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Malaysian Police Volvo C304 (4x4) Restore

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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Nov 19, 2016 8:48 am

Re: Malaysian Police Volvo C304 (4x4) Restore

30 October 2016

Remount the gas stuts they are all the wrong way round - oops

The cheap labour is working on the bolting in the intercooler and air cond condenser. Brackets are wire brushed and painted
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Meantime I work on the air tank and wire brush it and undercoat it

Then the owner turns up and we connect up the compressors and amp test them. Hmmmm 46 amps drawn from each. Not good on 100 amp wires so 2 new wires are laid 100 amps each direct to the batteries.
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Finally the intercooler is finished all I need is 1 new silicon hose and a few clamps
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Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Nov 19, 2016 8:49 am

Re: Malaysian Police Volvo C304 (4x4) Restore

6 November 2016

Tow the boat up to the workshop the trailer needs surgery its flexing like mad the old boat weighed a mighty 70kg lol. This one is more like 700kg.


One day on the Volvo yesterday was attend a sultans birthday in KL so I worked on Volvo 2 instead.

Felt really sick so the owner and me work on the stuff underneath o the floor can be bolted in for final time.

We relayed the Winch cables into nice neat rows. Set batteries in new location an recrimped the ends and started on the T-Max winch cables. A new Cable holder was made (left bottom) and one more to be made.
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Then I decided HOME. I was getting worse not better

The trailer left in the workshop for surgery
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Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Nov 19, 2016 8:51 am

Re: Malaysian Police Volvo C304 (4x4) Restore

12 November 2016

First some pics of my boat holiday

A lone Elephant. My friends first time seeing a wild elephant he was stoked
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A remote camp site early in the morning
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Kayaking in the same cove
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Saturday

Depart KL 6.30am its a cold 26c im shivering lol just floor it and sit on 150k arrive IPOH 8am im time to have a nice breakfast.

Arrive workshop 9am and everyone (hey wait a minute) is present working on the Volvo wow 4 people working on it. Battery box being changed to accommodate the 4 batteries in a line. 2 150 AMp and 2 DEEP CYCLE 150 amps for the 12V. Wiring is getting plugs attached.

First job join the 2 parts of the cabin together. Find the bolts damn 4 3/8th bolts missing we search the

shop and find 0. Why does Volvo mix imperial and metric bolts on the same part? I go to the bolt shop and get what we need and get 2 thread types to be sure. 1 hour later return - DAMN! they don't fit. Brett finds 3 and we are missing one. Finally we apply the glue and the sealant and lower the top to the base. Bolt it down. Yahoo done.

Lunchtime workers go home and then we start on getting everything under the floor ready so we can bolt down the floor.

First the lockers I have the wrong solenoids from ARB. Crap down to the hydraulic shop for new ones. Since I have to be back in KL to give a 6pm charity event I go to the hydraulic sop then head forr home however 1 hour in the hydraulix shop leaves me frusrated 2 sets pleas come out with etc . 50 feet of soft hose comes back with 6mm joints fark!!!!!!!!. Homeward bound yes of course it raains heavily turning the road to a ice skating rink. Arrive at the presentation 5 mins late give the presentation and I get participants joining up. Now I have 10 kids from the home to teach how to kayak and paddle for 8+ hours per day for 8 days.

13 November 016

Sunday

Up early no im not 1am I take cough medicine and its the sleepy one by mistake. 7.31am wake up fark!!!!! Floor the car even harder poor little Isuzu doesn't see the slow side of 160k much, arrive IPOH 9.08am.

First job run through the mods to the boat trailer.

Reinforced no longer the massive flex it had. he general view was it would have folded in half or snapped soon if it was not noticed. Discussion on batteries and fridge and hammock racks conttinues.
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Then its onto the Volvo

I have the wrong solenoids after all that effort yesterday sigh!

Sweep up everything around the Volvo takes me an hour to cleanup.

Discussion on the 12V and wiring changes and the 12v battery management takes another hour by then its lunchtime.

