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Malaysian Police Volvo C304 (4x4) Restore

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cicak

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Posts: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Jan 14, 2018 2:38 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

23 December 2017

Up 4am and on the road to avoid the traffic. 7am I'm sitting having breakfast 190k has whizzed past with the help of ZZTOP and BLONDIE.

The speaker panels are back and I test fit them. Still have to get the smoked Perspex and the LED light for the gecko fitted.
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I finish 8.30pm and find a hotel - really expensive like 4 times the rate I normally pay.

Sunday 24 December 2017

I get some help and we fit the 50" LED light then we realise the bottom panel needs to be remade with some more reinforcing it drops 5mm in the middle. Rats!
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The speaker panel is bolted down with 1 rivnut to replace.
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It's 3pm time to head back to KL for XMAS dinner. Mr Brown will not let me pat him as I leave. 6pm I’m sitting back in KL getting cleaned up for XMAS dinner.
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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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Jan 14, 2018 2:39 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

30 December 2017

5am on the road head off to Ipoh again actually the drive is getting to me. This is bad damn motor bike groups thousands of them heading north on their 150cc scooters then it rains making it even worse and I need new front tires. The mighty little Isuzu since I have started 2 years ago reassembling the Volvo has done 98,000 killer meters

I work on the roof panels by lunchtime I have carved one out. Meantime Brett comes in and starts making the bracket for the wiper motor. He has also made the left side of the air cond ducting only the right to do and made the new top for the blower. I realise I have also left my phone at home again.

I start on the rear panels also and get long ways then realise I need to fix up the design a little.
7pm home time back to KL I cannot be bothered with the excessive overnight rates for a holiday weekend. I end up in the bar with my mates and it’s a long night.

31 December 2017

6am I wake up late and just step on it to IPOH the 190k goes past not so nice I need new front tires and it gets dicey rapidly after 120kph in the rain.

The right roof panel is done.
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The finished wiper motor. Just need the arms and the wipers completed.
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I toil away all day and get the rear panels ready and then realise I need a little redesign on the top portion. Doing big panels by myself is not easy on the guillotine.
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Final pics of the year before I head home.
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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
<<

cicak

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Posts: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Jan 14, 2018 2:41 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

6 January 2018

I wake up late 6am I'm on the road and I have a set of Volvo axles in the rear to deliver to Penang tonight.

9am at the workshop fed and ready to go.

Lunchtime it’s down to get new front tires and a visit to the bolt shop for 150 rivnuts to fit the rear panels.

Bolt down the gearlever cover - it's marked ready for final cut and prep. The rear panels are now split into 3 parts a top 100mm piece (4"), the middle part (in the next pic) and the bottom piece.
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8.30pm I finish up after spending 4+ hours making the top rear panel twice - first one ended up as an alloy template.

7 January 2018

Mornings work, make the middle panel.
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Mid afternoon I have the bottom panel bolting down started but I need a double fold done to finish it.
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The middle panel fits finally but needs the bottom panel and top panel bolted in to finish it.
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I bolt in the centre console and slip the steering wheel on and the engine cover. Gear lever cover is cut and trimmed and the holes all drilled to test finally bolt down
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It actually looks really good.
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Time for home its 6pm
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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stilivn

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Posts: 1116

Joined: Wed Jan 23, 2008 8:56 pm

Location: central coast down under

Post Sun Jan 14, 2018 8:06 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

That's bloody awesome really coming along now. Love the drone footage of the boat and elephants. 2 months with no updates I was going out of my mind :lol: Please get those front tyres, I need to see this thing finished :armsup:
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
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cicak

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Posts: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Jan 14, 2018 9:29 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

stilivn wrote:That's bloody awesome really coming along now. Love the drone footage of the boat and elephants. 2 months with no updates I was going out of my mind :lol: Please get those front tyres, I need to see this thing finished :armsup:


Sorry had a huge issue with ISP our access via filezilla suddenly failed and we had a few issues getting support as they work 9-5 and I work 8-7 lol

Front tires were bought last weekend in IPOH MICHELINS - they are awesome in the rain - I can sit on 140k on a wet highway again.

The boat is not bad considering its all completely recycled from parts lying outside in the factory yard. Hull from a returned river jet boat with the 2 engines cut out of it giving us 6 feet back. A new transom welded on. Canopy from alloy pipe lying in the yard. 60HP 4T mercury from a returned film boat which was really smashed up. Cheap plywood floor. Gives us usually 45 kph and about 4k a litre.

