First 480, first real project car

Here you can talk about the joy owning a Volvo 480 brings. Non-technical discussions take place here, like what is the difference between an ES and a S version.

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Alan 480
480 Is my middle name
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Re: First 480, first real project car

Post by Alan 480 » Thu Jan 16, 2020 9:22 pm

well done on tackling a 480 as a first off.

don't be tempted to take too much apart at any one time as the project can quickly become daunting!!

if arches are not too bad, you can do quite a lot with P45 vs P38 as it is filled wwith chopped strand and is much stronger / bridges gaps etc, having run GRP cars for most of life, I'm a big fan of GRP / composite / injection mouldings etc sometime I wish they go back to a chassis and body :-)

by plastic arch liner things, you mean the short vertical section at back wheels?

I fitted builders galv sections to replace the vertical bracket (see Nora Thread) if the mounts at the top are broken off then I fitted a short piece of 1 1/2" galv angle bolted through the floor, used 'dexion' domed heads so neat underneath, nuts within boot. I could have fitted a piece of 'joining plate' from floor to bumper but then there would have been no adjustment

if you mean the stupid sponge holders ? I ground the heads off the screws with angle grinder, a wee bit at atim eto keep cool and not melt plastic. they should be VERY hard so wo'nt drill easily :-( to reattach I just used a single long cable tie suitably pre bent to go in front hole and out rear, fiddly but saves dicking about with rusted screws in future, although I have just received 2 or 3 kg of mixed small SS bolts (and a few nuts, sadly ratio of bolts to nuts seems to be ten to one .. . . . I'm hoping the last box will have all the nuts (hoping)

bumper should come apart easily, as long as you can get a purchase on ten of the phillips headed screws!!! if not Mr grinder to rescue as vice grips will slip off the top curve :-(
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

jifflemon
480 Is my middle name
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Re: First 480, first real project car

Post by jifflemon » Fri Jan 17, 2020 8:35 am

Alan 480 wrote:
Thu Jan 16, 2020 9:22 pm
well done on tackling a 480 as a first off.

don't be tempted to take too much apart at any one time as the project can quickly become daunting!!
THIS!

Take a look at my project thread - The bodywork on my 480 is battered and 3 years on, it's still the same whilst lots and lots of other jobs are being tackled.

Set yourself a goal of getting it MOT'd and on the road. The only exception I'd make is that where something bodywise HAS to be done (structural welding for MOT), then do it properly. Then make sure the repair is properly rust proofed so that you don't have to revisit in a few years time.

People on here would rather see a tatty 480 turn up to an event than no 480 at all!

Plus, driving and using a 480 will help you find the oh so many more things for your list of things to fix! :lol:

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WalkableBuffalo
480 Newbie
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Re: First 480, first real project car

Post by WalkableBuffalo » Sat Jan 18, 2020 5:27 pm

Alan 480 wrote:
Thu Jan 16, 2020 9:22 pm
by plastic arch liner things, you mean the short vertical section at back wheels?

I fitted builders galv sections to replace the vertical bracket (see Nora Thread) if the mounts at the top are broken off then I fitted a short piece of 1 1/2" galv angle bolted through the floor, used 'dexion' domed heads so neat underneath, nuts within boot. I could have fitted a piece of 'joining plate' from floor to bumper but then there would have been no adjustment
Yup that is the one. Still only got one side properly removed, but I'll take a look at Nora cheers. 👍
jifflemon wrote:
Fri Jan 17, 2020 8:35 am
Alan 480 wrote:
Thu Jan 16, 2020 9:22 pm
well done on tackling a 480 as a first off.

don't be tempted to take too much apart at any one time as the project can quickly become daunting!!
THIS!

Take a look at my project thread - The bodywork on my 480 is battered and 3 years on, it's still the same whilst lots and lots of other jobs are being tackled.

Set yourself a goal of getting it MOT'd and on the road. The only exception I'd make is that where something bodywise HAS to be done (structural welding for MOT), then do it properly. Then make sure the repair is properly rust proofed so that you don't have to revisit in a few years time.
I am trying not to take too much off. :lol:
Slightly too late now, and it's sad coming home every day to her on jackstands.
But the rear bumper is all apart now, just got to figure out how to get a couple of new bolts on there. Will probably just hand it off to a welder my dad knows.
Nothing else is coming off the car, fingers crossed, except the part of the exhaust covering the handbrake adjuster, struggling to turn it much with it in the way.
So once the bumper is ready I should have put all the other bits back on. As for the rust on the arch, I think the hole can be patched with a bit of metal from the scrap door I got with the car, but I'll wait to look at it since I've got so much going at once already.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

jifflemon
480 Is my middle name
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Re: First 480, first real project car

Post by jifflemon » Sat Jan 18, 2020 6:43 pm

I tend to work a little hap-hazardly, jumping from one thing to the next.
Setting a goal, and Making a list of whats needed to achieve it is a really good thing.