So the afternoon is spent finishing the compressor take installation. Paint trim paint fit test fit fit ec. Then it's done just one little paint touch up to go later. It's not perfect but its practical and removeable.
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Battery boxes realigned and more cable brackets have been installed. The 12v electric cart battery's are huge.
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The 12v battery monitor is to be obtained next week
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The cabin joined. Now I need to paint it again.
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Since i'm at a cleanpoint I decide its home time I will go work on Volvo 2.

Next weeks tasks:
Lockers finish install
T-Max winch finish cables
Start clutch slave cylinder install
Finish PTO and 4x4 Vaccum and breather hose installation
Finish rear panel install and window install

Hell drive home pouring rain - I just cruise Bruce Springsteen then Blondie on the stereo

8pm i'm sitting in a little restaurant 500 metres from the KL workshop watching a motor bike accident happen

9pm i'm in the workshop working on Volvo 2.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:34 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

19 November 2016

Got the locker mechanisms changed so now they are installed correctly.
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Couple of bolts missing from the rear panel and it's all ready.
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20 November 2016

Sunday time for the t-max to be wired up. Have to start from stripping the solenoid to see how to connect the winch wiring up. Took all day to get it finished and have nice lengthed cables. Only the remotes to wire in now.
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The drive home is horrendous it pours most of the way home and it a 3 hour journey sigh
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:38 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

26 November 2016

Wake up late then have to go collect the trusty Isuzu from the workshop using the spare keys after it's had the gearbox out to replace a main seal and yet another oil change I believe no. 8 for the year so 40,000k has whizzed past.

Floor it for the 190k to Ipoh and arrive at 9:06 and wow all hands on deck again working on the battery box expansion and wiring up the rear tail lights and startin to plug up the front wiring so it can be removed if we lift the cabin off.

24v batteries connected
Image
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:39 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

27 November 2016

Spent the morning putting the front prop shaft in.
My lunch view every weekend out over the limestone temples and hills.
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Made a bracket to hold the accelerator cable a quick tidy up needed next weekend and it's ready.
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The front prop shaft in. Apparently it's the wrong way round sigh.
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The trip home again is horrendous 3 hours 45 mins. I'm really starting to hate the Sunday nite home drive
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:42 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

5 December 2016

One week on the Volvo coming first we move the cabin ready for a trial fit sometime this week. The whole crew is available to work on the Volvo all week. So I'm calling it the big rush week.

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All hands on deck to install the ceiling.
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Poor Yap trying to figue out how to do the front ceiling.
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Mr Brown jumps up to assist and supervise
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End of Day 1 of thhe big rush we have the roof done
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Evening I end up 90k away at the closing ceremony of the 2016 RFC with 2 other friends who decided in a drinking session in Chang Mai in Thailand on Saturday night to fly to Malaysia lol and several other friends also came at the last minute.

6 December 2016

Picked up the kiwi video crew from their RFC 2016 hotel took them to see the Volvo in IPOH did a video interview for OFFOAD EXPRESS NZ and then back to Kuala Lumpur and out for dinner with the others.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:43 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

7 December 2016

Slow morning after the long 190k drive backup to IPOH I managed to fly up early in the morning rather quickly lol

By the middle of the afernoon all the top removeable panels are completed except one which is being remade in the morning
Image

I work on the front cabin panels getting them all to be removeable correctly for easy access.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:44 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

8 December 2016

I'm out getting window rubber and bolts then have to go out again when we realise the window rubber is incorrect anD we cannot get the reversing camera to work and until it works we cannot glue down the roof so out I go again to find EPILSON reversing camera's a quick call to the importer from the box gives me the local IPOh supplier. Buy a new one and we replace the cable on the roof retest tomorrow 6PM hometime.

Then it's time to assist with the bottom panel gluing session 5.01pm we start have to finish by 6pm. 4 of us get it done withh 15 minutes to spare.
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Tomorrow we will know if its all looking good.

