1994 Volvo 480 Turbo Diary - Update December 2020

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MisterH
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Re: 1994 Volvo 480 Turbo Diary - Update October 2020

Post by MisterH » Fri Oct 30, 2020 11:12 pm

Oh my word that is just heart stopping :eek:

I am not particularly practical, or at least not as practical as I'd like to be when it comes to cars, but that looks like a massive job.

I'm just trying to work out how that is possible
to mess up, given that the arches are part of the tub, but did you say it was a dodgy repair?


I am so sorry to hear this, but as you said the positive to this is that you found it before spending c.£3k on paint :D


Hope this can be sorted and we can help out as a community

Ben
Current Jobs to do (1/1/21):
Fix Central Locking
Fix drivers side speaker
suspension creaking below 40mph

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Jay-Kay-Em
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Re: 1994 Volvo 480 Turbo Diary - Update October 2020

Post by Jay-Kay-Em » Sat Oct 31, 2020 12:15 am

jifflemon wrote:
Fri Oct 30, 2020 9:25 pm
Just to be ABSOLUTELY sure (and I'm sure you've checked) but have you measured from window frame down to arch?
Measurements validated from floor > up, as well as window line > downwards.

The history file has an invoice in 2010 for 'bodywork' by a garage in Abergavenny. This will be it i'm sure.

Its comical really; wheel arch replaced 20mm too high and I have fitted 20mm lowering springs only to obtain a standard ride height :rofl:

Looking back at the few photos I have of the car it was always there to be seen NS vs. OS..... but I never really studied the car because it was always seen as a project.

It'll keep me busy in Lockdown #2 !

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1994 Volvo 480 Turbo Diary - Update December 2020

Post by Jay-Kay-Em » Sun Dec 13, 2020 12:20 pm

Hi all!

December 2020 - The Wheel Arch Procrastination Edition!

What can you find to do instead of cutting all your hard work to pieces?

Instrumentation

I had the steering column out in the last update, so it seemed like a perfect time for instrument cluster removal...

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There are 'issues' to be seen already... corrosion...

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Three known defects to rectify:

1) Intermittent speedo operation
2) Odometer not working at all - irrespective of speedometer
3) Info Centre not visible

Plus, SRS and ABS lamp deletion for those two now-removed systems.

Firstly, a massive thank you to Jaster and Brinkie for the official thread here

Info Centre Bulb

You could only see the info centre if you shined a torch on the LCD... it was clearly an illumination issue.

The old bulb was seriously corroded with a dirty twist socket track...

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No worries, just clean the socket track right? Errrr, no! Some of the PCB track missing after cleaning... :shock:

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The prongs of the new bulb will have no metal to contact with.

Twist-track repairs underway... this is where Brinkie cringes.. I am no electronics guy!

Buy a length of clock spring copper...

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Solder into position...

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Testing for 30mins or so (so heat can be a factor)... all good!

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Odometer Cog

Again, I can't praise the "how-to" thread highly enough...

Remove the speedo head...

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Remove the odo wheel set...

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Open up and find the offending cog of doom...

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Available on eBay due to the amazing 3D printing community (again)...

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Speedometer (hopefully!)

In a search for speedometer issues, the mandatory "dry-joint" inspection can commence...

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The main culprit was the main board connector blocks...

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Really bad solder cracks that are easy to spot with magnification...

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Re-soldered...

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Hopefully that has cured all issues.


Ancillary Parts

In preparation for engine install, an assessment and cleaning of all ancillary parts...

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Upon which I noticed my fan shroud had a broken bottom clip, so a second hand item obtained. They are not quite the same, the fan motor orientation is different, but I think it will be ok...

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The problem with making things nice is that the project starts getting out of hand. You can't go bolting on shabby items when so much effort has occurred elsewhere.

I present "Exhibit A"... a shabby alternator...

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Stripped as far as the windings will allow and smartened up...

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Mounting bushes not good; all renewed...

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That's more acceptable...

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Parts back from Morley Bros Cambridge (yet more!). Battery tray, repaired rear engine mount and other fabrications (see last update)...

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Heatshields

Some are the salvaged, shot-blasted and powder coated originals. Some others wouldn't have survived a stiff breeze, let alone a shot blasting!

OE Heatshields are sadly on the unobtainium list. Boy, what i'd do for a factory fresh new set!

Some heatshields therefore 'sculptured' from scratch using dedicated corrugated heatshield material...

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Upon disassembly many moons ago, I noticed the fuel filler pipe had the soggy remains of a heat mat. Decided to make a heatshield instead...

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Fitted...

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Given the necessary clearance...

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Headlamp Motor Service

Embarrassment at an MoT station (sadly a few years ago now) meant this was on the list. Motors ran for a good while in a vain attempt to clean the tracks...

