360 turbo saloon tidy up

For drift/rally/builds cars projects, engine conversions etc...
Describe your plans, project(s) evolution, works progress and final result!
Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 03 Mar 2016 02:22 am

Took some picks for notes for the sprayer defect list. Looks good from a distance.

Clutch is now slipping oddly, Dia thinks its the pressure plates have a batch problem or something.
Attachments
IMG_2202s.JPG
IMG_2202s.JPG (145.05 KiB) Viewed 11779 times
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

MCHUDD
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Re: 360 turbo saloon tidy up

Post by MCHUDD » 03 Mar 2016 11:34 am

Hi mate.
Can i come over to Hollywood and steal it lol. Looks great.
Cheers Mark.
sm69 sm69 sm69 sm69 sm69 sm69 sm69 sm69 sm69

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SteveP
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Re: 360 turbo saloon tidy up

Post by SteveP » 05 Mar 2016 01:49 pm

Looks really good, what defects do you have to tidy up?
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 05 Mar 2016 06:12 pm

Think it was a bit of a rush job, there is a long list, from lumps/inclusions to white spots, unpainted edges and wet gouges or poorly prepared flatting. Anyway he did offer from the start to do a touch up after I had rebuilt it, but there are about 30 painting defects and I added one chip.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 07 Jun 2016 12:22 am

Well its finally back from the painters after being touched up. Better than it was but not a manufacturers finish as requested, it will have to do. So need some inspiration to get on with it now.

Fixing the 940 now in the good weather, alot more rust than I thought, tried to rest with a few wee jobs on the 360 like the driver door window trim, figured out how to get it back in, all neatly done and then realised I forgot the new vinyl, paah!

Main job now is to get the headlining done so i can get the back window in.

I have a plan for fixing the clutch slip (0.5mm in the wrong place), but heavy steering is still making it not fun. Tracked down the right part, but still no reply from the Scottish yard to get it out..pah!

Other Job list : Minor oil-cooler leak, speed output, exhaust, speakers, stereo, sticky throttle body, radius arm mounts, fog lights, quieten air filter, rear spoiler, trim and badges, rebuild petrol cap, boost to 200bhp.
13308721_1018860624834568_4986136512066696977_o.jpg
Raised eyebrow by the sprayers?
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 09 Jul 2016 01:41 am

Time for a few more updates and some time off work with some progress on the car.

As posted in the clutch upgrade thread, the clutch plate has now been changed from the Audi friction disk to the thinner Astra F20 friction disk and cured the slipping sounding like an automatic. Bit of an ebay win at £8 delivered but slightly used and a bit rusty.

Still working on the headlining, ebay seems to have a random line pattern off-white non-perf which would probably do, but the original seems more like regular moonstone pattern (rather than the random moonstone). Waiting for a few more samples to see if I can match it. Strangely my trimmer is not that interested in sourcing material and seems to want to wait for material samples to magically appear so I am having to sourcing it myself, but he is at least cheap. £60 + material but I have to fit and trim, saloon is a bit annoying being glued. Should be sorted in the next few weeks.
IMG_2316s.jpg
Remove glued rear sections with gentle heat gun
IMG_2316s.jpg (151.28 KiB) Viewed 11602 times
IMG_2318s.jpg
Remove springy rods
IMG_2318s.jpg (132.22 KiB) Viewed 11602 times
Door black vinyl now cut and fitted. Had a bit of trouble wrapping around the corners as it wanted to peel back off after a while but a bit of heat sorted it and is holding ok. Hope it works ok in the weather.
IMG_2323s.jpg
Cutting out with paper template
IMG_2323s.jpg (146.9 KiB) Viewed 11602 times
IMG_2325s.jpg
without trim, specally from the flash
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IMG_2338s.jpg
Without flash, with trim
IMG_2338s.jpg (138.72 KiB) Viewed 11602 times
Also Engine seems to be sitting on the steering bracket/rack. Not sure when this happened, original mount is a bit saggy
IMG_2336s.jpg
sump on steering rack
IMG_2336s.jpg (114.05 KiB) Viewed 11602 times
IMG_2337s.jpg
91.5mm from shoulder to mount.
IMG_2337s.jpg (151.59 KiB) Viewed 11602 times
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

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SteveP
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Re: 360 turbo saloon tidy up

Post by SteveP » 09 Jul 2016 12:29 pm

Really nice work on the door vinyls - sorry, I was meant to get back to you with measurements but looks like you must've got hold of some :)
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 09 Jul 2016 03:11 pm

Looking at photos it seems a bit variable, even refering back to the brochures. So I just went for roughly 80% of the length of the corners curve and used a paper template rather than measurement. 100% would mean infinite curve tail off.