Initial impression is the truck now looks clean and simple inside
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Dec 11, 2016 5:45 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

9 December 2016

The end result of last nights gluing session is shade awesome, but oh and we need new gas stuts damn the 400M one's are not strong enough I need 600N the doors start to drop down a little.
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So a 45 square foot jungle workshop is what it looks like now.
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We retest the reverse camera after laying the new wires and yup it fails again so afer much stuffing around it finally works and the Battery Monitor turns up from the UK. Fit next week.

Next is the windows I fit the 2 side windows and give them a clean they come out smick.
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Now the locks. Yap starts to modify the locks to accommodate the central locking while I clean out the holes for the locks to fit in.
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Next week this will be ready to install and test out wow a 36 year old truck with Cental locking lol. The welded up keyhole is getting something special made up to hide the welded up hole.
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We wanted to finish the roof by gluing down the top but alas we run out of time. It will be done first thing Monday morning.

So the end of the week we have thrown some 268 hours at it but missed the big goal of putting the cabin on.

10 December 2016 (Saturday)

Worked on the front panels went out to get some dome bolts for the ceiling as the roofing screws are going to cut my head and they look ugly.

Came back and had one panel almost finished and then the guillotine chopped to much off trying to trim 1mm off SOB. Down tools and we go to lunch and then I head back to Kuala Lumpur for a couple of days.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Dec 17, 2016 9:36 am

Re: Malaysian Police Volvo C304 (4x4) Restore

12 December 2016 (Monday)

Charity Day took People from Light up Borneo and potential donors to the scheme to a remote Orang Ali village to do a Mini Hydro recce. 11 4x4's and 37 people. Took my mighty Red truck for a stroll in the Jungle.

The girls from the group looked after the village kids while the other went to do the hydro meauring. Me I just relaxed for once.
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However I want one of these little jungle dogs a Telemonian climbs steps loyal, kills snakes, hunts squirrels.
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The mighty Red on its new Trepadors which I found to be quite harsh.
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Arrive home 11pm exhausted.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Dec 17, 2016 9:40 am

Re: Malaysian Police Volvo C304 (4x4) Restore

13 December 2016

Day 6 of the big rush and im in Kuala Lumpur sorting out collecting my new passport then into thhe office to sort out the paperwork for the work permit.


14 December 2016

Day 7 of the big rush and I'm picking up parts for the Volvo from the laser cutters. I have to wait for one part to be cut out as they do not wanna bend it. It's ok we will bend it you just cut it. I wait 1 hour. Then sorting out my work permit yet again. Eventually I arrive at Ipoh 1.30pm.

The door locks are now fited
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Cental locking also ready for wiring.
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The exhaust heat shield and the turbo shield waiting to be installed.
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Mr Brown getting a Subway cookie.
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Last edited by cicak on Sat Dec 17, 2016 9:43 am, edited 1 time in total.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Dec 17, 2016 9:42 am

Re: Malaysian Police Volvo C304 (4x4) Restore

15 December 2016

Day 8 of the big rush.

The exhaust shield is installed by 2 of us.
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I started on the watertank install and had a few issues which have taken a day to sort out.
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Brett started bending up the turbo heat shield.
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Only the turbo heat shield is needed to allow the cabin to be put on tomorrow.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Dec 17, 2016 10:39 am

Re: Malaysian Police Volvo C304 (4x4) Restore

16 December 2016

Day 9 of the big rush.

We work all day quietly on the Volvo, Brett continues to bend the turbo heaat shield slowly. Customers come in the shop 7+ and all gravitate to the Volvo many questions etc

I work on the Water tank repair/fit - 6mm spacers are welded to the rear of the tank to cater for the unexpected BUMP.

Brett finishes the welding and leaves me the job of fitting the turbo shield. 2 hours later and a few

unusual fixes to fit it and getting late in the day the turbo shield is bolted in.
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Quickly we setup for the cabin move
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15 minutes later we have mission success the weeks goal is achieved. But it will have to be lifted off Monday morning to fix up the harness sea belt mounts at the rear of the cabin. However everything else is all ok as we do the fit inspection.
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She looks great better than I could have imagined. People ask when is the top coat going on. Thats it Ford Creamy White (or Desert storm base paint colour - hehe)
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Had to have a pic with the grill in.
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Dinner later and we drink a lot of beer lol.g]
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Thu Dec 22, 2016 9:51 am

Re: Malaysian Police Volvo C304 (4x4) Restore

17 December 2016

Day 10 of the big rush.