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Noticed some cracks to the factory applied rubberised seal coat... cured with sealant.

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There are some HORRIBLE design issues on the 480 as we all know, this being one of them. Front end wiring management is all i'll say! Razor sharp edges on the front panel with wiring harnesses passing by. Be careful with your routing!

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The Mighty Taurus

For reasons that may seem bizarre to some, I bought a spare set...

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Set A - These are the original set I refurbished in 2016 and have done 30 miles since - just like the car sadly :cryhard:
Set B - An eBay set with dubious tyres and kerb rash

Why a spare set you ask?
1) They were super cheap (probably due to 1.7mm tread depths)
2) Handy to have a spare for what is a rare wheel nowadays - future pothole strikes pending.
3) I'd like a 'slave set' for when it goes to the paintshop. They can inadvertently overspray them all they want.
4) I need to start soaking Set 'A' in tyre dressing so it's absorbed over time - tyre dressing is incompatible with a paintshop!

When - heaven knows - it returns from this mystical paintshop, it will be nice mounting the best set to a freshly painted car. Kind of a cherry on the cake moment - that's how my brain works anyways!

Sunroof Drains

This might be an oversight on my part, but I have no recollection of where these went. Or, they didn't go anywhere, and just filled my entire back end with water. To be honest, with the amount of rectified corrosion in these parts - this may have been the case! :rofl:

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New holes made, painted, then grommets installed, drains poked through and sealed...

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Body Vents

Whilst I'm in that area... these vents are located in the same place, behind the rear bumper. All the rubber flaps disintegrated and some had vanished entirely. They should act as a one-way valve. Renewed...

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I guess repairing those vents was one procrastination step too far! Time to bite the bullet, get the grinder out again and turn my workshop into a dust-bowl :cryhard:

I hate bodywork - I don't have the patience and I hate the mess!

Offside Wheel Arch; Finally!

Step 1: Take one perfectly fine wheel arch (ignoring the dimensions obviously)...

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This was a project low, not going to lie. Really felt like taking a step six months backwards...

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As suspected - and the cause of my dilemma - historic evidence of arch replacement. With the wheel arch lip pulled backwards, the old weld line (yellow) and ugly inner wheel arch tub repairs (blue)...

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Didn't want this bit anyway... :cryhard:

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With that out of the way, you can treat and paint the inner tub - a task the Abergavenny garage failed to do.

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The credit card came out, again, for the THIRD wheel arch purchase from SKANDIX...

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Not to be sniffed at costing £170... and again, the quality annoyed me. I don't believe the termination at the bumper to be good enough...

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That, and the wheel arch lip is in some areas rolled and in other areas sharp...

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Given that this new panel will need a few hours rectification, I balanced up the pro's and con's, considering I had a spare section left over from previous work this year - so I could fabricate what's missing.... thus saving £170.

On that basis, I organised a SKANDIX return of the third repair panel and started work. To be fair Skandix were cool and organised a refund.

I made a template of the cut...

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Then compared and cut from my previous offcuts...

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I then created an inverse step with my "joggler"...

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This tucks it into the body quite nicely, and gives you meat to weld to - NOT blowing holes in a butt joint...

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Welding into place (at the correct height... triple checked!)...

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I follow all known precautions about heat build up when welding - doing spots at a time, left & right - but that didn't prevent some panel distortion. I think being welded twice didn't help matters. I don't think the previous garage were quite so cautious...

Anyways, many, many hours later, after filler and filler primer.....

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I'm 80% happy... there's a few quality issues that hopefully the paintshop can rectify with the aid of my cheque book :eek:

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Yes, they are the same height now, left & right :rofl:

What a caper! :wall:

Normal Service Resumes!

Ending on a high this time. Wheel arches done... so the engine can go back in...

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No problems with the Peugeot 407 rear engine mount... we are in!

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Talking of the rear engine mount, I had a lovely email from Rachel who has fitted this mount. She has an ECU-mod Turbo and is running it now. I feel a bit guilty she is doing my durability testing - but thus far, no problems to report!

For it to go back on its wheels, I need to torque the front wheel bearings; therefore, driveshafts required!

Time to fit the new SKF items bought last year....

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Offside Driveshaft

No Renault double-roll pin method for me.

I'm going jumbo split-pin, purely for ease of removal...

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Inserted with copper slip for a hopefully easy future removal...

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All in...

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Nearside Driveshaft

Hopefully I have the correct gearbox oil this time (discussion thread here)...

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• GL4 ONLY
• 75W80 (EP)
• Renault approved (TransElf equivalent)
• Yellow metal friendly

I need the oil already because the new roller bearings are supplied dry. Pre soaked...

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All in...

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Currently the easiest access in the world for a transmission fill...

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Galvanised driveshaft guard installed (with 26 years of grime removed!)...

