Duchess The Volvo 340 CVT

[benji1985]

Good day every one, Since joining I have been asked to put up the pictures of my project so far, this has been a long ongoing project for many years around uni and work, but it is coming on.. slowly..

I thought i would show the pictures in here and make a complete time line

So on my 19th birthday I decided I wanted to learn how to look after my car/s this was brought on by being ripped off by a tyre company in my home town. The car had been stood there for a good 6 years. I replaced the leaking radiator and a few little bits, while doing this with my Dad we saw that the exhaust manifold to cylinder head was leaking, which was then attempted to be tightened up, this then proceeded to snap the stud in the head.... My dad words were "no problem we can drill it out" as you can imagine it did not go well.

This lead me in to looking for a 2nd hand head and manifold, the chap on the phone said "yeah i guess we could get thos part off the complete engine if we must, 40 quid each... or you can have the whole engine for £40 and get it out of here" - no brainer there. Picked up the engine and a hynes manual and a socket set (the start of my own tool collection). so read the engine section least 4 times and then set to work. head came off new one went on and all went back together nicely - cue smug Benji grin .

She then went for an MOT on my 21st birthday and failed on sills, these were welded up and then she passed and she became my daily driver, so i could restore my Volvo 440 SE half way though the restore the little duchess decided to brake one of her CVT belt and throw it all over the road, await rescue, rescue came but couldn't tow her (even though i said that she was an AUTO, but they didn't listen, the part of the remaining belt had jammed up the CVT unit, managed to cut away the locking belt and then she was able to be tow, slowly.

At this time a young lad driving far to quickly over took us and after a corner or two smashed into an on coming car, his partner was thrown from the car and was not breathing, My recovery driver just stood there saying "what should I do" so there was me doing mouth to mouth, although i am very pleased to say that she was fine and i believe still is to this day.

So the multi coloured 440 was rushed back in to service, and she was happy to do it , Duchess the 340 then went off the road, and that is where she stayed, I got hold of a set of belts after painfully searching. and then proceed to remove the CVT units and remove the belts... well what was left of one of them. replaced the belts and there worked, but she was retired to the hard-standing, while this was all happening i claimed my dads Rover 600 and that was now my daily driver (he never looks after his cars, and sadly the piston rings died) but not before the the 440 was completed!

BILD0014_zpsunzecyc1 by Benjamin Charlton, on Flickr
BILD0015_zpsfqokxd5c by Benjamin
[url=https://flic.kr/p/VNGg6L]BILD0013_zpswyairp20 by Benjamin Charlton, on Flickr
BILD0008_zps0xa92hsh by Benjamin Charlton, on Flickr
BILD0006_zpsyh9n1lcw by Benjamin Charlton, on Flickr
BILD0004_zpss4ibomy7 by Benjamin Charlton, on Flickr


Sadly this success was short lived as she was written off not long after
This time in my life was not a good time with cars, after my lovely Lilac Lil was written off, I got a S40 this one lasted 3 weeks, before a women in a rush went into the side of me.... the pay out allowed me to get a better S40 T4 this time (i miss her)

However this now free up some time to work on Duchess.
I started with the rust holes and damaged boot lid, at this point i was still very much learning the rust was treated and filler was used... I know if you are going to do a job do it right, but the sills are on the list of things to be done now.
29032011164_zpsnsno2ef7 by Benjamin Charlton, on Flickr
29032011165_zpswu4tyqcz by Benjamin Charlton, on Flickr
29032011166_zpsjfuty0gg by Benjamin Charlton, on Flickr
29032011167_zpsvqlxke6g by Benjamin Charlton, on Flickr

The alloys were saved from my beloved 440
01052011177_zpsrljnpexy by Benjamin Charlton, on Flickr
the rear door was so badly rusted it was replaced and the arch was showing rust signs, as i was not able to find the time i did what every good engineer would do..... used duct tape!!
01052011176_zpspeyf8dq4 by Benjamin Charlton, on Flickr
another bad section of rust, this was due to the leaking rad and a Benji with not much knowledge
2011-06-21%2020.04.34_zpsqsjkctab by Benjamin Charlton, on Flickr
2011-06-30 18.49.00_zpswfrxxncr by Benjamin Charlton, on Flickr
2011-06-30 18.49.43_zps2njkwh1t by Benjamin Charlton, on Flickr

So now i decided to learn, I went to Lakes autos, and cut the front end off another 340 and a front valence and part of the wings off another.
2011-06-21%2020.05.25_zpsfu88l39k by Benjamin Charlton, on Flickr

and then set about fixing the duct taped arch and the sill holes
2011-06-21%2020.07.12_zps2luo7rk5 by Benjamin Charlton, on Flickr
2011-06-21%2020.07.23_zpsruta0mbl by Benjamin Charlton, on Flickr