I'm a little slow. Waste 3 hours getting bolts as I got given 4 7/16 bolts not 3/8 like I needed.

But ended up getting the harness seat belts fitted cleaned out threads etc and all the bolts cruised in. Inspection of the cabin shows it needs to come off as a few of the rollcage holes are a little out.
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Take a nap in the boat hammock late in the day as it's sinking hot.

18 December 2016

Day 12 of the big rush. Another slow day

Worked on the water tank slotted the top bolt holes to make it easier to fit - hey presto it was much easier to install. Now need to do the filler taps and the outlet taps sometime next week.

Fitted the shunt for the Battery monitor.
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Removed the cabin ready for tomorrows work marked all the holes to be trimmed. Removed the air cleaner as we are now attaching the air cleaner bracket and the supports for the harness seat belts together.

19 December 2016

Day 13 of the big rush.

Cleaned up the holes with the air tools.

Then we we mounted the cabin. Marked the position of the harness brackets and made up the tubes and welded them to the air cleaner bracket. Bolted down the 4 bolts of the cabin. 8 to go to the rollcage still it will be a long slow process to get everything to line up.

We redid the wiring to the injector pump to add a plug to it.

Mr Brown decided to wath everyone from the bow of the boat.
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Then it was time for the reason for the big rush to occur. The 12 horse horse float turned up for its revamp and intimidated everything in the workshop with it's size.

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Then suddenly it was hometime and this is the Volvo as I left it after 13 days of work on it.
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I took the boat home ready for a trip sometime after the Volvo is finished.

Merry XMAS everyone.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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Foo on patrol

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Post Thu Dec 29, 2016 10:10 am

Re: Malaysian Police Volvo C304 (4x4) Restore

:armsup: :x-mas:

Foo
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cicak

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Location: Jungles, Rivers , Lakes of Malaysia

Post Sat Dec 31, 2016 9:23 am

Re: Malaysian Police Volvo C304 (4x4) Restore

29/30 December 2016

Day 1 and 2 of a 5 day rush.

5 days to work on the Volvo in a row.

I work on creating the nice entry of the 4 power steering hoses into the cabin LEFT, RIGHT, POWER and RETURN .

Day 1

Remove the brake and booster and the clutch cylinders . We cut and brace the dash.

Cut the hole for the hoses and start the plate from 4mm alloy.

Day 2 then assist with the wiring of the central locking putting the wiring internally in the door frame.
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5.15pm we have glued down the rear cabin alloy valance. Day work is over no wait the horse float is out we can get to the front roll cage. Pick it up and install it slowly. The horse float is reversed back in as we finish. The truck is complete no more large parts remain to be bolted down.
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The roll cage looks good in the new colours.
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The 4 hole plate which is giving me grief
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6.10pm leave the workshop. Then the trusty Isuzu DIES about 500meters from the workshop engine check light on. It runs enough with light off to get it back to the workshop, leave it and leg it the 2+k back to the hotel via a halfway meal and a cold beer to cure my sorrows. I think its fuel filter will check in morning.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 9:14 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

31 December 2016

9am we take the Isuzu to the workshop but not before I walk 2.5k in the rain too get breakfast. Isuzu say they wil ring later in the day with a diagnosis. They do 2 fuel pressure sensors have died in the fuel line.

Cannot repair till next Thursday.

