Oooops I did it again....

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100
Started learning about 480
Posts: 96
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oooops I did it again....

Post by 100 » Mon Jun 15, 2020 9:32 am

How did the rear bumper bar come out of the mad scientist bin?

Also, what kind of drill bits did you use to drill out the seat bolt, they appear to made of the hardest material known to man and just destroys drill bits! I've tried Titanium Nitride Coated HSS Drill, but is there anything more suited!?

Those brake lines look like hell! Interesting that you commented on the size of the back box being quite small, it's certainly smaller than the box that just came off the back of mine but I think my new one is about that size and whilst its a vast improvement when compared to my buggered one. I'm coming to the opinion that the quieter the better with these cars... maybe a larger back box would have been better...!
1992 Volvo 480 ES ("TT") Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II
2009 Land Rover Discovery

jifflemon
480 Is my middle name
Posts: 1651
Joined: Sat Dec 17, 2016 11:03 am

Re: Oooops I did it again....

Post by jifflemon » Tue Jun 16, 2020 10:37 am

100 wrote:
Mon Jun 15, 2020 9:32 am
How did the rear bumper bar come out of the mad scientist bin?

Also, what kind of drill bits did you use to drill out the seat bolt, they appear to made of the hardest material known to man and just destroys drill bits! I've tried Titanium Nitride Coated HSS Drill, but is there anything more suited!?

Those brake lines look like hell! Interesting that you commented on the size of the back box being quite small, it's certainly smaller than the box that just came off the back of mine but I think my new one is about that size and whilst its a vast improvement when compared to my buggered one. I'm coming to the opinion that the quieter the better with these cars... maybe a larger back box would have been better...!
Bumper bar is still in the science bin! :shock: Totally forgot about that!

Drill bits were just good old HSS, lots of cutting fluid used and slowish drilling.

Brake lines are UTTER hell.... They were definitely fitted pre-tank during assembly and designed to catch the worst of the road crap. the routing over the crossmember seems illogical too, so that'll be being improved hopefully.

Finally, you've got two silencers - the turbo only has a single one. I'm convinced that this exhaust wasn't even a turbo silencer given it's size...

100
Started learning about 480
Posts: 96
Joined: Mon Mar 19, 2018 10:23 pm

Re: Oooops I did it again....

Post by 100 » Tue Jun 16, 2020 11:11 am

jifflemon wrote:
Tue Jun 16, 2020 10:37 am
Bumper bar is still in the science bin! :shock: Totally forgot about that!

Drill bits were just good old HSS, lots of cutting fluid used and slowish drilling.

Brake lines are UTTER hell.... They were definitely fitted pre-tank during assembly and designed to catch the worst of the road crap. the routing over the crossmember seems illogical too, so that'll be being improved hopefully.

Finally, you've got two silencers - the turbo only has a single one. I'm convinced that this exhaust wasn't even a turbo silencer given it's size...
Hmm... maybe the additional of cutting fluid and slower drilling will solve my problem, I never got the seat out so haven't managed to do the heated seat pads!

That's true, I do. I forgot about the smaller one 3/4 of the way down...!
1992 Volvo 480 ES ("TT") Limited Edition
2005 Renault Clio V6 255
1962 Land Rover Series II
2009 Land Rover Discovery

Alan 480
480 Is my middle name
Posts: 1221
Joined: Sun Aug 28, 2011 9:03 am
Location: Aberdeen

Re: Oooops I did it again....

Post by Alan 480 » Tue Jun 16, 2020 7:07 pm

jifflemon wrote:
Mon Jun 15, 2020 6:58 am
Shall find the "running total" and add those to the bill, along with the rear arms.
best not to . .. . . .. :shock:
Alan

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

jifflemon
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Re: Oooops I did it again....

Post by jifflemon » Tue Jun 16, 2020 9:06 pm

Alan 480 wrote:
Tue Jun 16, 2020 7:07 pm
jifflemon wrote:
Mon Jun 15, 2020 6:58 am
Shall find the "running total" and add those to the bill, along with the rear arms.
best not to . .. . . .. :shock:
so, we were at £528 in costs (wheeler dealer style, no labour or stuff I had lying around included)
Rear arms - £67
pair handbrake cables - £46
Rear brake hose - £6
25ft Brake pipe - £13

Sitting at £660 so far.....