But also....

Whilst the car is jack stands:

Clean the wheels (insides as well!)
Check brake linings, bleed the fluid.
check your front suspension condition - Spring cups in particular.

:rofl:

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dcwalker
480 Is my middle name
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Re: First 480, first real project car

Post by dcwalker » Sat Jan 18, 2020 6:51 pm

Will, getting the heat shield off to get at the handbrake adjustment can be tricky, as you are finding. before you fight further with it though, have you done the necessary adjustment at the calipers? From what I can see in the photos your rear brakes look to be in quite good nick, but adjustment of the handbrake always starts at the brakes themselves on these cars...

David
Current: 1994 480 GT, 1995 Celebration 331 (plus 2004 C70 Collection & 1995 440 ES)
Previous: Celebration 467 (returned to Martin Mc); Celebration 346 (re-homed with Alan480); Celebration 269 (scrapped abandoned project), Celebration 73 (sold on after 6 years), 1992 ES, 1988 ES - and numerous other non-480 Volvos!

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Mon Jan 27, 2020 4:09 pm

So finally managed to put some bits back on the car 😅
Rear shocks and roll bar links have been refitted. Exhaust backbox was sprayed with some high heat aluminium, just to make it a bit prettier, refitted with some assembly paste, new clamp and rubbers. Handbrake adjustment done, seems okay at about 4 clicks but will see how it goes.
Now back on all 4 wheels after nearly a month.

Bumper bar has had a patch and new stud, but still needs fully cleaning to go back in. People who have taken their bumper off, do you put the foam insert back in or do anything with it?
Image

Now I'm turning my attention to the lights as I've got a few new bulbs, LEDs for the DRLs. Turned out one of those plastic bushes which adjusts the headlight was damaged causing it to pop out a bit. I've already taken the headlight out but had to really fight the two undamaged bushes to remove it 😪. But I'll order 6 new bushes.

The auxiliary lamp seems to have quite a bit of moisture on one side, which I really don't like. It works fine but wondering if there's a way to get in there to dry it out and then prevent the moisture returning?
Image

After all the bulbs are done it's hopefully the one last step before MOT. The dreaded rust.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

Norm57
Knows an Aerodeck isn't a 480
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Re: First 480, first real project car

Post by Norm57 » Mon Jan 27, 2020 4:39 pm

Things seem to be progressing ok Will. If you get thru the mot maybe you can make the Waterfalls mini-meet on the 15th of March.There will be a few of the ‘locals’ along to that, so plenty of help and advice available if you need it. Good luck.

Alan 480
480 Is my middle name
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Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Mon Jan 27, 2020 5:55 pm

Ref foam
IMHO you need to put it back to keep the shape

Ref the water within the driving lights, on ours one gets wet, other stays dry(ish)

I've taken them out left on top of the old CH boiler (around 40C) sealed around the edge with silicon sealant, returned to car and three weeks later they are wet again .. .. . . :?

not called ES AKA 'en suite' for nothing :-)
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

jifflemon
480 Is my middle name
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Re: First 480, first real project car

Post by jifflemon » Mon Jan 27, 2020 6:17 pm

WalkableBuffalo wrote:
Mon Jan 27, 2020 4:09 pm
People who have taken their bumper off, do you put the foam insert back in or do anything with it?
Absolutley! The two bits of foam at the sides that sit on the plastic shelves though.... They need obliterating.
WalkableBuffalo wrote:
Mon Jan 27, 2020 4:09 pm
But I'll order 6 new bushes.
I know a man that keeps them in stock....
WalkableBuffalo wrote:
Mon Jan 27, 2020 4:09 pm
The auxiliary lamp seems to have quite a bit of moisture on one side, which I really don't like. It works fine but wondering if there's a way to get in there to dry it out and then prevent the moisture returning?
Bulb out, hairdryer pointed at it.... it'll get a tad toasty. Maybe enough to separate the glass.

Image

Although to dry for even longer, then reseal - But as alan says, they do tend to attract a bit of moisture!

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AleksanderHugo
Started learning about 480
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Re: First 480, first real project car

Post by AleksanderHugo » Mon Jan 27, 2020 9:17 pm

I think the lights shouldn’t be completely sealed. There are few “ventilation openings” — at least one on the back of the unit and one at the bottom. They allow air to circulate around the light, so it can dry out.

