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.

Moderators: jifflemon, coyote1980, Rachel

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

Post by jifflemon » Wed Jan 29, 2020 12:59 pm

Glass back - Always a need for heated seats!

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Wed Feb 05, 2020 6:24 pm

Finally managed to start getting my headlights reinstalled thanks to the new bushes from Jifflemon.
A+ packaging btw
Image

New bulbs, Phillips Racing Vision for headlights, LEDs for the DRLs.
I've cleaned up and resprayed the frames for the headlights, not that anyone will ever see them but made me feel a bit better.

Both the DRLs light up when no lights are switched on, but with sidelights and headlights on only the left stays on, any ideas?
Image

Bumper will be reassembled this week and finally some work on the rust I hope. Been topping the rear light seals up with creeping sealant to hopefully stop the leaks, feels like I'm close.
-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 » Wed Feb 05, 2020 8:35 pm

which DRL's did you get?

If you switch back to a standard bulb, does it do the same?

With ignition on, you should get the full fat 21w brightness.
With headlamps/sidelamps on, you should get 4w.

the pins are offset too - make sure you get the bulb in correctly.

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Fri Feb 07, 2020 8:22 pm

jifflemon wrote:
Wed Feb 05, 2020 8:35 pm
which DRL's did you get?

If you switch back to a standard bulb, does it do the same?
Honestly not sure if it was doing it before, have a couple pictures with the DRLs on but with the headlights on it's so hard to tell if the driver's on is working or not.
And with the old bulbs the passenger one was the weaker bulb so they were both getting replaced anyway. But if it doesn't sort itself out I will have a proper look soon, not that it's hard to get the housing out.

This is the LED I got for the DRLs. I didn't want to order some cheap crap from eBay and have it look shite. So this what I picked.
-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 » Thu Feb 27, 2020 5:59 pm

So finally after a couple weeks of no updates I have feel I have made some small progress.
I won't link every picture because I don't think most people will want to see everything but you can find mostly everything in my album.
480 progress album

Left arch
Began like this
Image
Currently like this
Image
Now composed of a lot of fibre glass filler. Could have been a bit smoother if I put more time into it but fairly happy. Might do the next coat of paint before MOT but not too bothered as long as it's all covered.

Began to look at the right arch and quickly found that another spot I thought might be a bit of trouble was actually very big trouble.
Fist for scale
Image
"Finished" welding
Image
Yes the welding is bad. Literally first ever time I have welded. Did a bit of practice but the boot doesn't have the best angle. Plus this welder is a very cheap one, and I didn't use any gas.

The remaining bit to do here is some filler underneath to make it a bit smooth and then underseal.
Would you put anything on the top or just primer and paint?

Predicting being all ready next weekend, would have been much sooner if not for these storms, and the fact that half of my tools are either in storage someplace or another. Finish line I think in sight, it really just is a bit more filler, bumper reassemble and back on, then front fogs.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

Alan 480
480 Is my middle name
Posts: 1063
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Fri Feb 28, 2020 12:41 pm

I use 'Grey stripe' body mastic, which is really for sealing seams but sticks like poo to blanket ! :wink:

almost as good as original under body stuff :hopping:

I apply it direct to the galvanised /bare metal
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 Feb 28, 2020 4:58 pm

Alan 480 wrote:
Fri Feb 28, 2020 12:41 pm
I use 'Grey stripe' body mastic, which is really for sealing seams but sticks like poo to blanket ! :wink:

almost as good as original under body stuff :hopping:

I apply it direct to the galvanised /bare metal
Yup, would avoid using filler anywhere where moisture can get to it. It absorbs moisture!

Seam sealer, body mastic (different names, same product) followed by lashings of a decent paint (por 15 for me!) will be the best defence

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Mon Mar 30, 2020 11:34 am

I have done a bit more welding and put the bumper back but I'll make a separate post for that.
In the meantime can anyone tell me what this hanging cable is? Guy I bought it from claimed it was a spare cable for another model.
Image
Also this rubber mounting here, for whatever that is. Search me I'm not exactly a mechanic. But any idea of spares or repairs for this?
Image
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

jifflemon
480 Is my middle name
Posts: 1302
Joined: Sat Dec 17, 2016 11:03 am

Re: First 480, first real project car

Post by jifflemon » Mon Mar 30, 2020 12:21 pm

Possibly the wiring for the additional oil pressure gauge?

Alan 480
480 Is my middle name
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Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Mon Mar 30, 2020 3:10 pm

WalkableBuffalo wrote:
Mon Mar 30, 2020 11:34 am
I have done a bit more welding and put the bumper back but I'll make a separate post for that.
In the meantime can anyone tell me what this hanging cable is? Guy I bought it from claimed it was a spare cable for another model.
Image
Also this rubber mounting here, for whatever that is. Search me I'm not exactly a mechanic. But any idea of spares or repairs for this?
Image
I 'might' still have a mount for the idle control valve, the rubber should warap around the WHOLE of the valve I'll have a look at week-end and you can have it (postage only) if none closer to hand.

also I see that the pipe from idle valve to inlet has been 'taped-up' with self amalgamating tape, not clever, again there might be a spare here
Alan

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

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

Post by AleksanderHugo » Mon Mar 30, 2020 6:16 pm

Isn't it an aircon compressor plug?