Alan 480
480 Is my middle name
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Location: Aberdeen

Re: Oooops I did it again....

Post by Alan 480 » Fri Jun 19, 2020 12:31 pm

not excessive then (yet)

only one rear brake hose :wink:
Alan

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

jifflemon
480 Is my middle name
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Re: Oooops I did it again....

Post by jifflemon » Fri Jun 19, 2020 5:25 pm

Alan 480 wrote:
Fri Jun 19, 2020 12:31 pm
not excessive then (yet)

only one rear brake hose :wink:
As I had one in stock! :D

jifflemon
480 Is my middle name
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Re: Oooops I did it again....

Post by jifflemon » Sat Jun 27, 2020 9:04 pm

Popped in to see Britney this morning; Didn't have much time but decided to see just how the filler neck came off.

For reference, the single 10 mm into the chassis rail is all that's keeping it there!

Image

You can see here the pipe that goes from the drain hole previously mentioned (and drains out onto the floor!)

Image

and up in the wheel arch wasn't too grotty either (the round hole is the filler cap hole, for reference!)

Image

jifflemon
480 Is my middle name
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Re: Oooops I did it again....

Post by jifflemon » Sat Jul 11, 2020 8:53 pm

Popped up briefly to the unit today (officially, I've been working, but I'm classing it as a lunch break!)

Took both the rear hose holders from looking like the left, to looking like the right....

Image

And then gave them a coat of shiny

Image

Also realised I've owned her for just over a year.... Really need to pull my finger out!

alfie12
480 Newbie
Posts: 40
Joined: Fri Nov 13, 2020 8:13 am
Location: Manchester

Re: Oooops I did it again....

Post by alfie12 » Mon Nov 16, 2020 5:14 pm

jifflemon wrote:
Sat Sep 21, 2019 6:31 pm

So first job, seat out:

Image

Right this is going to be one of those jobs....

Thankfully, the other three came out without a struggle

Image

A quick strip down and yes, popped off the pivot.

Image

So, before we can pop up it in, we need to drill out that snapped bolt

Image

drilled, drilled a bit fatter, then got the tap and die out and we were good - Well, I still need to find a replacement bolt if anyone's got one kicking about.
I've unfortunately discovered 2 of the 8 torx bolts have stripped heads on mine... any tips on getting these out? I don't have much specialist equipment to deal with this situation, is there a decent kit or something available to get these out?
Alfie

I've got 9,999 problems, and no. 480 is my car :nuts:
1989 1.7 ES 110k miles - first time restoration attempt!

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jamescarruthers
480 Is my middle name
Posts: 2007
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: Oooops I did it again....

Post by jamescarruthers » Mon Nov 16, 2020 6:22 pm

alfie12 wrote:
Mon Nov 16, 2020 5:14 pm

I've unfortunately discovered 2 of the 8 torx bolts have stripped heads on mine... any tips on getting these out? I don't have much specialist equipment to deal with this situation, is there a decent kit or something available to get these out?
My job has had me deal with a rediculous amount of seized fasteners over the years. Here is how we usually deal with them starting from quick and easy (no-drill), to getting your proper tools out (drill)!

FIRST CHOICE
If you are lucky, you can use some life changine stuff called Ez-Grip, Screw grab or similar. It is basically a friction material (think sand) in a suspension that by magic fills the gap between your screw bit and the worn fastener head. Clean the head out with a pick, put a few drops of this stuff in the hole and press down firmly and turn slowly. With a bit of luck the stuck fastener will come out.

Screw grab
6.99GBP: https://www.ebay.co.uk/itm/390551570261
Image


EZ-Grip (this is better in my opinion but I have used the above and it is also v good)
20.99 https://www.silmid.com/adhesives/specia ... oz-bottle/
Image


SECOND CHOICE
Can you get access to drill a hole down the centre? You only need to go about 10mm deep and not drill the head off unless it is a last resort.

