Volvo P1800ES...kinda

I still love reading this thread, though as you go along I sometimes feel like I need a map to figure out where you are on which car. I'm sure it's logical looking at the car(s) in person, but it taxes my imagination.

mazdeuce wrote: I still love reading this thread, though as you go along I sometimes feel like I need a map to figure out where you are on which car. I'm sure it's logical looking at the car(s) in person, but it taxes my imagination.

I agree that it has gone bit too macro to be interesting. There are a a bunch of little spots where the two cars come together that, while technically challenging to me, are really not much to look at.

This little job actually was one of the more challenging bits of fabricating in that it took the English wheel, the shrinker and stretcher, a bunch of hammers and the ability to curse fluently in three languages in order to get it done. And about 5 hours of time. It is a shame that the pictures can't convey that!

That said, this thread is as much about motivating me as anything else. I need to look back six months and see that I am getting small bits of the elephant swallowed down.

NOHOME wrote; I agree that it has gone bit too macro to be interesting.

I disagree. Admittedly, sometimes I can't tell exactly what you are doing, but I, for one, am always interested. I believe the key to great music, art, writing, car building, or anything else lies in first, entertaining yourself. If you're not involved, how can you expect anyone else to be?

I like having to scratch my head a bit to comprehend what you are up to in the latest episode.

I enjoy reading this thread. It's good to see that someone else is in deeper E36 M3 than I am. I love the way you are progressing without being able to completely predict the path you are taking. It's inspiring.

I've always liked the "plan to figure it out", plan as a means of keeping things moving. You're at the zen-master level of that. Mazdeuce is probably there, too, w/ the grosh.

I don't mind the "macro" details. They don't gloss over how difficult this project is vs. so many builds where this sort of stuff is ignored and makes you think it'll be easy. The devil is in the details for a build like this: building a real, usable car vs. some sort of bastard race car where fit, finish and sealing aren't as important. Plus, owning an ES as well, I have a good idea of where he's working.

NO HOME doin' it right.

Keep at it it will be worth it in the end.

If you can still stand to look at it!!!!

I like the devil in the details approach. Helps me think through fab and adaptation problems in face in my projects. You showing how you tackle them teaches me new methods.

I may not have any idea what the hell is happening, but I'm learning.

Maybe take a wide angle picture of the area/problem, and then your normal close up/solution shots.

Today's job is to do the same job on the PS. I will pause for a few more pics and do more of a tutorial tonight.

Like I said, this seems like a simple job, but it uses pretty much the full repertoire of metalshaping tricks and tool. Along with poor working access. If this were a challenge car, it would go a lot different.

OK, got it done on the PS but it still took all day.

Here we are ready to get at the PS. The goal is to join the lower part of the Volvo and Miata wheeltubs. I have my arsenal of tools laid out. If you look at the picture, the light shines on the area we will be working on. You can see the Miata chassis inboard and the remains of the Volvo wheel-well outboard. Bear with me as I am switching to IMGUR and will be editing a bazzilion times to get this posted!

So the green stuff to the left is Miata. The gray stuff to the right is volvo wheelwell. The goal is to use a remainder of the Miata and close the gap while adding rigidity to the whole car by creating a box section.

Complicating my effort is a rust spot. The rusted involves two layers of tin. The upper is the inner wheel-tub and the lower is the outer wheel-tub. In order to repair this properly, I need to dig down through the layers.

For those of you that follow along, I long ago gave up on buying spot-weld drills. I simply use a 1/8" drill bit to drill into the first layer. (look for the rust burst to know when you drilled through the first layer)

Then I chase the 1/8" hole with a 5/16" bit that I ground to a shallow point. This would not make a hole on its own, but will follow the 1/8" pilot hole to where it bottomed out.

So, when it is all said and done, the outer layer is peeled off and I can get at cutting out the bit of rot that was underneath. Note that none of this has anything to do with the task of joining the two cars together, this is just standard rust repair.

All cut out and cleaned. Note that this "clean" bit makes a huge difference to how well the welding s going to go. Now I need to make a bit of tin to fill in this hole that I randomly cut out with the angle grinder.