Captains seat is a recycled ESKY. Our seats in the boat are camp chairs. But it works and at 25feet has a crap load of room.
Last edited by cicak on Sun Jan 14, 2018 9:39 pm, 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
<<

cicak

User avatar

Posts: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Jan 14, 2018 9:32 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

14 January 2018

Volvo workshop not open and I had Volvo 3's axles in my ISUZU so I elected to drive 365K up to Penang instead and drop the axles off to the boat factory and then help them strip Shanty 1 ready for the 220HP 2JZ (Normally aspirated) engine install and the JET propulsion install since we are sick of the 800M-1K fuel economy out of the 85HP 2-stroke. When we are doing 250-300k per 4 day trip it gets rather expensive. Also the risk of busting a prop on a stump is very very high. I usually replace a prop every 3-4 trips as they eventually get damaged to the point they crack or bend. Then it will be painted same desert storm base colour as Volvo.

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Yes we believe the unit will power the boat they are the same unit they stuck on the 25 foot river boats that the factory built and the same boat in the video.

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Shanty 1 will be extended at the rear by 2 feet with a new transom to protect the jet unit making it 20 feet long.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Sun Jan 28, 2018 12:22 pm

Re: Malaysian Police Volvo C304 (4x4) Restore

Saturday 20 January 2018

Sleep in 6:08am on the road. Traffic for the last 90k was hell trucks being arseholes. Had breakfast at

7:40am and then at the workshop at 8.30 to wait for it to be opened. I have the overhead console with me which I collected last night it looks ok maybe.

A quick fit trial shows it's not in good enough condition and needs to be remade with a different style so no welding is needed inside.
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We bend up the top panel and the bottom panels. The bottom panel is trial fitted and looks ok.

I go out in the afternoon and collect new speakers and then spend hours preparing one speaker to fit the panel.

8.00pm decide its time for food and the hotel.

Sunday 21 January 2018

8.45am start

The bottom panel is trial fitted and looks ok.
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8pm I get assistance from the boat builder and we work on the speaker panels again. All 4 base plates are cut away to fit nicely. The 4" speaker holes are expanded for the 6" speakers and we trim a tab off and a test fit reveals they fit nicely. When finish they need to be stripped and re powder coated.

We test fit the chair. I already have bolted in the middle panel and spent the afternoon getting all the holes drilled some 80 rivnuts and been drilled and installed incpuding redrilling the speaker rivnuts from 4mm to 5mm.
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Then its time for a dash review and we set the drivers seat in then start the dash panel layout design.

However its 8.15pm and its really time for home.

Dinner before I leave Ipoh at 9.30pm for the 190k drive home. It's a 2 hour drive home.

Friday night - weekend is a bust. I wake up on monday with diaroeeha from dinner sigh then wednesday afternoon I'm down with the flu from the office. Any plans for the weekend on the volvo have gone out the window.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Mon Feb 19, 2018 10:04 am

Re: Malaysian Police Volvo C304 (4x4) Restore

Wednesday 31 January 2018

Public Holiday

4.08am I'm on the road and miss the holiday traffic. 1 hour 20 minutes later i'm at breakfast then the workshop at 8.30am. There is 3 of us working on the Volvo. One on the console. One on the air cond ducting and me I first convert the speakers from 4" to 6" holes.

I have assistance Raj the new guy and Brett the owner.

I pull the starter motor so it can be converted to 12v. OMG I realise the SUMP has to be removed to pull the starter.

So I drain the oil and pull the sump off. Then pull the starter motor.

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The passenger side of the ducting is ready.
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and the middle piping is alomost finished.
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Then it's time for home at 6.00pm I have the 190k drive to go as I have to look after the cats as wife is in IPOH visiting her mum.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Mon Feb 19, 2018 10:06 am

Re: Malaysian Police Volvo C304 (4x4) Restore

Thursday 1 February 2018

Another public holiday 5.30am I'm on the road I sleep in. I drive fast for the 190k - not saying how fast but the Isuzu spends most of the time on the wrong side of 150kph.The 190K whizzes by to the dulced sounds of Creedence.

Quick Breakfast and at the workshop 7:55am it's a workday in IPOH. Oh crap yesterdays worker Raj has dissappeared.

It's decided the 24v starter and alternator are to be removed and dropped down to 12v. So it's sump off damn to get the starter out else its engine out. We decide sump also needs to be trimmed and that prompts it being remade to chop the remaining sump wing and then fix it up so it can have the 2.5 litres we have chopped out.
The sump will be remade Friday.