If so, I swear by Snap On screw extractors. They have pretty much never failed me, and I have given them serious abuse at work, including seized 1/2" and 5/16" high tensile bolts.
Image

You can buy a set for over 100GBP, but actually there are just a few that are useful to keep in your tool box and you just need a few in your toolbox for a couple of quid each. Sorry, I am going to talk to you now in imperial measurements! You just drill the size hole in your seized bolt and then drop the tool in, give it a little tap and then put a socket on the back with a long armed ratcher or breaker bar and push-and-turn slowly but forcefully and the bolt should come out.

If one size doesn't manage it, risk the next size up.

I would recomend you buy 1/8", 5/32", 3/16" and 1/4" and you will be set for a good long while.

For your seat bolts, I'd start with 5/32", then if that doesn't work 3/16".

They have a lifetime warranty from Snap On so if you can find your local dealer (who will be mobile and in a big van) you can buy from him and return if they wear out

1/8" Snap On Part Number REX104A. (For 1/4" dia. bolts, although on 3/16" is fine too))
5GBP: https://www.ebay.co.uk/itm/293832401452
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5/32" Snap On Part Number REX105A (For 5/16" dia. bolts)
5GBP: https://www.ebay.co.uk/itm/293810015612
Image

3/16" Snap On Part Number REX106A (For 3/8" dia. bolts)
5GBP: https://www.ebay.co.uk/itm/293810016794
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1/4" Snap On Part Number REX108A (For 1/2" dia. bolts)
4GBP https://www.ebay.co.uk/itm/293835951850
Image

To drill the holes in seat belt bolts you need some decent drill bits. I would start by not wasting your time with anything you can buy on the high street. Buy decent quality HSS (high speed steel) bits from somewhere like Crowmell Tools. You can easily buy the metric equivalents to the imperial sizes in the UK.

For 1/8" drill 3.2mm
For 5/32" drill 4mm
For 3/16" drill 4.8mm
For 1/4" drill 6.3mm



THIRD CHOICE
Drill the head off entirely. Once the seat is out the way you can then use option two above or do what Jeff did. Fot me, the retapping method would be an absolute last resort though just because it is far too much effort!

For your reference imperial to metric for drill bits:
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: 2007
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: Oooops I did it again....

Post by jamescarruthers » Mon Nov 16, 2020 6:37 pm

Sorry for the thread hijack Jeff!

And before anyone goes more off topic with the debate of whether Snap On's eye wateringly expensive tools are worth their price, I just want to add that I'm not a fanatic and only keep in my box what they do best (and I'm tight!)
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)

alfie12
480 Newbie
Posts: 40
Joined: Fri Nov 13, 2020 8:13 am
Location: Manchester

Re: Oooops I did it again....

Post by alfie12 » Mon Nov 16, 2020 6:56 pm

You can buy a set for over 100GBP, but actually there are just a few that are useful to keep in your tool box and you just need a few in your toolbox for a couple of quid each. Sorry, I am going to talk to you now in imperial measurements! You just drill the size hole in your seized bolt and then drop the tool in, give it a little tap and then put a socket on the back with a long armed ratcher or breaker bar and push-and-turn slowly but forcefully and the bolt should come out.
Judging from how bad they're stripped I think option two will be the one! Super helpful thank you! I'm hoping the access will be ok... The back rest adjuster is broken (just spins) so is stuck in one position to make things all the more fun! Can the back rest be removed from the seat easily while still bolted in the car?
Alfie

I've got 9,999 problems, and no. 480 is my car :nuts:
1989 1.7 ES 110k miles - first time restoration attempt!

User avatar
jamescarruthers
480 Is my middle name
Posts: 2007
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: Oooops I did it again....

Post by jamescarruthers » Mon Nov 16, 2020 7:10 pm

The hinge of the backrest is just a simple clevis pin with a terry pin retaining it. Normally you'd recline the backrest then get to this pin to remove the backrest . Hopefully if you dig around in the hinge area you will find the pin. remove the clip and pop the pin out. You'll have to disconnect the heated seat wiring plug under the seat too
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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