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Happy(er) Endings

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I know it still looks like an absolute pile of junk, but.... :lol:

1st December 2019 that went wheel-free on axle stands... 3rd December 2020 and the wheels make contact with the ground again. Best part of a year with 323 recorded hours of tasks. Aesthetics will follow, but that is now a sound bodyshell throughout, all refurbished and powder coated sub-assemblies, with all new/overhauled suspension & steering. It should see me a good few years and hopefully be MoT stress-free for a decade of my ownership.

It currently sits as high as possible for:

a) Suspension tightening at ride-height.
b) Rear axle at a representative height for pending exhaust manufacture.

Suspension all torqued at a normal ride height...

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Some light at the end of the tunnel now. Just ordered all my stainless exhaust parts which should be here next week.

All the best for the Christmas holidays.

Jay.

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jamescarruthers
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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by jamescarruthers » Sun Dec 13, 2020 2:05 pm

This is looking great! As usual a tremendous amount of skill and time which I very much admire.

Lets hope Morley's work lasts as both of our 480's have had their undercarriages pass by there!
1987 Volvo 480 ES, 507274, 217 - Red (Ness)
2001 Volvo C70 2.4T convertible (Olivolvo)
2003 Renault Avantime 3.0 V6 (Big Ren)
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)

Alan 480
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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by Alan 480 » Sun Dec 13, 2020 3:35 pm

some serious dedicated effort.

well done although best not cost the 'man-hours' at anything more than £5/hour?

I like the wind up ramps, gets height without a four-poster!
Alan

480 ES 2litre x 2 (1 x Normal, 1 x 'Celebration' ? ), C30 1.8ES, SS1

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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by edie_fox » Sun Dec 13, 2020 8:58 pm

Do you think, after all of this, that you'll ever want to drive it? What if it rains? :lol: All that perfect work!

Amazing updates, as per. Green(er) with envy at each new post!

It's nice to see what it's like to spend money on one too. What you get for that extra £300 on this, that or the other. You are not a make-doer!

Are you keeping it the original colour? Without looking: was it black? Fresh respray will be a proud/exciting moment I bet. :D

jifflemon
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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by jifflemon » Sun Dec 13, 2020 9:52 pm

Jay-Kay-Em wrote:
Sun Dec 13, 2020 12:20 pm
I present "Exhibit A"... a shabby alternator...

Image

Stripped as far as the windings will allow and smartened up...

Image

Mounting bushes not good; all renewed...

Image

That's more acceptable...

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Stop immediately! Do not pass go, do not collect £200....

[Nerd mode]
Originally, the stator would have been red. Red stators were used on New Units. A black stator indicates a a remanufactured unit.
[/Nerd mode]

Obviously, not a seriously comment, but more a passing observation from my time reconditioning starters and alternators many,many years ago!

Although please tell me you've put a new starter on there? its a bloody awful job once the engine is fitted

Absolutely bloody stunning work as ever. Your monthly updates are fast becoming my favourite thing on the board!

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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by Jay-Kay-Em » Mon Dec 14, 2020 8:21 pm

Evening all; thanks for the comments...
jamescarruthers wrote:
Sun Dec 13, 2020 2:05 pm
Lets hope Morley's work lasts as both of our 480's have had their undercarriages pass by there!
Hi James – I gave the subframe a lot of grief installing the stubborn bushes and it's been fine. I did pay extra for the zinc primer which might help things. That primer has gone into all sorts of hard to access places – that’s the joy of electro-static painting! I think we are good; time will tell.

Alan 480 wrote:
Sun Dec 13, 2020 3:35 pm
well done although best not cost the 'man-hours' at anything more than £5/hour?

I like the wind up ramps, gets height without a four-poster!
Hi Alan - Can you imagine including a labour rate?!? Even at a timid £25/hour it is utterly eye watering. You can easily see why only E-types (et al.) get restored professionally because there is the financial gain to do so.

By the way, they are worm-gear ramps from "CJ Autos" – they are super quick with my air ratchet and get really good height. They are however really heavy and still a bit nerve-racking to drive up to with a fully painted nose-cone like the TVR. There is no free-lunch with any jacking solution. Even a two-poster is a nuisance as you can’t open the doors!

edie_fox wrote:
Sun Dec 13, 2020 8:58 pm
Do you think, after all of this, that you'll ever want to drive it? What if it rains? :lol: All that perfect work!

Are you keeping it the original colour? Without looking: was it black? Fresh respray will be a proud/exciting moment I bet. :D
Hi Edie – The vehicle when complete will be my summer daily... so it will have to earn its keep, doing the commute, April –> October. I don’t mind the rain so much, it's the salt I despise. It will never go head-to-head with a gritter again, that’s for sure!

My Golf has done summer commuting for ten years and that's still going strong as a H-reg... so an M-reg is positively modern for me :lol:

The colour is 305 “Black Metallic”...