Start next on the wings and doors
2011-06-29%2009.56.28_zpshueculj3 by Benjamin Charlton, on Flickr
2011-06-29 09.57.23_zpsnuefx0rd by Benjamin Charlton, on Flickr

Tea break time..
2011-06-29 09.57.41_zps4ax1cmbe by Benjamin Charlton, on Flickr

at some point in her life the front wing was dented, instead of taking it of and fixing it, they just cut a hole through the bulk head to get to the dent...
2011-06-29 15.08.31_zpsuf1zhrdy by Benjamin Charlton, on Flickr
2011-06-30 18.48.50_zpsvht0ymov by Benjamin Charlton, on Flickr

cleaned it up painted and welded a new piece of metal in
2011-09-04 12.50.30_zps7toctvfy by Benjamin Charlton, on Flickr

Next attempt was to take care of the front slam panel and valence
2011-06-30 18.51.28_zpsn4te76tf by Benjamin Charlton, on Flickr

ground off the original front panel
2011-08-12 16.49.27_zpsozokam5i by Benjamin Charlton, on Flickr
2011-07-20 13.35.48_zpsmouibrtw by Benjamin Charlton, on Flickr
2011-07-20 13.36.17_zpsxosuiovv by Benjamin Charlton, on Flickr
2011-08-06%2019.35.50_zpsllt5pwcz by Benjamin Charlton, on Flickr

in place for the new one
2011-08-06%2019.36.00_zpsstht1cgo by Benjamin Charlton, on Flickr


while this panel was off I decided "I know i'll remove the water container so i dont damage anything when I weld" this was not so easy, as I soon found out that the water container was only held in place by the underseal in the wheel arch.... and the battery tray was equally as bad.
2011-08-06%2019.35.33_zpsjean8li5 by Benjamin Charlton, on Flickr
2011-08-06%2019.36.10_zpsfkx4vxzn by Benjamin Charlton, on Flickr

so sorting this first while i could get in
2011-08-31%2013.21.43_zpszfzx3a34 by Benjamin Charlton, on Flickr


and welded everything up
2011-08-31%2012.28.09_zpsfiivuiw8 by Benjamin Charlton, on Flickr

Yes hind sight is great... these were very bad welds


welded the new bottom sections in the wings and gave them a large coat of underseal
2011-07-14%2019.44.07_zpsdnvhvjrp by Benjamin Charlton, on Flickr
2011-07-14%2013.52.17_zpsdhzjm2nc by Benjamin Charlton, on Flickr
2011-07-14%2019.44.45_zpso5fhs2n0 by Benjamin Charlton, on Flickr
2011-07-14%2019.45.13_zpsc9ifucnm by Benjamin Charlton, on Flickr
2011-07-14%2019.46.29_zpsjvbvx63a by Benjamin Charlton, on Flickr
2011-09-04%2012.48.57_zps2s4qf28r by Benjamin Charlton, on Flickr
2011-09-04%2012.48.48_zpsyzpaptvx by Benjamin Charlton, on Flickr

Fitted a the new bumper mount and a second horn, she does not sound like noddy coming around the corner
2011-09-04%2016.06.56_zpsev7wclpq by Benjamin Charlton, on Flickr


Made a new battery tray
2011-09-04%2016.06.56_zpsev7wclpq by Benjamin Charlton, on Flickr


and then turned my attention back to the door and body work, i used this blue hammerite stuff... NEVER AGAIN!!! it sprayed ok and nice colour tbh, but when it came to remove it it was a nightmare, it never actually dried
2011-07-05%2021.17.42_zpsofqjbqxd by Benjamin Charlton, on Flickr
2011-07-05%2021.17.32_zps3lqm967s by Benjamin Charlton, on Flickr
2011-07-07%2009.56.06_zpswyzcfjil by Benjamin Charlton, on Flickr

This now saw the end of summer and time for me to go back to Uni, so she was wrapped up for the winter, here she is ready to be wrapped up
2013-07-06 11.01.57_zpsemz0e9mv by Benjamin Charlton, on Flickr

The next year in spring, she was uncovered to find that the rust i thought i had got rid of was not so gone...

the bonnet saw the worst of it
2013-07-06 11.02.16_zpsqoczkceo by Benjamin Charlton, on Flickr
2013-07-06 11.04.07_zpsp2mtudqb by Benjamin Charlton, on Flickr

I decided to sand back the rust and re-clean it up, and went way over the top with primer to seal the rust away, this kinda work for a bit - this is how she stayed until i finished uni and found a stable job, which leads on to present day and when she was moved to devon

Sorry for the long post, but wanted to give a detailed look in to what has already been done over the last 11 years

some pictures were not included but are here:
https://www.flickr.com/photos/150679011 ... 6752540995

Thank you for looking

Ben

[benji1985]

Any advice and guidance would be greatly appreciated.