Since I hate measuring, I just slather tape over the hole, press my fingers around the edge and cut along the imprint.

Place the trimmed pice of tape over a piece of tin. Cut to fit and weld in place ( yeah there is some file work involved, but I skipped over that)

The finished product. I kind of messed up in that I cut the Miata filler piece too short and had to do a series of stitch welds rather than plug welds.

The last picture shows the complex filler piece that was required to join the Volvo wheel-tub to the Miata deck. This piece curves in three dimensions and needs a bit of shape. On top of all that it is in an awkward spot to get into. This is looking back through the Miata seat belt mount. Not a bad fit to the Volvo tub and the weld penetration looks good. I am pretty happy with this work. Seam sealer and ruberized undercoat will make all of this work look much better.

I really understood and was able to follow that one.

Thanks!

And how do you like imager vs photo bucket?

Dusterbd13 wrote: I really understood and was able to follow that one. Thanks! And how do you like imager vs photo bucket?

Having a hard time figuring out imagur, and how it wants me to organize my pics, so retrieval is a bit of a pain at this point. Good news is that imagur does not seem to have the endless phising adds that Photobucket does.

So, the Minion text me and mentions that I should perhaps drive past his place on the way home tonight. Something in the driveway that might amuse me.

It's a 302 with AOD conversion done by "Converse".

The picture is not the actual car, but pretty much exactly what was under the hood.

Went for a drive. Once again, affirmation that I am on a righteous path if I can pull this off!

You're on a righteous path no matter what power train you end up with!

Stuffing EFI 5.0's into mac-strut RWD Volvo's is pretty common. Lot's of "real room" in the engine bay (vs. the 1800, where there's an "illusion of room"). When I bought my ES, the seller also had a 240 sedan with a 5.0 5spd he was selling. My ex- and I were drooling. If it had been a wagon, my entire Volvo story may be different right now.

So, turning to the rear of the same wheeltubs, there is a pesky rust repair that is common to both sides. Bit tricky in that several panels come together in this spot and you have to pick the layers apart.

I wont bore you with the details of cutting this out and making new parts, but will do like the cooking shows and skip to the finished version:

And this brings up a question regarding my sanity.I went to great lengths to make the repair out of two pieces that are carefully fitted and butt welded. The end result is that I maintain the line that runs along where the two panels overlap. Never occurred to me to do this any other way.

So, as I wrap up the one side, the Minion ask me how this repair will be finished? I say paint and eventually rubberized undercoat. He then ask why I did all that work when I could have easily just made a one piece patch panel that wont look any different once undercoated?

I admit that I might have a problem.

NOHOME wrote: He then ask(ed) why I did all that work when I could have easily just made a one piece patch panel

Because you are a detail man all over. That's why you want to extend the rear rails with genuine miata pieces. That's why you don't want to flare the wheel wells, and that's why this thing will turn out to be a magnificent beast.

Also, shut up, kid (who happens to be right).

And done!

Before and after.

hi.im the "minion" that will be having a chat with HR.i find that term to be derogatory,and believe that its an attempt to make fun of my single eye and large yellow head.and unless you're over 50 you cant call me "kid".and he does have a problem

petey wrote: hi.im the "minion" that will be having a chat with HR.i find that term to be derogatory,and believe that its an attempt to make fun of my single eye and large yellow head.and unless you're over 50 you cant call me "kid".and he does have a problem

Lets see what you are up to when left alone....

Yeah.. I have a problem

woah, what motor is that in the stang?

and you can blame the "minion" part on me from asking about who was in a picture :p

bluej wrote: woah, what motor is that in the stang? and you can blame the "minion" part on me from asking about who was in a picture :p

Hey...I DID blame it on you! Still holding me accountable for contributory harassment. Means I gotta feed him beer until a squirrel walks across the yard and he forgets.

That would be a Coyote stuffed in the 69 Mustang. Equally impressive, if not more so, is the late model dash. The independent rear suspension is cool also.

yikes! OK, Petey, we're gonna need build threads on all those, stat! Looks great!

Wait a sec, how old is our OP?

tuna55 wrote: Wait a sec, how old is our OP?

We speaking Calendar or Behavioral age?