Duchess The Volvo 340 CVT

[benji1985]

Hello all another update for you all
12/07/16
well today was a disappointment in trying to remove the windscreen it decided to crack this was all i did today as the future wife and I had to go and look at our registry office.
So no pictures as i was in a mood that the glass broke.

14/07/16
Today was an early start, was ready to go at 8am, so not to make to much noise I welded in the new panel i made for the floor pan and inner (inner) sill.
IMAG0127 by Benjamin Charlton, on Flickr

IMAG0128 by Benjamin Charlton, on Flickr

IMAG0131 by Benjamin Charlton, on Flickr

IMAG0132 by Benjamin Charlton, on Flickr


By this time i was able to make noise, so cracked on with the other chassis leg
IMAG0129 by Benjamin Charlton, on Flickr

IMAG0130 by Benjamin Charlton, on Flickr

Sorry for the lack of photos, I'll be honest I was to engrossed in the welding
IMAG0133 by Benjamin Charlton, on Flickr

IMAG0134 by Benjamin Charlton, on Flickr

15/07/16
So today as the weather was threatening to not be nice, I decided (when i say decided there really is a plan behind all this and which job to tackle ) to strip down my donor cars lower window panel.
marked all the spot welds and cracked on
IMAG0135 by Benjamin Charlton, on Flickr

removed the very rusty corner inserts
IMAG0136 by Benjamin Charlton, on Flickr
IMAG0137 by Benjamin Charlton, on Flickr
IMAG0138 by Benjamin Charlton, on Flickr
IMAG0139 by Benjamin Charlton, on Flickr

Have not decided if i am going to rebuild them or make new or use the ones that are on my car at the moment
Then layer number 2 came off
IMAG0140 by Benjamin Charlton, on Flickr

and the remaining piece
IMAG0141 by Benjamin Charlton, on Flickr

So then i decided to look at the panel on the car, marked all the spot welds and then well i....ermm....got bored so removed the spot welds and then removed the top layer.
IMAG0142 by Benjamin Charlton, on Flickr

the inserts are better condition than the donor
IMAG0143 by Benjamin Charlton, on Flickr

Removed the 2nd layer
IMAG0146 by Benjamin Charlton, on Flickr

IMAG0147 by Benjamin Charlton, on Flickr

And now we can see the extent of the rust (Ride_on going to have to pick your brains).
IMAG0144 by Benjamin Charlton, on Flickr
IMAG0145 by Benjamin Charlton, on Flickr
IMAG0150 by Benjamin Charlton, on Flickr

So as you can see, going to have to rebuild the corners, both 2nd layers are the samebut the donor top layer is better than mine but going to use/make new corner inserts.

If anyone has any suggests on how the corners that have rusted are layered up (pretty pics welcomed) that would be great please.
Thank you

Got 16 days off soon, so will hopefully tackle and complete the corners

Ben

[Ride_on]

I know the feeling, presumably you have seen the dreaded rust thread. The expoded drawings give some idea, but your nearly complete side is the best reference. Take off the step over plate to hopefully find solid material and further understand the construction. My right side was also nearly solid and there are pictures of that.

When reassembling/rebuilding you need the wings and bonnet for alignment to make sure the outer skin is in the right position.

[benji1985]

I know the feeling, presumably you have seen the dreaded rust thread. The expoded drawings give some idea, but your nearly complete side is the best reference. Take off the step over plate to hopefully find solid material and further understand the construction. My right side was also nearly solid and there are pictures of that.

When reassembling/rebuilding you need the wings and bonnet for alignment to make sure the outer skin is in the right position.

wings and bonnet for reassembly, that was something i had not thought off..... yes i have seen the the "dreaded rust" thread that thread has been a guide throughout this and been so very helpful.

I my biggest issue atm is that both sides are just as bad, so just trying to work out the reconstruction of the metal. being a little blonde atm.

Ben

[bogbasic]

Epic work - keep up the awesomeness.

[benji1985]

Next installment for a couple of days
24/07/16
Today was a short day, clean and painted all the middle sections and back of the top section that goes under the windscreen
IMAG0161 by Benjamin Charlton, on Flickr
IMAG0162 by Benjamin Charlton, on Flickr
IMAG0163 by Benjamin Charlton, on Flickr

Only a little bit done today

28/07/16
Today was a lot more in-depth, start to tackle one side of the rust
Started by cutting out the rust from the center section
IMAG0164 by Benjamin Charlton, on Flickr

and then the rust from the A-pillar to the inner wing
IMAG0165 by Benjamin Charlton, on Flickr

then the center section was the first to be repaired
IMAG0166 by Benjamin Charlton, on Flickr
IMAG0167 by Benjamin Charlton, on Flickr

the next section prep-ed
IMAG0168 by Benjamin Charlton, on Flickr
IMAG0169 by Benjamin Charlton, on Flickr

then the top piece welded in place
IMAG0170 by Benjamin Charlton, on Flickr
IMAG0171 by Benjamin Charlton, on Flickr
the view from the inside
IMAG0173 by Benjamin Charlton, on Flickr

IMAG0174 by Benjamin Charlton, on Flickr

Sorry for the lack of pictures, but wanted to get on with it

Tomorrow will be the other side

Ben

[bogbasic]

Epic work.

