1987 480 ES Project -- D-reg, 2nd oldest in UK

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eye of ra
Can tell where the 480 was built
Posts: 352
Joined: Tue Dec 04, 2012 7:33 pm

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by eye of ra » Fri Aug 17, 2018 11:00 am

Alan 480 wrote:
Wed Aug 15, 2018 11:49 am
ref 'yellow fittings' There was one on the N/S when I went to re-fit the subframe, was unsure if there should have been one on O/S as well :-( , I'd have thought there should been two to keep subframe lined up, front is rattle fit bolts so no advantage?
I hadn’t even noticed the plastic fitting (although the rear fittings are still on the car) but just been out and checked and I only have one on the rear N/S.

Also parts manual only says one and only on Auto and Manual after 524247.
Current:
480 ES Auto 1989
480 ES Auto 1991
CLK430 Conv 2001
Hyundai i10 2015

Alan 480
480 Is my middle name
Posts: 1156
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by Alan 480 » Fri Aug 17, 2018 11:49 am

eye of ra wrote:
Fri Aug 17, 2018 11:00 am
Alan 480 wrote:
Wed Aug 15, 2018 11:49 am
ref 'yellow fittings' There was one on the N/S when I went to re-fit the subframe, was unsure if there should have been one on O/S as well :-( , I'd have thought there should been two to keep subframe lined up, front is rattle fit bolts so no advantage?
I hadn’t even noticed the plastic fitting (although the rear fittings are still on the car) but just been out and checked and I only have one on the rear N/S.

Also parts manual only says one and only on Auto and Manual after 524247.
OK, saves me asking my mate to check his garage floor and/or pit for the offending object.

I spent ruddy ages on last Saturday 'trying' to get a thin sleeve pushed up the O/S, and bolt wasn't very central so brute force required :-)
Alan

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

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jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Fri Aug 17, 2018 1:17 pm

Stripped down and head sent away to local specialist as I figured this will hopefully not be out ever again. That way the valve clearances will be right (even though it is the sweetest sounding 1.7 I can ever remember having) and I'll get the valve stem seals done too, just as a precaution. 

Block will get painted which should leave the engine bay looking great when it eventually all goes back in. ‎

All the core plugs are knackered and one had completely rusted out years ago but was behind the inlet/outlet manifold gasket and that is all that was keeping the coolant in.‎

I'm going to switch to waterless coolant after all. Recommended very highly by some people I trust on the BX club‎

Imagepicture uploader
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Fri Aug 17, 2018 1:18 pm

Image

Image
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
480 Is my middle name
Posts: 1156
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by Alan 480 » Fri Aug 17, 2018 6:10 pm

good grief, not hanging about , hope you know where it all goes back together? :eek:

nae sure aboot yer toe-tectors tho . . . . . . :wink:
Alan

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

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jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Tue Sep 04, 2018 10:58 am

Block is painted:

Imagegrab screenshot
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Tue Sep 04, 2018 11:00 am

Cylinder head is overhauled. This engine sounded lovely but will be interested to hear how it sounds with perfectly shimmed valves:

Imageupload image free
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Tue Sep 04, 2018 11:09 am

I'm not 100% sure I'll be ready for the Hampshire meet which is sad as I really wanted to see the two resurrected D-reg cars together.

I am being slowed down trying to get these pipes copied in stainless steel. The problem is that the bends in one are so close together that most people can't do it. One company had them for ages after saying they could do it before ‎changing their mind. They are on their way to P D Gough who are incredibly expensive exhaust manufacturers and hopefully they can do it.

Also being slowed down by powder coating taking quite a while. Subframe is the main thing being done here (which is also getting zinc coated after seeing Jeff's post about his rear bumper bar) along with suspension‎ bits and engine bits. Exhaust manifold is just being painted, I couldn't afford ceramic coating. 

Basically the front will be like new. I seem to have the last Bilstein B4 front shock absorber in the world and am waiting, with fingers crossed, for one more to be made in Germany. They should come back in stock for everyone in a week or so hopefully.