I ended up with 45.9cm at the front and 45.5 for the rears. I'm not sure if thats normal or if they should be equal, you would think they should, but not really enough width to measure the vertical at 90 deg to the horizontal line. At the end of the day it looks ok and is within the door position accuracy.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 12 Sep 2016 02:21 am

September updates:

Got the new headlining, only cost £40 for the labour (to make it) and <£40 for the material. Glued in around the rear window and doors and trimmed. Quite tough to get in.
IMG_2346s.jpg
Headlining glued in
IMG_2346s.jpg (142.85 KiB) Viewed 11108 times
This then allowed the back window in, didn't realise it has a brake light, but wired this up and fitted a red LED bulb. Speakers and rear parcel shelf and back seat followed.
IMG_2353s.jpg
Back window in
IMG_2353s.jpg (175.01 KiB) Viewed 11108 times
Proper painted fuel cap finished with recoded rebuilt lock, reassembly is difficult, treat it like a tyre.
IMG_2355s.jpg
Reassembled the fuel cap with the recoded key
IMG_2355s.jpg (139.79 KiB) Viewed 11108 times
Essential tune player
IMG_2364s.jpg
Treated her to a new mechless headunit
IMG_2364s.jpg (87.8 KiB) Viewed 11108 times
Fix the engine height issues from the failed remaining 360 mount using 940 parts and fabricated chassis side.
IMG_2357s.jpg
Built 940 sit-on engine mount for left side
IMG_2357s.jpg (165.85 KiB) Viewed 11108 times
Fixed the oil leak
IMG_2344s.jpg
Replacing the oil cooler seals
IMG_2344s.jpg (206.71 KiB) Viewed 11108 times
IMG_2342s.jpg
Oil cooler parts
IMG_2342s.jpg (209.11 KiB) Viewed 11108 times
Got a custom stainless system. Its louder than I intended using all straight through, but I'll enjoy this for a bit until I get stopped ;) Its not super loud and quite deep.
Also noticed that the 360 and 940 both have narrow tail pipes as standard, so the 360 now has a wider tail pipe than the 940. Looks a bit suggestive, and em.. arousing.
IMG_2360s.jpg
Stainless powerflow 2.5" system
IMG_2360s.jpg (143.18 KiB) Viewed 11108 times
Additionally I have fixed the idle issues, the final problem was the throttle body was not positioned correctly for the linkage adjustment. A loosen of the bolts with the engine running and twist until the idle dropped.

Uprated ARB-steering arm touch issues also resolved with longer bolts and tubes, all stainless and heavier section than the steel stuff supplied (which refused to dissassemble after only 2 drives in salty winter roads).

Fitted my 3D printed speed sensor for the LH2.4, although it didn't resolve any of the problems, I'm still not sure what it does other than keep the rpm high after a cold start until the car stops (for some reason). Now that everything is running better, maybe I'll disconnect it and see it anything changes

Window trims and door bumps also added, doors bumps are not great condition, letting the car down a bit with scratches and whitening so are going to need gel/oil wiped for shows. Tried rubbing down and T-cut but no significant improvment.

Working on badges at the moment, have a process for spraying but need the right paint. And soon to rebuild rear lip spoiler with a new rod.

New problem is a clutch groan after fitting the (old) clutch disk so have ordered a decent one on a supply when available from amazon, could also be the release bearing or pilot bearing, but these where also both new. Maybe I damaged the pilot when putting it back in.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

benji1985
Posts: 503
Joined: 30 Oct 2015 06:58 pm
Location: Helston

Re: 360 turbo saloon tidy up

Post by benji1985 » 12 Sep 2016 02:54 am

This looks great, please may i ask where you got your headliner made?
your posts have been so helpful for my restore :)

Ben

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 12 Sep 2016 11:51 am

It was a local trimmer in Belfast. He just copied the original, reusing the plastic edging. I'm sure any trimmer can do it.

