipe gaskets

Engine rebuild with uprated Conrods, big end bearings, new seals and gaskets all round

All new vac hoses 

Replaced leaking coolant hoses

New turbo control solenoid

Distributor cap and rotor

Cam seals

Cam sensor

HT leads

PCV rebuild with new hoses

Oil cooler delete

Injector seals

Front calipers and flexis

Wood steering wheel

You have to wonder if there's anything left to change..

Why did I bother? 

I like to see things through, I don't need it as a daily driver, I looked at it as a rolling (sometimes stationary) project / way to learn how to do pretty much anything on a car. I didn't have any pressure to get it fixed which helps a lot with the tolerance levels. Quite distinctly not the autoshite way. If it was my daily this would have been bridged a long time ago.

And that would have been a massive shame because this is a BRILLIANT car.

Kicking its arse up the back roads on an autumn evening, the soundtrack of burbling / offbeat grumpiness / utter madness at WOT,  the comfiest heated seats ever, perfect driving position, and the best sound system I have ever heard in a car.. that's enough to make this all worth it.

Can now focus on getting the 240 back on the road, which isn't far away at all.

Link to comment
Share on other sites

  • juular changed the title to Juular's scandi dramas. Ovlov 240 / C70. Bolting the 240 back together.

All that's left for the 240 is to basically put everything back on.

Fuel tank got a quick coat.

resizer_163613840012415.jpg

 

Replaced the faulty in-tank fuel pump.

 

resizer_163613840012417.jpg

resizer_163613840012418.jpg

 

Gave the sender tracks a good scrub with acetone and the readings are far more reliable.

Full:

resizer_163613840012419.jpg

Empty:

resizer_163613840012420.jpg

 

Fuel pump tested with a battery and a bit of water.  As you can see from the pools on the tank it works fine, and pumps in the right direction (some aftermarket pumps are wired in reverse).

 

resizer_16363720909079.jpg

 

Last bit of the fuel tank puzzle is the front bracket which has started to deteriorate, so I made a copy.

 

resizer_16363720909075.jpg

 

resizer_16363720909076.jpg

 

Exhaust and filler neck refitted.

 

resizer_16363733378521.jpg

 

resizer_16363720909074.jpg

 

resizer_16363720909073.jpg

 

Tank fitted, new bracket in place.

 

resizer_16363720909070.jpg

 

Brake lines cleaned up.

 

resizer_163613840012414.jpg

 

New braided flexis.

 

resizer_163613840012416.jpg

 

Underfloor pump tray refitted.

 

resizer_16363720909078.jpg

 

Fuel lines refitted and clamped down.

 

resizer_16363720909072.jpg

 

And the first oil change in 12 years!

 

resizer_16363733378520.jpg

 

May as well treat it ( was cheaper than the cheap shite, to be fair!)

 

resizer_16363720909071.jpg

The next job is to refit the rear axle.

I'll also be pulling some bits and pieces off this veteran!

resizer_16363720909077.jpg

 

Link to comment
Share on other sites

Another bit done on the 240.

Carpets scrubbed up nicely, they are in really good condition. They were properly foosty when taken out of the car last year, but just being stored in a heated room was enough to get rid of any dampness.

resizer_163697010655512.jpg

A couple of bits arrived to finish off the fuel sender unit, so that got put back into the tank and everything wired and plumbed in.

resizer_163697010655510.jpg

Popped off the old fuel filter, the fuel inside didn't smell particularly healthy.  There are a couple of adapters on the filter that need to be moved over to the new one.

resizer_16369701065559.jpg

Bulkhead furniture refitted.  I got a replacement foam mat from a scrap car to keep it OEM.

resizer_16369701065558.jpg

Just as things were going well the wiper motor fought back. I was just tightening up the bolt that connects the linkages to the spindle when it sheared off.  Then the linkages decided to spontaneously explode on me and throw their weird steel wire connections in my face.

resizer_16369701065557.jpg

 

I'm not sure on the way forward with that. I've tried drilling it down and using a bolt extractor, but as you probably already know they are total shite and this achieved nothing. My next move is to drill it and tap it for an M7 bolt which should still fit within the diameter of the spindle.

I sacked off doing anything else on the front of the car and went to the back.

Rear axle moved into position.

resizer_16369701065553.jpg

Using axle stands for an actual axle, NOVEL APPROACH.

resizer_16369701065552.jpg

Stripped a boatload of underseal off the axle brake lines and polished them up.

resizer_16369701065556.jpg

New flares and unions.

resizer_16369701065555.jpg

resizer_16369701065554.jpg

Secured in place before anything else goes on.

resizer_16369701065551.jpg

resizer_16369701065550.jpg

It then got mega dark and cold very quickly so that got abandoned until next week.

Before the half shafts go in, I noticed that one of the bearing outer races that was sitting in the axle had gone mega rusty.

It's not possible to buy these separately so I had to buy a complete wheel bearing.  Changing the actual bearing needs a large floor standing press to fit the shaft in, so I'm hoping I can get away with just swapping over the outer races. Then, if I need a new bearing in the future I'll have one lying around.

resizer_163697010655511.jpg

 

Link to comment
Share on other sites

Rear axle almost done now.

SPORTS SHOCKS. GET YER SPORTS SHOCKS. TWO FURRA POUUUUUN-A!

resizer_163757368030136.jpg

resizer_163757368030135.jpg

Half shafts, new splash guards and brake shoes refitted one side, the other side shoes have fallen apart.

resizer_163757368030134.jpg

I hoped to get the calipers on but Autodoc have sent the wrong pad fitting kits. Still, it's a nice thing to look at.

resizer_163757368030133.jpg

There is a surprising amount of lateral play in the offside half shaft. When I checked the bearing against the new one I have, there was no difference in play. I am led to believe this might be normal?