Martin Mc
Can tell where the 480 was built
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Re: First 480, first real project car

Post by Martin Mc » Tue Jan 28, 2020 7:32 am

AleksanderHugo wrote:
Mon Jan 27, 2020 9:17 pm
I think the lights shouldn’t be completely sealed. There are few “ventilation openings” — at least one on the back of the unit and one at the bottom. They allow air to circulate around the light, so it can dry out.
Yeah, like that is ever going to happen on a wedgie! :lol: None of my 6 cars (so far) has ever had dry eyes :)Design Genius!
Volvo 480 - There's NOTHING like it!
Previous 480 pedigree: 1992 ES (1.7 White) 1993 ES (2.0 Red) 1994 S (1.7 White) 1994 ES 2.0 (metallic red) 1995 S (1.7 Black) 1993 ES (2.0 Paris Blue) (0ver to you Keith!) #467/480 Celebration (flame red metallic)
Every decent bloke deserves an extra-marital car (so my wife tells me)(apparently it keeps me out of mischief.... really..)

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Tue Jan 28, 2020 12:44 pm

Norm57 wrote:
Mon Jan 27, 2020 4:39 pm
Things seem to be progressing ok Will. If you get thru the mot maybe you can make the Waterfalls mini-meet on the 15th of March.There will be a few of the ‘locals’ along to that, so plenty of help and advice available if you need it. Good luck.
Fingers crossed I will make it. Just after my birthday so would be a good treat. If I don't make it through MOT by the end of Feb I will be thoroughly disappointed.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Tue Jan 28, 2020 12:46 pm

Alan 480 wrote:
Mon Jan 27, 2020 5:55 pm
not called ES AKA 'en suite' for nothing :-)
:cryhard:
To be fair the 480 is the best equipped stock car I've driven so far. Heated seats, electric sunroof, and electric aerial as standard is certainly nice.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

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WalkableBuffalo
480 Newbie
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Re: First 480, first real project car

Post by WalkableBuffalo » Tue Jan 28, 2020 12:48 pm

Since I couldn't find it in the manual or on the forum, are these 3 screws how you take out the front fog lights?
Image
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

jifflemon
480 Is my middle name
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Re: First 480, first real project car

Post by jifflemon » Tue Jan 28, 2020 1:24 pm

I normally remove the whole grill first, because OMG you'll struggle with the upper ones.... :angry:

Norm57
Knows an Aerodeck isn't a 480
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Re: First 480, first real project car

Post by Norm57 » Tue Jan 28, 2020 5:09 pm

WalkableBuffalo wrote:
Tue Jan 28, 2020 12:44 pm
Norm57 wrote:
Mon Jan 27, 2020 4:39 pm
Things seem to be progressing ok Will. If you get thru the mot maybe you can make the Waterfalls mini-meet on the 15th of March.There will be a few of the ‘locals’ along to that, so plenty of help and advice available if you need it. Good luck.
Fingers crossed I will make it. Just after my birthday so would be a good treat. If I don't make it through MOT by the end of Feb I will be thoroughly disappointed.
Ok Will hope all goes well.let me know as soon as you decide. That’s for booking the meal I need a rough idea of the numbers.cheers

Alan 480
480 Is my middle name
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Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Tue Jan 28, 2020 5:38 pm

WalkableBuffalo wrote:
Tue Jan 28, 2020 12:46 pm
Alan 480 wrote:
Mon Jan 27, 2020 5:55 pm
not called ES AKA 'en suite' for nothing :-)
:cryhard:
To be fair the 480 is the best equipped stock car I've driven so far. Heated seats, electric sunroof, and electric aerial as standard is certainly nice.
totally agree, but when you consider that they were around £15000 when new!!!! :wink:
mine is fitted for heated seats, just no-heat :(
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

jifflemon
480 Is my middle name
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Re: First 480, first real project car

Post by jifflemon » Tue Jan 28, 2020 6:16 pm

Alan 480 wrote:
Tue Jan 28, 2020 5:38 pm
mine is fitted for heated seats, just no-heat :(
Gonna but upgrading mine soon - Very cheap, relatively simple to do...

A feel another "how-to" is coming...

arthuy
Advanced 480 rookie
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Re: First 480, first real project car

Post by arthuy » Tue Jan 28, 2020 7:29 pm

I would drill the screw heads for the fogs. The plastic can break.

Alan 480
480 Is my middle name
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Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Wed Jan 29, 2020 12:37 pm

jifflemon wrote:
Tue Jan 28, 2020 6:16 pm
Alan 480 wrote:
Tue Jan 28, 2020 5:38 pm
mine is fitted for heated seats, just no-heat :(
Gonna but upgrading mine soon - Very cheap, relatively simple to do...

A feel another "how-to" is coming...
summer is here , no need for heated seats? :wink:
Alan

480 ES 2litre x 2, C30 1.8ES, SS1

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