I scoot the Starter down to the nice sparky shop. They say come back 5pm it will be ready converted to 12V.
Image

The sump before it gets chopped (already chopped for front prop shaft) and hacked into its new shape.
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Time for home at 6pm 2.5 hours later I arrive home damn traffic was horrible.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Mon Feb 19, 2018 10:07 am

Re: Malaysian Police Volvo C304 (4x4) Restore

Saturday 3 February 2018

Sleep in, way in I hit the road at 6:08am and hit the 6am saturday traffic the trip is hell 190k takes me an hour and, 40 minutes.

Some idiot in a showpony V8 Landcruiser really gets up my nose pass then pull in and slow down then I have to pass over and over. He decides to try and flash pass me at 160kph on a long uphill as a truck pulls out in front of me and we slow rapidly to 80kph. Pissed I let him pass, I pull up beside him at 160k on the downhill and goad him into racing me. He cannot resist I slam the brakes on at 160k and he races past the speed camera at 160k then flash flash then he decides to slow down I pass him with a BIRD salute lol 13k later it's the IPOH turnoff.

Fast breakfast then its 8.30am at the workshop

First install the radiator back in with its new metric pressure cap welded on last night in Kuala Lumpur at 8pm. Check everything and trim hoses etc to stop any rubbing.

They have remade the sump to retain the 2.5 litres lost when cutting the sump wings off and spend the morning welding the new bottom to the top.

I re-fit the second air compressor after the workshop destroyed the previous one and leave it for them to re-wire.

I have to pull the 12v and 24v alternator today and then take the starter down for conversion.

I get the 12v alternator and brackets stripped off. Then pull the 24v alternator. Down to the auto sparky shop. Get a 12v replacement for the 24v alternator. They convert the old pulley to the new alternator I wait an hour for this to happen.

Meantime I go find cotton canvas for inside the Volvo cabin and oil for the engine. 5pm I return to the workshop and the compressor has been wired in and sump is sand blasted ready to paint.

I collect the powder coated items and fit the door lock covers.
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Meantime Raj has built the removeable drivers dash panel template (access to clutch and brake fluid) ready for them to now make the swingaway instrument panel.
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Tomorrows work fit these.
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Compressors all fitted and wired in again.
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The sump is completed and sandblasted and now ready to be painted Monday.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Mon Feb 19, 2018 10:09 am

Re: Malaysian Police Volvo C304 (4x4) Restore

Sunday 4 February 2018

Workshop 8.45am fit the starter and by 12.00pm it's all installed and I have hopefully made it waterproof and the engine sump is cleaned ready for the sump install.

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Lunch then the fone goes - office I pull the work laptop out. I get the alternator installed with 3 turns holding it in and the office calls again the day is a bust and by 5.30pm I have done no work on the Volvo all afternoon except stare at office computer screens.

The trip home is not worth talking about Sunday night traffic hell. Blondie gets a workout on the stereo along with ZZ Top.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Mon Feb 19, 2018 10:10 am

Re: Malaysian Police Volvo C304 (4x4) Restore

Saturday 10 February 2018

God is it Saturday already can I sleep in for 4 more hours - its 4am - No then sleep in on the road eventually 6.08am. Stuff it I floor it and arrive in IPOH 190k away in 1 hour 15 minutes the speedo rarely under 160kph.

Some idiot really annoys me this time in a BMW for miles guess these idiot don't like being passed by a beaten up Isuzu pickup. I eventually get him back with him getting a speed camera ticket at over 160kph in the pitch black the double flash lights up the morning darkness lol. He stops annoying me.

Breakfast and arrive at the factory 8am ready for work. Funny no Mr Brown at the gate. He's on the trailer shaking. I thought he had been poisoned jump the gate and find he is Caught by his collar on the metal grill he is frantic. He is all over me when I free him.

I work on stuff outside the cabin while Raj finishes the air cond ducting mounting points and drivers vents.

I try and get the windscreen trimmed to make it fit. It's a bust they need to be remade as tempered glass cannot be trimmed.

Raj starts on the flip up instrument cluster to on top of the dash cover he has just made.

I manage to finish the top panel it all lines up and bolts fit perfectly.
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: 292

Joined: Sun Dec 16, 2007 10:22 pm

Location: Jungles, Rivers , Lakes of Malaysia

Post Mon Feb 19, 2018 10:11 am

Re: Malaysian Police Volvo C304 (4x4) Restore

Sunday 11 February 2018

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By lunchtime I have the middle panel fitted and it is almost finished just the window trimming to go.
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By evening I have all the rear panels fitted nicely and have 1 hole to weld up and 2 holes to relocate to avoid the speaker panels.

Cleaned up the panels look ace well worth the effort.
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I fit the wifes seat to see how it will look.
Image

Home time - next weekend is CNY so no work on the Volvo I have been confined to KL
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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