Day 3 of the little rush. Brett takes me down to the hydraulic shop we ercut hoses to length and clamp up the end etc for the power steering. So afternoon I start off labelling the power steering hoses at both ends with clear shrink wrap.
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The water tank is ready to be tapped up, However we have decided to make one out of stainless steel instead.
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I make a bracket to hold the power steering hoses up high under the cabin
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Now it's almost completed.
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As I leave the workshop for the long walk to the hotel via a beer and a meal. Tomorrow is a new year
Image
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 9:16 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

1 January 2017

Does not start well a walk in the rain to breakfasst then picked up and taken to the workshop we decide to bolt down the front roll cage. Hmm it will not the top bolts do not line up I confirm with Brett I have to trim 7mm of the right side top and 1mm form the left side due to the welds stopping the tubes sliding in and we also need to clean up the joins they look awful and some scraps and water damage. It's decided off it comes.

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Making the plug to seal the top tubes from a piece of 4*2 that the guard puppy chewed up,
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Then fitting with sealant
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Then fixing the welds and the grinding mistakes from removing a cross joint gone wrong.
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Then we check the gear lever to see if it'ss working. It is but we discover 4 wires we had missed from the loom. Damn!!!!!!!!

Now we have the issue of the ugly hole from some beaver who called themselves a workshop from the previous owner to deal with also this will burn vauable time. The deadline is 5/March/2017 my birthday.

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Home time I have the front roll cage sanded, filled and undercoated and repainted it looks smick and I cut the ends off correctly an verify with a vernier ruler. The roll cage fits as I fit it myself with the forklift and a bit of string. It bolts in 10 bolts of the 14. The last 4 well I missed thats 6mm hole with a 8mm thread. Needs to be fixed also.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 9:16 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

2 January 2017

Day is for pedals I find everything I neeed, hen its lunchtime and then the heart plays up cos I forgot to take the tablets yesteray and this morning I have to rest for the rest of the arvo.

Hometime pic.
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The 5 day visit ends sadly with a wasted 1/2 day.

Train home to Kuala Lumpur
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

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Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 9:17 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

7 January

Damn the Isuzu is not ready so ISUZU inform me leaving a lasst minute plan of taking the mighty Landcuiser up with its dead air conditioning of taxi train an taxi's I elect the Landcuiser. So we (Joe fom the kids home) arrive 10.00am yes I'm late hot wet with sweat and the windows rolled down for 190k.

First time for Joe make 8 2" Square plates with a nut attached for the underneath of the seats so there is no chance of seat mount bolts pulling through in an emergency. So guillotine lessonss under strict adult supervision.
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My job searching for nutz an bolts and missing wipers part. I fluke the end of the steering lock nut. One WF nut left that we that at the bolt shop by taking the whole steering assembly to the bolt shop.
Image

Then its time for the pedal assemby it does not go well. The master cylinder bolt hole does not line up with the brake pedal.

End of the day what do we have pedal assembly not working. Seat bolt down points done without turning on the argon gas damn. Pedal assembly failed. Steering ready waiting for pedals to be installed.
Image
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 9:19 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

8 January 2017

It's decided after measuring the pedal travel and position etc that the pedal axle needs to be 30mm lower to give 40mm of travel and match up to the lower position of the master cylinder.
Image

The two part pedal is made.
Image

Then I make the bottom of the pedal and the bushes from solid bar and drill them out. They will be welded up Monday as we do not have a long enough 14mm bolt in the workshop but it's now ready to go.
Image

The new templates for the floor coverings are made
Image

Image

Home via a visit to my Ipoh Mum and then windows down the whole 205k drive home
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 10:57 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

31 December 2016

9am we take the Isuzu to the workshop but not before I walk 2.5k in the rain too get breakfast. Isuzu say they wil ring later in the day with a diagnosis. They do 2 fuel pressure sensors have died in the fuel line.

Cannot repair till next Thursday.

Day 3 of the little rush. Brett takes me down to the hydraulic shop we ercut hoses to length and clamp up the end etc for the power steering. So afternoon I start off labelling the power steering hoses at both ends with clear shrink wrap.
Image


The water tank is ready to be tapped up, However we have decided to make one out of stainless steel instead.
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I make a bracket to hold the power steering hoses up high under the cabin
Image


Now it's almost completed.
Image


Image
As I leave the workshop for the long walk to the hotel via a beer and a meal. Tomorrow is a new yearr
Image
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 10:58 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

1 January 2017

Does not start well a walk in the rain to breakfasst then picked up and taken to the workshop we decide to bolt down the front roll cage. Hmm it will not the top bolts do not line up I confirm with Brett I have to trim 7mm of the right side top and 1mm form the left side due to the welds stopping the tubes sliding in and we also need to clean up the joins they look awful and some scraps and water damage. It's decided off it comes.