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

Post by jifflemon » Tue Mar 31, 2020 9:20 am

AleksanderHugo wrote:
Mon Mar 30, 2020 6:16 pm
Isn't it an aircon compressor plug?
Oooo Thats another good possibility

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Tue Mar 31, 2020 1:58 pm

Alan 480 wrote:
Mon Mar 30, 2020 3:10 pm
'might' still have a mount for the idle control valve, the rubber should warap around the WHOLE of the valve I'll have a look at week-end and you can have it (postage only) if none closer to hand.

also I see that the pipe from idle valve to inlet has been 'taped-up' with self amalgamating tape, not clever, again there might be a spare here
Sounds good Alan, do let me know!
What is the problem with the self amalgamating tape? Wasn't my doing.
AleksanderHugo wrote:
Mon Mar 30, 2020 6:16 pm
Isn't it an aircon compressor plug?
That would be curious as I don't have air conditioning, but as long as it's not an issue. I've just got it tied back there as I didn't like it so close to the alternator.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

Alan 480
480 Is my middle name
Posts: 1063
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Tue Mar 31, 2020 4:51 pm

WalkableBuffalo wrote:
Tue Mar 31, 2020 1:58 pm
Alan 480 wrote:
Mon Mar 30, 2020 3:10 pm
'might' still have a mount for the idle control valve, the rubber should warap around the WHOLE of the valve I'll have a look at week-end and you can have it (postage only) if none closer to hand.

also I see that the pipe from idle valve to inlet has been 'taped-up' with self amalgamating tape, not clever, again there might be a spare here
Sounds good Alan, do let me know!
What is the problem with the self amalgamating tape? Wasn't my doing.
well I found the idle valve mount,

the pipe is probably not a problem, just to make things a bit tidier for you
I'm sure there is a pipe as well,(or 2) just been put in a safe palce, never tidy the garage/shed etc :wink:

if you are in no rish I'll have another proper look for the pipe at week-end when allowed out
Alan

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

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Wed Apr 01, 2020 7:52 pm

Alan 480 wrote:
Tue Mar 31, 2020 4:51 pm
well I found the idle valve mount,

the pipe is probably not a problem, just to make things a bit tidier for you
I'm sure there is a pipe as well,(or 2) just been put in a safe palce, never tidy the garage/shed etc :wink:

if you are in no rish I'll have another proper look for the pipe at week-end when allowed out
Yeah no rush mate. Just wrestling with trying to get my front fogs out now, so hopefully next week everything will be ready to finally go further than the end of my street!
-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 » Sat Apr 04, 2020 5:43 pm

Here is the complementary hole from my other wheel arch.
All welded, sealed, and painted now.
Image

I hate to agree with the "Hayne's book of lies" comments but at least for the 480 it is patently useless in so many areas. I thought the front foglights were just the front 3 screws on each side, but you really do have to remove the entire front grill to access the area shown in the book. And boy that was a lot of fun for my dad and I. Thankfully managed to get a few out with just WD40 and brute force, but most of the others had to be drilled. The foglight mounts themselves, while also very stuck, did come out eventually.

Also is the nut for the rear wiper a unique one? I have the whole wiper assembly, which was off the car when I bought it, but no nut. From pictures it looks to be very thin so not sure if I can acquire a replacement.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

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Anadinolin
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Re: First 480, first real project car

Post by Anadinolin » Sun Apr 05, 2020 12:39 am

That plastic stuff you sliced up, someone suggested hammer and chisel. If you are on Facebook I am the guy with the rotten silver turbo 460 that keeps spamming the page with my recent work on the car!

Well done with everything you are doing so far!

https://www.facebook.com/groups/564695 ... 178186650/

Andy V 👍
What good music needs is full deep bass to give it warmth

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Sun Apr 05, 2020 10:33 am

Anadinolin wrote:
Sun Apr 05, 2020 12:39 am
That plastic stuff you sliced up, someone suggested hammer and chisel. If you are on Facebook I am the guy with the rotten silver turbo 460 that keeps spamming the page with my recent work on the car!

Well done with everything you are doing so far!

https://www.facebook.com/groups/564695 ... 178186650/

Andy V 👍
Thanks mate! Yeah I have been keeping up with your antics there. Appreciate all the nitty gritty detail, fingers crossed you can get it all sorted. I think I've seen to most of the rot on mine, I am hoping I've managed to get enough to get through the MOT now. I don't mind if I have to renew a few components but hopefully no more welding for now 😬

I actually worked out to use a hammer and chisel when I first did the other side. As long as you are careful not to scrape up the boot floor too much. I also used a Stanley knife and Dremel on the rubber bits above that.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

Alan 480
480 Is my middle name
Posts: 1063
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: First 480, first real project car

Post by Alan 480 » Sun Apr 05, 2020 5:28 pm

the rear wiper nut is a 'half thickness' but a normal M8 will be fine :wink:
Alan

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

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WalkableBuffalo
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Re: First 480, first real project car

Post by WalkableBuffalo » Thu Apr 09, 2020 11:54 am

Slightly prettier for ~£5 including new clips, cheers Alan
Image

Just waiting on some new bolts for my foglights and then I should be good to go. Wait for me to prove myself wrong.
-Will
1991 480 ES, 1.7, Arctic Blue
Current status: No MOT, 99% ready I swear

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