A very busy 480 bank holiday arch restoration

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jamescarruthers
480 Is my middle name
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Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

A very busy 480 bank holiday arch restoration

Post by jamescarruthers » Mon Apr 05, 2010 7:24 am

I just thought I'd share some pictures of my red 480 getting some much needed tlc over the holiday. I've never seen paint oxidised so bad but I choose to rescue this one as it was remarkably sound under the terrible paint and had prettygood arches that seemed only to be just starting to go. So this weekend I've been grinding and treating the arches they went into primer last night. They'll be in top coat today and most of the car cut back to shiney goodness with G3.

Unfortunately the car can't stay in overnight so I have to remask it every morning (this'll be the fourth day). That's getting a bit tedious!

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Last edited by jamescarruthers on Mon Apr 05, 2010 7:38 am, edited 2 times in total.
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

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jamescarruthers
480 Is my middle name
Posts: 2501
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: A very busy 480 bank holiday

Post by jamescarruthers » Mon Apr 05, 2010 7:35 am

Oh, and if anyone can help with increasing the wing to door gap, I've posted in the body section of the forum too.
http://volvo480.dragons.org.uk/forum/vi ... 6e10b31b0c
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

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Van
480 Connoisseur
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Joined: Sun Sep 23, 2007 8:27 am
Location: Ich bin ein Berliner!

Re: A very busy 480 bank holiday arch restoration

Post by Van » Wed Apr 07, 2010 7:10 pm

You sure found yourself some location to do the job.
after over 10 years parted with the 1995 Volvo 480 ES 2.0

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jamescarruthers
480 Is my middle name
Posts: 2501
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: A very busy 480 bank holiday arch restoration

Post by jamescarruthers » Thu Apr 08, 2010 7:29 am

Van,

Yes indeed. That's where I work although technically I don't think I'm supposed to be in the hangar with a car so I took the four day Easter holiday as a good opportunity when work was quiet. Those are Citations in storage in the background. I normally work on C-130s which I think you can just about see a tail of one in the distance.

480s all sprayed red now where I did the work. Just a few days to harden then stonechip paint and a good cut and polish (fingers crossed the colours will match well). Also, I've got some GT wheels on the way to make it look a little different.
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

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pol
480 Is my middle name
Posts: 2794
Joined: Wed Jan 22, 2003 10:48 pm
Location: Eastbourne

Re: A very busy 480 bank holiday arch restoration

Post by pol » Thu Apr 08, 2010 2:54 pm

Nice work and nice hangar!

I did something similar last year (but in a barn and without cool aeroplanes) and am annoyed to find rust creeping through already :( I probably didn't do a good enough job. Rust is orrible.

pol

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chriskay
Friend of Club 480 Europe
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Joined: Tue Sep 30, 2003 12:02 pm
Location: Shrewsbury UK

Re: A very busy 480 bank holiday arch restoration

Post by chriskay » Fri Apr 09, 2010 9:12 am

jamescarruthers wrote: I normally work on C-130s which I think you can just about see a tail of one in the distance.
Thought it looked familiar. I've got a son who spent a few years as a nav. in one. So, is that Marshall's?
2 Kings; Chapter 9 Verse 20

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jamescarruthers
480 Is my middle name
Posts: 2501
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: A very busy 480 bank holiday arch restoration

Post by jamescarruthers » Fri Apr 09, 2010 11:48 am

It is Marshall's yes. But shhhh!

Rust is horrible, yes. I don't normally have to deal with steel but I applied the principles of aluminium corrosion treatment to steel and am confident of the results. Aluminium needs great care not to corrode again so surface conversion is vital and no corrosion must be left in.

I am hoping no rust will come back through. I ground out a lot of corrosion back to bare metal (lucky it wasn't too far gone) but where I considered it too deep I went as far as a I dared then cleaned it up with a rotary nylon brush and treated the whole lot with Jenolite jelly (never used this before but its so much bloody easier than liquid stuff) then treated with anti-corrosion zinc paint, then red primer before final red top coats. I didn't want to leave any in, but if Jenolite is as good as it says it is, the existing stuff that was just a bit too deep but the metal was still sound should have been neutralised.

I don't think it will come back through but if it does it might just be the odd patch and not the whole lot (i.e. if the Jenolite hasn't taken at some point for some reason). So I'm fairly confident!

I did loose a chunk of metal on one arch at the bottom (underneath the car so not really visible) from the worst spot of corrosion. Although its now a bit mishapen it is now neutralised so I am happy to build this up at a later date with sealant. The point is the the car is now corrosion free.

My arches weren't too bad. I have started this with a rustier 480 before and ended up with no arches left (hence launch car now owned by gingerheed has new arches welded on). So don't take my actions with this car as a how to manual on all 480 arches, Ive just been lucky with this one!

Just some underseal to put on the inside of the arch now, stonechip paint on the inner lip and bottom forward section and job done. Oh and still gotta polish the bugger at the weekend so it all matches (I hope).

Finally I thought I'd treat myself to some new wheels so snapped up some 480GT wheels. Now a slight problem but thats for the parts wanted section I guess!
http://volvo480.dragons.org.uk/forum/vi ... 7ce02c8b09
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2006 Citroen C6 Exclusive 3.0 petrol/LPG
2008 Mini Cooper convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES auto
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo auto
E981 KHM -- ES (509849)

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