Image

Making the plug to seal the top tubes from a piece of 4*2 that the guard puppy chewed up,
Image

Then fitting with sealant
Image

Then fixing the welds and the grinding mistakes from removing a cross joint gone wrong.
Image

Then we check the gear lever to see if it'ss working. It is but we discover 4 wires we had missed from the loom. Damn!!!!!!!!

Now we have the issue of the ugly hole from some beaver who called themselves a workshop from the previous owner to deal with also this will burn vauable time. The deadline is 5/March/2017 my birthday.

Image

Home time I have the front roll cage sanded, filled and undercoated and repainted it looks smick and I cut the ends off correctly an verify with a vernier ruler. The roll cage fits as I fit it myself with the forklift and a bit of string. It bolts in 10 bolts of the 14. The last 4 well I missed thats 6mm hole with a 8mm thread. Needs to be fixed also.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 10:59 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

7 January

Damn the Isuzu is not ready so ISUZU inform me leaving a lasst minute plan of taking the mighty Landcuiser up with its dead air conditioning of taxi train an taxi's I elect the Landcuiser. So we (Joe fom the kids home) arrive 10.00am yes I'm late hot wet with sweat and the windows rolled down for 190k.

First time for Joe make 8 2" Square plates with a nut attached for the underneath of the seats so there is no chance of seat mount bolts pulling through in an emergency. So guillotine lessonss under strict adult supervision.
Image

My job searching for nutz an bolts and missing wipers part. I fluke the end of the steering lock nut. One WF nut left that we that at the bolt shop by taking the whole steering assembly to the bolt shop.
Image

Then its time for the pedal assemby it does not go well. The master cylinder bolt hole does not line up with the brake pedal.

End of the day what do we have pedal assembly not working. Seat bolt down points done without turning on the argon gas damn. Pedal assembly failed. Steering ready waiting for pedals to be installed.
Image
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Tue Jan 10, 2017 11:00 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

8 January 2017

It's decided after measuring the pedal travel and position etc that the pedal axle needs to be 30mm lower to give 40mm of travel and match up to the lower position of the master cylinder.
Image

The two part pedal is made.
Image

Then I make the bottom of the pedal and the bushes from solid bar and drill them out. They will be welded up Monday as we do not have a long enough 14mm bolt in the workshop but it's now ready to go.
Image

The new templates for the floor coverings are made
Image

Image

Home via a visit to my Ipoh Mum and then windows down the whole 205k drive home
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

stilivn

User avatar

Posts: 1114

Joined: Wed Jan 23, 2008 8:56 pm

Location: central coast down under

Post Wed Apr 26, 2017 9:49 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

Any updates on this one?
1993 80 series, 4" tough dog adjustable bb lift kit, LPG, 35" MTR'S

brooksy wrote:Branden Tagg.....He is the King of all f@rkups & a Gimps bitch after hours
<<

Andy55778

User avatar

Posts: 2

Joined: Tue May 23, 2017 8:02 pm

Post Tue May 23, 2017 8:45 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

Amazing! My goodness, you must have put a lot of work into this!
I know almost NOTHING about cars. I can drive one, I can put gas in it and I can change my windshield wipers. That is the extent of my car knowledge. So when I had one headlight out, my fiancee told me to buy led fog lights by OPT7.
And I am so glad I bought these. They are very clear (on my 10yr old Jeep Liberty with foggy headlight lenses) and I can see for miles and miles and miles :D
I am so proud of work we made. :cool:
Image
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Wed May 24, 2017 7:36 am

Re: Malaysian Police Volvo C304 (4x4) Restore

22 May 2017

Well it's been 8 weeks at least since I last saw the Volvo. After being off work sick for 6 weeks with a stomach virus from something I ate and now training the orphanage kids for the August Kayak adventure I took a day off work to visit it for progress.

