Volvo 480 Club Europe

Well I have finally reached the point that no more dismantling from the bulkhead back is required. With the possible exception of the rear lights which I can’t decide whether to risk trying to remove as they have been glued in.









Having got to this point most of the rust found is light but best found now so it doesn’t get worse.

A few examples.









With a few exceptions.

I don't know about no more dismantling "required" - it doesn't look as if there is anything left to dismantle!

Look it the good condition of the rear light in your photo, I wouldn't risk damaging them trying to get them out. Just make sure they're well masked and protected and work around them.

Most rust doesn't look too bad at all, as you say; clearly you have the traditional solid rear bumper bar

When will it all be done and back together, do you think?

David

mmm, I can quite see why you might not be in a 480 on the 7th October.....
Never mind, far better to get it all sorted properly and let us see the result next year. As long as you get to the meeting yourself everything's fine.

dcwalker wrote:I don't know about no more dismantling "required" - it doesn't look as if there is anything left to dismantle!

The door handles and fuel cap will have to come off when she goes to the paintshop (but doesn’t affect what I’m doing at the moment) the rest can be masked off or is internal and is mostly wiring looms.

dcwalker wrote:I wouldn't risk damaging them trying to get them out. Just make sure they're well masked and protected and work around them.

My thought exactly if it wasn’t for the damage just below the light, will probably still leave it in and get it repaired around it.

dcwalker wrote:... clearly you have the traditional solid rear bumper bar

What it looked like after wire brushing.





Not as bad as I was expecting, its reconstruction is well under way.

dcwalker wrote:When will it all be done and back together, do you think?

To be honest I don’t know, I hope early next year. Plan at the moment is to put running gear back on once undersealing is completed now rust has been sorted and then refit interior.

Should really then do front end before paintshop but may put back on road temporarily, the plan keeps changing.

are you putting underseal back on?

Lots of classic guys are removing it and using epoxy mastic. I have done some of the 480 sills but plan to remove the underseal on my other classic and paint in Epoxy Mastic.

I really is getting rave reviews.

http://www.rust.co.uk

What I wrote doesn’t make it exactly clear but it’s the underside of the car (floorpan, wheel arches exterior of the box sections etc) that I’m using underseal on, the running gear will be put on after that is completed. The running gear itself (along with the box section and sill interiors) will/has been treated differently on a part by part basis.

I did look up Epoxy Mastic when you mentioned it in other treads but didn’t get very far so thanks for the link I’ll have a read.

Not had as much time as I would have liked recently and had hoped to get to the point of being able to but the fuel tank back in but ran out of underseal. More ordered so maybe next weekend.

Did manage to get one repaired side done thought.

Before


After

Well the underseal turned up





Hope to get it finished and the fuel tank back in this weekend.

All this is so beyond my capabilities. My hat to you

Finished the undersealing (up to the engine) and got the tank back in with a few new pipes, bolts and clips.





Nothing ever goes quite to plan and I did have an issue with the new fuel filter being bigger than the original so had to modify the holder a little.

That is coming on soooo nicely.

You'll have a lovely car once it's all finished - I look forward to seeing it in due course!

David

Be a skoosh doing the brake pipes and probably faster than i was replacing them.

The brake pipes would certainly have been a lot easier to replace with everything removed however mine were in a good condition so they got a clean, rust treated and painted as I was doing the underside and have now also been coated in underseal as well.

Over the weekend got the new hand brake cables fitted and the bracket that the panhard rod attaches to back on.

Now to put the axle back in.

As it came off the car.



Now



Blue – New parts
Red – Parts I have refurbished.

This is a truly impressive rebuild - wanna do 4 more ?

I know one of those brackets very well!

You do. Thanks very much.

Axle wouldn’t be going back in without it.

dragonflyjewels wrote:This is a truly impressive rebuild.....

Thanks, not quite the quick "tidy up" it started out as.

dragonflyjewels wrote:.....wanna do 4 more ?

Not sure the better half would appreciate more time in the garage right now.

Have been thinking about getting a second to use till this one is finished but not seen the right one at the right price that’s not too far away to go and see.

The axle went back on without too much trouble.

Now for the brakes.



Blue – New parts
Red – Parts I have refurbished.

mmmmm dust covers?

wot are they?

I had two wee bits of rusty metal attached (well four if you count the front wheels as well)

rear covers made from galv ducting and front from the side panel from somat, plastic coated ally (the stuff with the fake leather effect) but keeps worst of c**p off

Alan 480 wrote:mmmmm dust covers?

wot are they?

I had two wee bits of rusty metal attached (well four if you count the front wheels as well)

rear covers made from galv ducting and front from the side panel from somat, plastic coated ally (the stuff with the fake leather effect) but keeps worst of c**p off

Take it you are talking about the black Frisbees

Not sure what they are for, at a guess I would say a heat shield or as you have said a protector to help stop the c**p.