I got 3m, hatch maybe less needed, also easier to swap out with a good original as I don't think there is any gluing.

http://www.ebay.co.uk/itm/272286175735? ... EBIDX%3AIT
Last edited by Ride_on on 27 Oct 2016 08:31 pm, edited 1 time in total.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

benji1985
Posts: 503
Joined: 30 Oct 2015 06:58 pm
Location: Helston

Re: 360 turbo saloon tidy up

Post by benji1985 » 12 Sep 2016 02:53 pm

Ride_on wrote:It was a local trimmer in Belfast. He just copied the original, reusing the plastic edging. I'm sure any trimmer can do it.

I got 3m, hatch mabe less needed, also easier to swap out with a good original as I don't think there is any gluing.

http://www.ebay.co.uk/itm/272286175735? ... EBIDX%3AIT
Thank you :)

Ride_on
Posts: 2262
Joined: 26 May 2009 05:34 pm
Location: Belfast, N. Ireland

Re: 360 turbo saloon tidy up

Post by Ride_on » 11 Oct 2016 01:59 am

Some more updates, getting the boot together.
IMG_2372s.jpg
Badges rubbed down with 600
IMG_2372s.jpg (180.57 KiB) Viewed 10922 times
IMG_2371s.jpg
Liquid mask
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IMG_2423s.jpg
Chrome paint
IMG_2423s.jpg (169.84 KiB) Viewed 10922 times
Spoiler I had was rusted and broken.
IMG_2426s.jpg
Spoiler rod remaking in stainless
IMG_2426s.jpg (201.34 KiB) Viewed 10922 times
IMG_2430s.jpg
Jig for stud welding
IMG_2430s.jpg (228.2 KiB) Viewed 10922 times
IMG_2431s.jpg
Ground out bolt heads with power file
IMG_2431s.jpg (97.63 KiB) Viewed 10922 times
IMG_2441s.jpg
Almost complete
IMG_2441s.jpg (294.09 KiB) Viewed 10922 times
Rod was then glued in with 2hr epoxy, rubber has previously been derusted, which it pretty hard, lots of rust lumps stuck to the rubber. This is a hard process, took a lot of time and the result was not perfect in the end. The rod has to be exactly the right shape, including the end squashy bits and the studs welded on at the perfect height.

The badges were carefully rubbed and scraped to remove the liquid mask and make a good edge for the paint against the bevel. Chrome paint is very delicate and you can't lacquer it, just goes silver, so we'll see how well it lasts. I used Promatic, which is a bit brighter than original so all the badges have to be done.

Injection badge still to go on, big thanks to Steve for the badge, and big thanks to Mark for the Volvo Badge.

For positioning the badges are justified to the boot edges with about 28mm in from edge at the top of the letter and about 83mm from the bottom edge and aligned with it (don't try to use a spirit level).

Anyone got the measurements for the injection badge position? It looks aligned with the GLT end and maybe halfway up.
Also the wing badges would be useful.
1980 345 DL_______1987 360 GLE (project car restored to GLT spec and B230FT'd)
1984 360 GLT______1987 360 GLT
1983 360 GLS______1989 360 GLE
1985 340 GL_______1986 340 1.4
1985 360 GLS______1995 940 SE 2.3 Turbo Estate (daily)
1987 340 GL 1.7

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SteveP
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Re: 360 turbo saloon tidy up

Post by SteveP » 11 Oct 2016 06:16 pm

Looks so good in that final pic!

I'm not sure if the Injection badge positioning was the same on the saloon as the hatch? But if the hatch is any use I can grab some pictures and measurements.
1989 - Volvo 360 GLT
1985 - Volvo 360 GLS
2008 - Volvo S60 SE Lux

360beast
Posts: 873
Joined: 27 Dec 2013 08:40 pm

Re: 360 turbo saloon tidy up

Post by 360beast » 11 Oct 2016 09:01 pm

Absolutely brilliant, are you going to get any coach lines on it?

I can get measurements for the badge on my saloon tomorrow, it does sit level with the end of the E on GLE on mine.

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