Meantime in the 7 weeks I have obtained new front windows cutoms made and cut for the wonderful price of 40USD a pair for 9.7mm laminated autoglass oh and I left it at home damn curses. I have new LED headlights. The new stainless steel water tank is still being made.

So whats been done.
- Powersteering is almost completed
- Rear 12v power panel is completed no pics as the Volvo is way up on the hoist.

They collected the power steering parts from the engineering shop and I fitted then to the power steering cylinder. Went down to the hydraulic shop cut the hoses to length and got new ends fitted. Then connected the power steering hoses to the new cylinder. New holding brackets for the left and right hoses made and mounted. Could not fit the top power steering hoses as the Volvo is way up on the hoist. But next visit I will have it done.

Mr Brown was so happy to see me he decided to help me on the workbench while I chopped 10mm off the mounting bolts.
Image

Finally it was all bolted down. We may have to change the design of this does not work.
Image

Discussion on the switch rollcall we have 5 to buy to have them able to complete the front switch panel.
Then it was time to test out the new LED headlights. Ooooh they are cool. Bonus they have sidelights and indicators built into them.
Image

So now we can weld in the inserts I made and touch them up with paint etc.
Image

Image

A few things left to do:
- Air conditioning
- Assemble doors
- Build new Drivers dash panel
- Wipers build and fit
- Connect remaining switch panel wires
- PTO find switchs and refit
- Test everything
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
<<

cicak

User avatar

Posts: 235

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Wed Jun 14, 2017 9:40 am

Re: Malaysian Police Volvo C304 (4x4) Restore

9 June 2017

Took the week off to take 17 orphanage kids on a 4 day intensive kayaking training camp. Then had the Friday to myself. So a visit to the Volvo was in order. 5:5am Leave KL with young Joe from the orphanage with me . 7.30am in IPoh for breakfast and 8.15am at the workshop.

So whats been done.
- Powersteering is almost completed - still have resivior to mount
- Bull bar was bolted down but not correct so I have this to fix today.
- Rear floor has been bolted down
- Covers are being made for the inside of the door locks.
- The side bars on the bumper have been remodelled to protect the underneath of the cabin door frame.

Image

Image

Then we moved onto the power steering resivior - cut hoses ready to bolt it in. Damn the braket is imperial bolts 6mm will not fit. We need to go to the bolt shop later.

Cut and fit the brake booster vaccum hose.

Then we found the engine mounts we had missed bolting down the underside of the engine mount locking washer. So we made 2 8mm washers from steel and bolted them in - 1 hour gone

Connected up a missed brake pipe part.

Then it was time for a test fit of the glass we had so happily brought from KL.

Great dissappointment they did not fit. Turns out some idiot made them bigger than the exact tenmplates we supplied. Quality was terrible. They were returned to the glass factory much tot he anger of the big chinese shop manager who looked like he wanted to string the cheap bangaldeshi labourer up when he explained how he made the windows.
Image

Image

Then Joe tried out the hammock setup and gave it the thumbs up.
Image

Oh we missed getting to the bolt shop.

Soon it was hometime and the end of a very unsuccessful day and Mr Brown decided to get friendly with Joe by holding his hand with his teeth.
Image

Final view of the Volvo before I see it in a couple of weeks.
Image

Image

So whats left
- Doors assemble and bolt on
- Air COnd to do
- Dash wiring
- Switch Panel to be cut out
- Power steering final connection
- Fix the loose rubber hose we found under the engine
- Window wipers buy and fit
- PTO Switches find and install
- GEar lever hole repair
- Windows fit.
Dave is www.geckoadventure.net
RED LC II-13/14B-T @ 1.5Bar,35" XTs, GOD Winch +.
YELLOW BJ75-13B-T, 8274 winch,35" XTs,Lockers.
GREEN LC II 1KZ and 35" XTs.
VOlVO C304 Under restoration
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