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It looks nothing to shout about in the brochure...

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and yet, the more I see it the more I love it. It has a huge purple effect...

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When I took the carpets out and you see the factory overspray to the footwells, you can see the incredible purple-ness to it...

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It will stay the same to match the engine bay – and I’m foolishly thinking I can save money by not doing the door-shuts; but like all these things they escalate. My only disappointment in the colour is the name itself. All literature & brochures simply state “Black Metallic” when it really deserves a moniker much more dramatic and glamorous!

Really looking forward to your stainless exhaust update as this is my next job. Keep us updated!

jifflemon wrote:
Sun Dec 13, 2020 9:52 pm

[Nerd mode]
Originally, the stator would have been red. Red stators were used on New Units. A black stator indicates a a remanufactured unit.
[/Nerd mode]

Obviously, not a seriously comment, but more a passing observation from my time reconditioning starters and alternators many,many years ago!

Although please tell me you've put a new starter on there? its a bloody awful job once the engine is fitted
Hi Jeff!

I know you're joking, but I couldn't help myself...

I got out all my brochures and only the 440 range has full engine pictures.

The only Turbo engine I can find pictured must be very early. It has the black inlet manifold and the all-one-piece metal cambelt cover. It has a red-stator alternator just like you say, but a slightly different shape to mine....

Image

The oil cooler is on the p*ss too compared to mine.

The only later engine picture (and admittedly a naturally aspirated one) that I can find with the plastic cambelt cover, has my corrugated Valeo stator in black...

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That's an incredible shout on the early red alternator as pictured.

If you can find me a factory image, of a late engine or engine bay, with the "corrugated" Valeo, in red, then I will paint it in a heartbeat!

Round by the starter motor now looks like hell as you say. It didn’t when it was on the engine stand! It’s why I wanted the ease of the driveshaft split-pin because I can see how any job in this area means the driveshaft coming out... which isn’t the end of the world as it doesn’t require gearbox oil drain/fill to do so.

What has annoyed me is all my hose clips applied with the engine on the stand are now in completely the wrong positions with all the shields installed (with regards to screwdriver access).

I’ll hold my hands up – I have two spare turbo starter motors and didn’t want to purchase new when I have so many in reserve. On that basis, there is no point swapping used for used, so the original Valeo was cleaned, checked, lubricated and reinstalled. You can by all means have the first laugh when it fails! The only positive spin I can put on it, is that if the starter has failed, the car must be in use again – so that’s good news right?! :wink:

jifflemon
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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by jifflemon » Mon Dec 14, 2020 8:30 pm

That early shot is a Bosch alternator - Yup, that's how sad I am....

Personally I did away with the stator painting worries and went with the later internal fan, slightly higher output valeo ones!

Image

:rofl:

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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by edie_fox » Tue Dec 15, 2020 10:20 am

Jay-Kay-Em wrote:
Mon Dec 14, 2020 8:21 pm

Hi Edie – The vehicle when complete will be my summer daily... so it will have to earn its keep, doing the commute, April –> October. I don’t mind the rain so much, it's the salt I despise. It will never go head-to-head with a gritter again, that’s for sure!

My Golf has done summer commuting for ten years and that's still going strong as a H-reg... so an M-reg is positively modern for me :lol:

The colour is 305 “Black Metallic”...

Image

It looks nothing to shout about in the brochure...

Image

and yet, the more I see it the more I love it. It has a huge purple effect...

Image

When I took the carpets out and you see the factory overspray to the footwells, you can see the incredible purple-ness to it...

Image

It will stay the same to match the engine bay – and I’m foolishly thinking I can save money by not doing the door-shuts; but like all these things they escalate. My only disappointment in the colour is the name itself. All literature & brochures simply state “Black Metallic” when it really deserves a moniker much more dramatic and glamorous!

Really looking forward to your stainless exhaust update as this is my next job. Keep us updated!

Oh, that is a good colour. In my early 20s when I admired the 480 from afar, there was a man who had a (rare) P-reg one in my village. His was the same. It does look nice! Even nicer when it'll be all shiny and new.

That's great you're actually going to get to enjoy it after all of your hard work! Parking 12 miles from Tesco entrance though! :lol:

Well, I hope I understand what they're doing (for the exhaust)....will ask more questions when I take it in. I'm not sure what parts they intend to replace....

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Re: 1994 Volvo 480 Turbo Diary - Update December 2020

Post by MisterH » Tue Dec 15, 2020 11:32 am

That certainly is a stunning colour, reminds me of my father's late Golf TDi MkIV.

My car is a daily all year round and while I do fear the salt, I find hosing it down regularly seems to keep it in check
Current Jobs to do (1/1/21):
Fix Central Locking
Fix drivers side speaker
suspension creaking below 40mph

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