Oli's 1992 Volvo 480ES Limited Edition

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100
Started learning about 480
Posts: 75
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by 100 » Thu Apr 30, 2020 9:42 am

Turbo calipers, rebuild kit and paint kit are enroute to me now, need to get this bumper back on before my attention is drawn away to more exciting things!

Any tips on pads or discs, I know it comes up for discussion quite regularly in the brake section but does anyone have first hand experience with the Tarox/Black Diamond stuff?

On initial browsing these look like they might do the job: https://www.demon-tweeks.com/uk/black-d ... bd2583com/

https://www.demon-tweeks.com/uk/black-d ... kbd584com/

All show and no... stop? I always treat drilled discs with great suspicion, although I've never had any.
1992 Volvo 480 ES Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II

100
Started learning about 480
Posts: 75
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by 100 » Mon May 04, 2020 9:14 am

Small update:

De-rusted and protected:
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Back in the bumper:
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Finished bumper:
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Excuse the filthiness of my work area!

Rust treatment is on going on the rear of the car, and the other arch
Image

Hopefully prep and painting will take place over the course of this week.
1992 Volvo 480 ES Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II

100
Started learning about 480
Posts: 75
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by 100 » Sun May 10, 2020 7:38 pm

An update for the last few days work, I've been taking this very steady and making mistakes every step of the way so it's been a bit painful...!

To summarise:

Before:
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After:
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Removing some tape was enough to remove my 'limited' badge...

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Started on the arches today but it was too cold/windy to make any real progress.

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My Turbo brakes arrived, which I'm very pleased about. It has got me wondering whether there is any difference in the master cylinder between a N/A 1.7 and a Turbo? Does anyone have any Turbo brake diagrams so I can find parts etc. The pistons look okay but if replacements are cheap I may as well!

It also occurred to me whilst looking at the tiddly rear brakes, is there any reason the existing front couldn't be moved to the back?

Any thoughts much appreciated as this is all new to me - particularly the bodywork which I have to say i haven't particularly enjoyed but I'm sure that has a lot to do with how good (bad) a job I did. It's enough to protect the car, but is miles away from anything professional.
1992 Volvo 480 ES Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II

jifflemon
480 Is my middle name
Posts: 1297
Joined: Sat Dec 17, 2016 11:03 am

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by jifflemon » Mon May 11, 2020 12:56 pm

100 wrote:
Sun May 10, 2020 7:38 pm
Removing some tape was enough to remove my 'limited' badge...
I'd probably removed the other one, gives you a chance to scrub them both clean, and the panel behind it too.
100 wrote:
Sun May 10, 2020 7:38 pm
My Turbo brakes arrived, which I'm very pleased about. It has got me wondering whether there is any difference in the master cylinder between a N/A 1.7 and a Turbo? Does anyone have any Turbo brake diagrams so I can find parts etc. The pistons look okay but if replacements are cheap I may as well!

It also occurred to me whilst looking at the tiddly rear brakes, is there any reason the existing front couldn't be moved to the back?
Piston diameter is the same across the range (54mm). Fwd cars don't really need bigger brakes at the back. They tend to do very little as it is until you get some passengers in there. Then of course, the complete lack of handbrake mechanism would also not help - I know as 480 owners were used to a lack of handbrake, but Mr MOT tends to get annoyed when you remove it altogether!

For replacements parts I use Brakes International

Alan 480
480 Is my middle name
Posts: 1060
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by Alan 480 » Tue May 12, 2020 6:41 pm

jifflemon wrote:
Mon May 11, 2020 12:56 pm
Then of course, the complete lack of handbrake mechanism would also not help - I know as 480 owners were used to a lack of handbrake, but Mr MOT tends to get annoyed when you remove it altogether!
are you allowed to use a 'line lock' ie a quarter turn ball hand valve on the hydraulic circuit, or is this only a thing the 'racing' boys use for weight saving?
Alan

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

jifflemon
480 Is my middle name
Posts: 1297
Joined: Sat Dec 17, 2016 11:03 am

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by jifflemon » Tue May 12, 2020 7:58 pm

Never used to be allowed.

Handbrake was to be independent of hydraulic circuit in case of failure. I suspect the modern (and equally stupid!) electronic handbrakes fail "on", and electricity is applied to release them.... Never had to deal with such stupidity, so don't know for sure.

100
Started learning about 480
Posts: 75
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by 100 » Wed May 13, 2020 4:46 pm

jifflemon wrote:
Mon May 11, 2020 12:56 pm
I'd probably removed the other one, gives you a chance to scrub them both clean, and the panel behind it too.
Definitely what I'll be doing!
jifflemon wrote:
Mon May 11, 2020 12:56 pm
Piston diameter is the same across the range (54mm). Fwd cars don't really need bigger brakes at the back. They tend to do very little as it is until you get some passengers in there. Then of course, the complete lack of handbrake mechanism would also not help - I know as 480 owners were used to a lack of handbrake, but Mr MOT tends to get annoyed when you remove it altogether!
That's good to know thanks, I didn't consider the handbrake on the rears. How do they work, on my other car the handbrake is completely separate from the caliper? It's not that the car needs bigger rear brakes its just a case of utilising the bigger ones because I've got them... Bigger is always better right!
jifflemon wrote:
Mon May 11, 2020 12:56 pm
For replacements parts I use Brakes International
Out of stock, but I think for the sake of £18 each it'll be worth getting them and as much other new bits as I can.

Fresh goo in the arches:
Image

I've also thoroughly cavity waxed the inside of the arches and rear quarters, as well as the sills. Clearly I can't get a pic of this!

Arches painted:
Image

New airbox pipe:
Image

New storage tray as I broke the last one replacing the heated seat button... little things make all the difference!
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1992 Volvo 480 ES Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II

100
Started learning about 480
Posts: 75
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oli's 1992 Volvo 480ES Limited Edition

Post by 100 » Wed May 20, 2020 9:00 am

So thankfully, the car is back together which is a bit of a relief, even took it to the pub!

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Social distancing at Wills:

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The back box cooked the exhaust tape so it's back to sounding like a shit rally car and I'm still sans-splitter but at least I can drive around in the sun!
1992 Volvo 480 ES Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II

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