While fitting the brake shoes I noticed that the offside brake expander has two clevis pins holding the parts together that have gone missing.

resizer_163757368030132.jpg

So it's either £30 for a complete expander, or unbelievably, £50 EACH for the pins themselves.

Of course I'm doing neither.

An M5 bolt fits the centre hole exactly. I cut it to size, peened one end over with a ball peen hammer, then ground the bolt head at the other end right down.

resizer_163757368030131.jpg

resizer_163757368030130.jpg

For the handbrake cable end, an M6 fits nicely.

resizer_163757368030128.jpg

Cut to size.

resizer_163757368030127.jpg

It has to be an exact length as it needs to slide inside the mechanism when installed. 

resizer_163757368030126.jpg

The next job will be recommissioning all of the  car's electrics before fitting the interior.

Link to comment
Share on other sites

I'd hope to be way further on than this, but the car is fighting back.

Hooked up the wiper linkages to the repaired spindle.

resizer_163757368030114.jpg

Refitted the handbrake cables.

resizer_163757368030121.jpg

 

One of the sunroof pipes that drain into the A-pillar was leaking, so I cut and lengthened it with a barbed connector and a bit of water hose left over from my camper conversion.

resizer_163757368030125.jpg

resizer_163757368030124.jpg

 

Next I made an attempt to refit the fuse panel so that I could then test the electrics.  This screws into a metal plate that in turn screws into the door hinge support bracket.  Of course, when I remade this, I folded it in the wrong direction and the panel no longer has anything to screw into.

 

resizer_163757368030123.jpg

To solve this I extended it with a small bit of steel.

resizer_163757368030122.jpg

Then the whole lot gets secured with a self tapper.

resizer_163757368030116.jpg

 

Next I wanted to test the electrics while the interior was out and all wiring was accessible.

I fitted fuses and tested systems one by one. This is how it went.

Wiper motor - dead

Screenwash pump - dead

Headlight wipers - dead

Horn - dead

Fuel pumps (both) - dead

Electric windows  - dead

Lights - working

Starter motor - working

So that's just the main stuff, I haven't fitted the dash and tested that yet.

Let's start with the wipers. Of course I had to disconnect everything again and bench test the motor. Nothing at all from supplying power straight to the low or high speed pins.

Opened it up.  Ah. That commutator is looking pretty corroded.

resizer_163757368030120.jpg

After a clean.

resizer_163757368030119.jpg

I then continuity tested it from the pins to the commutator and got a reading so good to go.

These motors earth directly to the bodywork under the scuttle so I cleaned up the earthing bolt point.

 

resizer_163757368030118.jpg

And scraped the paint off the earth point.

resizer_163757368030117.jpg

Boooooooooooom.

Screenwash pump - that turned out to be a simple fix by sorting this excuse for an earth point.

resizer_163757368030115.jpg

 

Next up, horn.

Pressing the horn did nothing, so I took the black wire out of the back of the steering column and ground it against the chassis (the horn works on a switched earth). It worked.. happy times.

So I pulled off the horn pad to have a look.

resizer_163757368030112.jpg

Unfortunately the connector ring underneath the steering wheel seems to be loose / broken. Of course the bolt on the wheel needs a deep socket that I don't have, so I can't go any further for now.

On to the electric windows.

With each door individually plugged into the system none of the switches did anything. 

I then realised that the whole system was wired to run via the driver's door 4 way switch. Since the driver's door had been stripped down already by the previous owner  (not a good sign) I had to dig through the spares to find it.

resizer_163757368030111.jpg

Still nothing worked. I had to go round with the meter and check every connection, where I found quite a few corroded pins.

resizer_163757368030110.jpg

And finally..

However only 3 windows were working and the driver's side was still dead. Going by the stripped down door I assumed the motor was seized and the previous owner had tried to sort it.  Applying power directly to the pins confirmed this.

Taking the regulator out is a right faff, mainly because the hole in the door is too small.

Also, before removing the motor you have to cable tie the mechanism together otherwise it just springs open and then you're fucked.

resizer_163757368030113.jpg

Before looking at the motor I also pulled out the headlight wiper motors as well so that I could do these all in one go in the evening.

Door window motor:

resizer_16375736803019.jpg

On opening up it's clear to see there's a bit of a water ingress problem.

resizer_16375736803016.jpg

resizer_16375736803017.jpg

Again, this one had a filthy commutator which I cleaned up.

resizer_16375736803018.jpg

resizer_16375736803015.jpg

Tested before reassembly and we're back in business!

resizer_16375736803014.jpg

Onto the headlight motors.

resizer_16375736803013.jpg

resizer_16375736803012.jpg.

On these ones the small motors were working fine, but the toothed wheels that move the wiper spindles were jammed solid in their bearing frames.

resizer_16375736803011.jpg

The fix for these was to push the wheels out (not easy!) and use the power file to enlarge the bearing holes by around 1mm.

resizer_16375736803010.jpg

These both went back together and worked perfectly.

Since I had to take the lights and grille off again to remove the motors, I gave them a bit of a polish.

Before.

resizer_16376752541023.jpg

After

resizer_16376752541022.jpg

Before

resizer_16376752541021.jpg

After

resizer_16376752541020.jpg

 

 

 

 

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
×
×
  • Create New...