[trabitom99]

It all works! Well done for putting all that work in, it's great to watch a car that's slightly "rough around the edges" being brought to its former glory.

Tom

[benji1985]

Thank you

[benji1985]

Well she was picked up on Saturday and transported to Devon, blew her tyre out while on the trailer, but all safe and sound and now ready to have some work done to her!

[bogbasic]

Awesome work. What are the plans? Looks like loads has been done already.

[benji1985]

my plans is to restore her, with a bit of a twist, i am going to strip everything down like the suspension rear axle etc, and re-new all the bolts (thank you Mac) and paint it all, parts of the engine are going powder coated, then i hope to paint her the same colour blue bit of bodywork to sort but it is only minor now. I want to have some fun with colour but not wanting to do things like lowering etc. I hope from the outside she will look standard with the exception of the 440 alloys

Bog your blog has been some of the inspiration along with Anjo's

First task on friday is the rear axle dismantle

Ben

[MCHUDD]

Hi mate.
Fair play for takeing that project on.
At the begining of those pics i thought it had spent some time in the sea
Dash clocks need a rev counter. Its a streight swap with the clock.
Good luck.
Cheers Mark.

[benji1985]

Dash clocks need a rev counter. Its a streight swap with the clock.

Hello Mark,
Thank you . I have done the swap
I like to see what is going on lol

There will be more pictures coming soon... Watch this thread

Ben

[benji1985]

Well hello all. So last couple of weekend saw the car down in Devon and up on stands, tools all sorted out and parts slowly mounting up, all exciting times.
(this is my first post with pictures)

so here she is jacked up on axle stands on the front and ramps on the back



after the tools were sorted out a walk around showed that the last 6 years had not been to kind on the drivers side and bonnet, but the passengers side is holding out well, aircraft rust killer and anti-rust paint for the win!!
IMAG3767 by Benjamin Charlton, on Flickr
IMAG3766 by Benjamin Charlton, on Flickr
IMAG3765 by Benjamin Charlton, on Flickr
IMAG3769 by Benjamin Charlton, on Flickr


My repaired cover
IMAG3768 by Benjamin Charlton, on Flickr


Last weekend saw the rear on stands and the dreaded task of removing the drive shaft (with memory that the head of the bolts were rounded) so armed with a army of tool to remove hard bolts i set to work, un-did the first of the 12 bolts (going to the wheels) then decided i would have better access with out the wheels and the drive shafts hanging down, so un-did them from the CVT unit and let them hang. This did indeed improve the access massively and with the aid of my new impact driver and a large hammer the second bolt came out, as the point 10 to go and me thinking "that was easy" but 3 - 6 all came out the same way. First drive shaft out, Benji with a massive sense of achievement on his face . Now for the second shaft bolts 7 - 12 all came out easy too
By this point I was very very wet and cold, but even though it rained i was not going to give up getting these shafts out, wrapped them up and put them in my S80 to be taken back home to work on them in the garage, it was raining to heavy by this point.

IMAG3771 by Benjamin Charlton, on Flickr
IMAG3772 by Benjamin Charlton, on Flickr

Back at the garage, dismantle of the drive shafts/CV joints, a first for me.
Cleaned them all up and with help from Tom's guide (Thank you Tom and a massive thank you to Mac) , started dismantle them made the silly mistake of doing all 4 joints at the same time and mixing them all up
IMAG3779 by Benjamin Charlton, on Flickr

Cleaned and now shiny silver shafts
IMAG3783 by Benjamin Charlton, on Flickr

After a bit of confusion with gaskets on the drive shafts it turns out that mine has 8 in total not the standard 4 due to a change, luckily Mac was on hand and found out why

So rear axle is next on the list

Ben

[360beast]

Brilliant work, looking forward to the next installment.

[volvomania]

Looks super!

[benji1985]

Brilliant work, looking forward to the next installment.

Next installment will be over the weekend

[benji1985]

would people like me to update the first post to show what i have already done with the car?
instead of just looking at at a link with pics

Ben

[benji1985]

First post has been updated to give a timeline of what has happened so far

Ben