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Ok so while rebuilding the Volvo I got the idea to restore another and do it faster this time and do the work myself where posible.

Volvo's here for sale are few and far between.

Suddenly we had one for $70,000rm(15,000EU) "restored" looked terrible. Then one popped up for 16,000rm (3,000EU) I rung and got an appointment. To my surprise when I viewed it he had turned down offers for the truck as people only wanted the axles.

I made an offer showed him pics of Volvo 1 and he said SOLD.

So this is the story of a secret build (my wife has no idea) until I finish it.

Pickup condition

It's ROUGH I know the tourist resort it ran out of and saw it being abused never thinking I would ever own it.



Right rear cross member is ripped of the chassis. Left side is bent.


It seats 12 people.


It's nice side


The wheels turn


Looks better in the setting sun in my friends private ship salvage workshop or does it?

21 September 2016

First nights work on it remove the ugly front winch mount




Finished looks nicer already


Removed the passenger seat and cleanup up. The rust becomes apparent.


The pile of scrap metal starts to grow. I'm sure they will make a compact Ford out of this soon.

16 October September 2016

Two of us attack the rear tray object is total removal of it over the coming days


3 hours later and 38 cutting wheels are consumed but the sides are removed.


The pile of scrap gets bigger


Peter runs around and takes pics of the inside for me.

23 October 2016

New Makita 7" grinder in hand.

Commence to cut the bed up. A plasma cutter arrives Tuesday

2 hours I got this far.


Then I got a process going and 4 hours I had the left side removed.


The pile of scrap grows



So what is the plan.

Since Volvo 1 is 2 hours away I am planning to work on Volvo 2 at night after work until I

finish Volvo 1.

This is the idea so far:
- Bad Arse big offroad tuck like they have never seen in Malaysia
- Rugged shopping trolley to go to expensive malls and jockey park it beside the farking

porches ferraris's and Bentley's if you think I'm joking I'm not lol.
- Toss the rear tray steel round tube tray with alloy tray and slightly chopped.
- Full restore of cabin covered in a comp spec rollcage - think Dakar truck - Rahmat from

Rahmat playhouse garage is already crying after seeing the pics
- 2 winches probably 8274's
- fix missing section of right rear chassis
- Bob the rear chassis 12inches
- Rear mounted radiator and intercooler etc
- Air suspension and if I can get past road transport a-frame suspension
- 2 sets of doors one with windows chopped off other full doors (handbag days out with wife).
- fit race harness seats and belts
- Engine possibly 15B-T (4.1 litre 4 cyl diesel) and Toyota auto gearbox and that will be it

one big fun offroad truck that I may use in comp to show because I CAN lol
- Air suspension kit has been ordered and the air guy came around to look at the truck.
- Rollcage made in IPOH rest done in KL at a workshop near work or home.

Hmm. How can you handle this one too?! That thing would take an army and 1000 hours. Sure you dont want it just for parts?

There is a plan and its being executed slowly

I believe I have sourced a 13B-T (Toyota Diesel) engine and a 5 speed H55F gearbox for free. I am almost ready to scrap my beloved BJ75 TROOPY as the body has 5 splits in it 4 of them are unrecoverable. Sad but a decision will be made this week. If so the Engine will be looked at to expand it to a 14B-T under the covers with 1.5BAR of boost , modified CT26 Supra turbo and 14B-T timing gear and fuel pump (modified of course) and a few more 14B-T parts which remain secret lol.

I have collected the Plasma cutter and the new compressor.

A set of PVC pipes will be bought to setup the rough layout of the rollcage, winch locations and spare tire locations etc and the new tray hopeefully next week once we finish cutting the bed out of the truck.

Once that is done we are going to try and start it . Battery missing, No fuel tank, No Key , some xfer case components missing.

If you go the H55F route... Took me quite a while to get a nicely working cable shifter setup done. Looking forward to your solution! If I can help you in any way, feel free to contact me.

.martin

5 November 2016

One day tomorrow is Volvo 1 day.

Collect the boat from the shop have breakfast and 1pm we are ready to cut with the new Plasma cutter

Finally we get the plasma cutter up and running





3.30pm time for home I got the Sultan's birthday bash to attend

2 more cuts and one half of the rear bed comes off.





Final result from todady is a lot of cutting


2 more cuts and one half of the rear bed comes off.

This should go really quickly! You have some much experience from Volvo 1!!

Keep the pictures and write up coming - it very interesting to read and see what's happening in someone else's life!

John

13/14 November 2016

Evening shift. The workshop is only 8k from the office, beats the 190k to IPOH every weekend. No the wife still does not know.

However tonight i've come straight from Ipoh (190k+26k) to the workshop via dinner where I witnessed a stupid motor bike accident across the road from dinner when the motor bike ended under the night market stall afer a car turned right in front of it hilarious stuff.

9pm I'm in the workshop

Awesome 2 cuts and a big chunk of the rear comes off later I find it's a 35kg chunk lol.


Midnite cutoff time and wait the 30 mins to see if any fires etc are starting and look at progress


Yeah it look pretty good


One more night of cutting and I can take it all to the scrap shop.

Still I cannot remove the wheel nuts fom the flat tire. I snap a breaker bar using a 6 foot pipe to assist me. The air rattle gun will not move the nuts either. I need a bigger compressor damn.

Did you let a penetrate-type oil sit on it overnight yet? Torch it to heat it up? Smack it with a heavy hammer?

VinceAtReal4x4s wrote:Did you let a penetrate-type oil sit on it overnight yet? Torch it to heat it up? Smack it with a heavy hammer?

Yes every visit. Nex is heat and the rattle gun.

If all else fails you may have to cut the rim so that a nut splitter can be used. Have you tried an induction heater on the nut? I've seen them get a nut red hot in seconds and come right off with impact then.

Good luck! I have an old text that lists rust as a type of welding.

Cheers, Clive

Nice big pair of bolt cutters to put some nice crevices in ready for the old hammer and chisel technique!

Heat should work without any issues.

John

16 November 2016

Night shift dinner with wife then cruise off to work on Volvo 2

This is my goal tonight cut the remainder of the rear tray off.


By 11.30pm it's done




The pile of scrap steel has stopped growing


17 November 2016

Visit the workshop where the rollcage will be created. Oh my my mates Pinzgauer is also there getting its makeover so I eventually leave 8pm afer a 2+ hour visit. My rollcage design gets the thumbs up.

18 November 2016

Friday night I load up almost all the steel (turns out 260kg) into the trusty Isuzu then 10.15pm arrive at hospital to pickup my mates "wife" and take her out for dinner after she got kicked out of ICU 10:05pm so I can get the low down on his bad operation.

So I realise he is going to have trouble running his workshop after so a set of car ramps and a lie on trolley etc are being organised to be delivered to his workshop before he goes back to work in 4 weeks.