welding project Juular's Scandi Noir. Volvo C70, 240 &122. Worst job ever.

[big_al_granvia]

splendid splendid work, agree with working in summer, prefer spring and autumn myself

[juular]

Just a small update as I have been advised my hole is too small.

This is the Auxiliary Air Device - it feeds extra air into the inlet when the car is cold, essentially keeping the revs up during the warmup phase.  It has a little spring inside that expands and contracts with heat and opens /closes a port.  Like everything else on the KJet system it's entirely mechanical and really simple, but sometimes calibration goes out.

Off the car, when cold, mine looks like this.

Apparently it should look more like this.

There is a little nut on the back that allows you to calibrate it - I totally missed this. Loosening it and giving it a shove left or right opens or closes the port a little bit.

So eventually, I got it to here - which looks a lot better.

I can also test that it still closes when warm by aiming a hairdryer at it.

I love simple engineering like this.

In other news, the planets must have aligned because I found an inlet manifold gasket for less than £2, from Euro Fucking Car Parts of all places.  And what's even more amazing is that it arrived on time and was the right part..

Lottery ticket going on now.

 

[KitKat]

Love this thread, and the end is in sight now. So morale boosting watching this come together 

[stuboy]

do love a volvo..........

[juular]

It's close now. 

Decided the front needed new brake discs since there's no point coming this far and reusing the rusty ones.

@Lacquer Peelhelped me bleed the brakes and refit the inlet manifold, pcv, etc.

Changed the water pump and dropped a screw right down inside the timing cover. The wee bastard. That wasted an hour and a half.

 

Went round the suspension and checked torque of all fasteners. Happy with how the underside looks.😬

 

It's starting and running not too bad now. Quite smelly, I'm not sure if it's rich or the exhaust is full of fuel from earlier.

Alternator charging well.

Wheels on.

 

Double checked all the lights.

Just some snags to sort out tomorrow.

I'm aiming for a Monday MOT. 

The C70 passed its MOT yesterday, hopefully a good omen.

[KitKat]

Oh this is looking wonderful, fingers crossed for you that Monday goes well. You deserve it!!

[juular]

Seems to start and run fine.

Set up the tracking.

Had a drive on a Private Road 

A couple of brake unions are leaking, as is the water pump - still..

[KitKat]

Why is it so high at the front @juular?

[juular]

32 minutes ago, KitKat said:

Why is it so high at the front @juular?

New springs on the front, this is the first time it's had weight on it. Plus the front valance is missing making it look a lot higher

[juular]

First drive in 12 years.

 

I definitely* wasn't out working on it in the dark last night.

For a bit of insight, I want to be able to pick my 87 year old Dad up in this on Christmas day. He's been teaching me to weld (over the phone) for about a year now and he has no idea how far this has come along. I think it would be an amazing surprise for him.

Ordered a water pump, although it may pass MOT with the slight leak.

Working on the leaking brake unions today. It looks like I may have used metric where imperial was needed and vice versa.

[juular]

Brake lines done.

No room at the MOT place today, it's in for tomorrow afternoon. Which is just as well as the bastard wouldn't start this afternoon.

Currently out in the dark dismantling the k-jet system...

 

[juular]

It's been a mental 24 hours trying to get this running properly.

I pulled apart the fuel distributor as the metering plunger was really sticky. Cleaned out with carb cleaner and given a bit of oil it started moving much more freely .

Then, putting it back together this morning was a race against the clock. Of course, shit like this was bound to happen.

Thankfully cutting it and refitting it worked fine.

Did a fuel flow test from the pump.  Needed 700ml in 30 seconds, got 1200ml so working fine there.

Tested the injectors.

#2 had really intermittent flow. After a bath in carb cleaner for an hour things improved a lot though.

@Lacquer Peel helped me do another express bleed of the brakes and helped me put things back together. I'd have been stuffed without help.

After testing all this - it started!

Took it a short drive, all great!

Left the car off until an hour before the MOT ,decided to leave early and the bastard wouldn't start again!

I fettled. I'm not exactly sure what I did but I eventually got it to the MOT place half an hour late.

And the MOT man, he say.. NO!!

The indicator, fair play. The clip broke as I went over a speedbump and it was literally dangling as I drove into the MOT place.