Image
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Tue Sep 04, 2018 11:11 am

Alan 480 wrote:
Fri Aug 17, 2018 6:10 pm
nae sure aboot yer toe-tectors tho . . . . . . :wink:
Hahaha, didn't realise I'd caught my flip flops! Promise you, I did actually have my safety shoes on for the real work
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)

eye of ra
Can tell where the 480 was built
Posts: 352
Joined: Tue Dec 04, 2012 7:33 pm

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by eye of ra » Tue Sep 04, 2018 2:55 pm

I have been looking into using stainless steel for various things and from what I have found it is not a good idea to use it in contact with aluminium as it causes the aluminium to corrode due to galvanic corrosion and I think the smaller of the two pipes pictured fits into the cylinder head.

It might be better to use normal steel and then zinc plate it.

PM sent or will be soon.
Current:
480 ES Auto 1989
480 ES Auto 1991
CLK430 Conv 2001
Hyundai i10 2015

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Tue Sep 04, 2018 4:44 pm

Well that is food for thought! I see stainless is more cathodic than the cast iron engine block and the steel pipe that used to go in to the head so you definitely have a good point.

 It will be going in with sealant which will help reduce the surface area that is contact with the aluminium. ‎I think your point is that the coolant acts as a path for the electrons so it probably doesn't matter where it is in the system.

Funnily enough, I was actually thinking of going for ‎waterless coolant, but hadn't considered that I was adding a new less reactive metal in to the system, and that this might help, as it shouldn't be conductive. This will be an extra £100-200, although I could miss out the prep fluid as the system is completely drained. I have heard good things about from some people I respect on the BXClub forum. ‎This might allow me to continue using the stainless steel.

I'm not sure if P D Gough do anything other than stainless steel. I will ask them. ‎
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Wed Sep 05, 2018 10:16 am

I did some research and David is right, putting stainless steel in contact with aluminium is a bad idea. To be honest so is regular steel but stainless is even further away from aluminium on the galvanic corrosion scale and ‎will cause the aluminium to corrode easier.

So, the pipes are now being made in mild steel and will get cadmium or zinc plated. More time lost!‎
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)

jifflemon
480 Is my middle name
Posts: 1524
Joined: Sat Dec 17, 2016 11:03 am

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jifflemon » Wed Sep 05, 2018 10:08 pm

but sooooooooo worthwhile in the long run.

Personally, I love a deadline - I like the sound they make as they go whistling by! :rofl:

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jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Wed Sep 26, 2018 7:10 am

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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Wed Sep 26, 2018 7:10 am

Image

Well, it looks amazing but it's still ‎not back in the car yet!
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)

eye of ra
Can tell where the 480 was built
Posts: 352
Joined: Tue Dec 04, 2012 7:33 pm

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by eye of ra » Wed Sep 26, 2018 9:05 am

Very impressive. WOW :eek:

Not been sure what to do with my mounting brackets that fit onto the block as its going to be black like yours. Decision is now made and it’s not black.

Is the gearbox white or is it a trick of the light/camera/my screen?
Current:
480 ES Auto 1989
480 ES Auto 1991
CLK430 Conv 2001
Hyundai i10 2015

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Wed Sep 26, 2018 9:29 am

Gearbox is painted with silver paint (VHT stuff, so let's see if the gearbox gets hot enough to bake it on as per instructions). It was bare aluminium alloy but with wouldn't clean up very bright with the stuff I bought so went with this option instead. 

Resisted painting the intake as I don't actually want a bling engine bay, just clean and tidy looking
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Mon Oct 22, 2018 3:18 pm

I was searching for 480 stuff on Google and came across my car on Flickr! Pleasant surprise with a few nice comments:
https://flic.kr/p/Lo8Nv5

https://flic.kr/p/Lo8NV3
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Mon Oct 22, 2018 3:19 pm

Back end if apart for refurbishment now with many parts off for powder coating. Rear bumper bar is toast so will be ignored for a little longer then will likely get the 400EUR (eek!) Geman replacement. Rachel, you were happy with yours from this place?
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)

User avatar
jamescarruthers
480 Is my middle name
Posts: 1931
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 1987 480 ES Project -- D-reg, 2nd oldest in UK

Post by jamescarruthers » Mon Oct 22, 2018 3:29 pm

Last edited by jamescarruthers on Mon Oct 22, 2018 3:30 pm, edited 1 time in total.
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)

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