The corrosion fail I'm pretty gutted by, since it's not corrosion at all. On the nearside, I welded up a cavity waxing grommet hole, yet on the offside I left it open.

So ironically I need to cut a hole into the nearside and fit grommets to both holes for it to be structurally sound. Shrug.

On the way home I continued to have indicator problems so I stopped off at a place of repair.

Volvo, meet Volvo.

MINT

On the bright side, it should definitely pass tomorrow.

[big_al_granvia]

what a wank that tester was, clearly not had his nat king... he had better pass it tomorrow

[KitKat]

 

Excessive corrosion? Someones clearly pissed in his cornflakes. 

[warch]

I remember my Landrover thrice had advisories relating to severe corrosion around the rear suspension mounting point.

Every year subsequently it got nowt, so either the rust dropped off or it got better.

[juular]

 

[SRi05]

[big_al_granvia]

splendid splendid splendid splendid  splendid splendid

[Split_Pin]

46 minutes ago, juular said:

 

Well done chap, no other words to describe this achievement! 

[jaypee]

Excellent work chief! 

[KitKat]

That’s brilliant, so glad this is back on the road after all your hard work and determination. It’ll be a big surprise for your dad on Christmas Day too

[captain_70s]

Doing the impossible and returning a Volvo to the road.

[GMcD]

Absolute top, well done man! 

[juular]

Mission accomplished. Dad was over the moon with a wee tear in his eye. 

Seen arriving at Volvo towers (central).

Merry Christmas folks.

[juular]

For those wondering, yes dogs and their owners do look alike.

Here's wots has been happening with the 240.

I've had a nasty clunk from the front right since taking it for MOT. I've had the car in the air about 10 times checking bolts and prying suspension parts. As you know almost everything on this car is new so it's not going to be a worn component. As you can imagine it's taking the shine off actually driving the car. 

Today I finally found it - the rear nut on the offside wishbone had worked itself loose about 1/4 turn. With that nipped up it's finally driving like a brand new car.

The water pump got swapped for a new one since it was leaking from the shaft.

Whilst in there I decided to check the timing was OK because I was still having starting issues. (It's easy to do on a redblock so may as well).

As you can see it's right on the money.

 

So it's something else that's becoming frustrating to track.

With the fan off I tried freeing up the spring on front as it's running constantly. A good drown in plusgas got it all moving again.

It's still running more than I'd like so I may need to change the oil in the coupling.

Now onto the running and starting problems. The issue is that it always takes 3 goes to start, and when it runs, it initially hunts between 200rpm and 2000rpm suggesting an intake leak somewhere.

Since I had the throttle body off but reused the old gasket, I decided to chuck that away and seal it up with anerobic sealant.

Next I checked the injectors. I noticed that if I wiggled #2 it sometimes changed the RPM.

The seals are all new but not convinced they were sitting right. I cleaned out the seats on the block as they were full of gunk.

I also had to clean out the holder on #2 as it wouldn't click into place, and it looked a bit damp.

While I was there tested the flow, cleaned them up and retested them.

With that all done it does seem to start a little bit better and run smoother. Still feel it's holding back a little bit at high RPM so the next job is to get a timing light and set that up correctly.

The most important thing is, the car is brilliant. Really comfy, squishy yet handles very well. Everything inside is so clunky and boxy in a very 70s-80s fashion. Driving it home on Christmas Eve with the yellow headlights and the dim glow of the heater controls as it belts out maximum heat - it's one of the cosiest and most pleasant experiences I've had driving a car.

 

[juular]

Went a very enjoyable 200 mile drive with @Lacquer Peel today. 

[DodgyBastard]

Reminds me of my old 240, wish I'd kept it.

 

 

[sdkrc]

Spectacular photos @juular

[captain_70s]

Boxy style.

Do we know the cause behind the SUV stance at the front?

[Lacquer Peel]

7 hours ago, captain_70s said:

Boxy style.

Do we know the cause behind the SUV stance at the front?

It wants to Off Road.

I had a decent shot of the 240, it drives really well, feels planted and solid even in these conditions and is comfy and quiet at cruising speeds. What a great car. It feels weird to be driving something I saw in pieces and rotten but @juularhas done an amazing job making it safe and solid.