[benji1985]

Good evening the next update from today
29/07/16
under the windscreen on the drivers side was tackled today
first the center section rust was cut out
IMAG0178 by Benjamin Charlton, on Flickr
IMAG0179 by Benjamin Charlton, on Flickr
IMAG0180 by Benjamin Charlton, on Flickr

the new piece of metal cut and shaped ready for welding
IMAG0181 by Benjamin Charlton, on Flickr

then a big leap to the end, sorry i forgot to take photos
IMAG0182 by Benjamin Charlton, on Flickr
IMAG0183 by Benjamin Charlton, on Flickr
IMAG0184 by Benjamin Charlton, on Flickr

IMAG0185 by Benjamin Charlton, on Flickr
IMAG0186 by Benjamin Charlton, on Flickr

had a bit of time left over today, so also made a start on part 3 on both sides, this is the layer that joins to the outer top panel under the wings, i have made them to big and i will trim them down to fit the top panel after that has been welded on
also thought it would be a good time to practice my spot welding
IMAG0187 by Benjamin Charlton, on Flickr
IMAG0188 by Benjamin Charlton, on Flickr

after grinding
IMAG0189 by Benjamin Charlton, on Flickr
IMAG0190 by Benjamin Charlton, on Flickr

Now just need to put it all back together and make a new set of inserts for the top panel
more to come soon

Ben

[benji1985]

Hello everyone, a big update for you all today
02/08/16
Today started off by reassembling the lower panels to the windscreen

The inner panel set in to place
IMAG0197 by Benjamin Charlton, on Flickr

first two plug welds done
IMAG0198 by Benjamin Charlton, on Flickr

lower set of welds done and ground down then some paint added for protection
IMAG0199 by Benjamin Charlton, on Flickr
IMAG0200 by Benjamin Charlton, on Flickr
IMAG0201 by Benjamin Charlton, on Flickr

then i reconstructed the curved part on the top panel
IMAG0202 by Benjamin Charlton, on Flickr
IMAG0203 by Benjamin Charlton, on Flickr

decided to use the scuttle panel i brought as a insert on one side of the top panel
IMAG0204 by Benjamin Charlton, on Flickr
IMAG0205 by Benjamin Charlton, on Flickr
IMAG0206 by Benjamin Charlton, on Flickr
IMAG0207 by Benjamin Charlton, on Flickr

the insert for the other side was reused from my old panel
IMAG0208 by Benjamin Charlton, on Flickr
IMAG0209 by Benjamin Charlton, on Flickr

the panel was then painted and left over night to dry


03/08/16
the other insert was welded in and then then the top panel was repainted again
IMAG0210 by Benjamin Charlton, on Flickr

IMAG0211 by Benjamin Charlton, on Flickr

while the paint on the top panel was drying i decided to start work on the A-pillars and rebuild them
IMAG0212 by Benjamin Charlton, on Flickr

IMAG0213 by Benjamin Charlton, on Flickr

rebuilt the rusty areas
IMAG0214 by Benjamin Charlton, on Flickr

IMAG0215 by Benjamin Charlton, on Flickr

and welded the 1st layer in
IMAG0216 by Benjamin Charlton, on Flickr

and put the layers back together


Top panel laid in place
IMAG0217 by Benjamin Charlton, on Flickr

IMAG0218 by Benjamin Charlton, on Flickr

with the wings and bonnet put back in place too
gaps
IMAG0219 by Benjamin Charlton, on Flickr

IMAG0220 by Benjamin Charlton, on Flickr

IMAG0221 by Benjamin Charlton, on Flickr

really not happy with the way the drivers side is sitting
IMAG0222 by Benjamin Charlton, on Flickr

IMAG0223 by Benjamin Charlton, on Flickr

but after spending a long trying to get it to sit right and not being able to, i called it a day


04/08/16
the top panel re-positioned and a little metal taken off to allow it to sit straight
20160804_093147 by Benjamin Charlton, on Flickr

20160804_093157 by Benjamin Charlton, on Flickr

once i was happy ish with the panel location i clamped it all down
20160804_110116 by Benjamin Charlton, on Flickr

the first few plug welds done, being sure to move from side to side to allow panel not to wrap
20160804_112757 by Benjamin Charlton, on Flickr

all the welds along the window done
20160804_121227 by Benjamin Charlton, on Flickr

20160804_121231 by Benjamin Charlton, on Flickr

20160804_121239 by Benjamin Charlton, on Flickr

the rest of the welds done
20160804_141315 by Benjamin Charlton, on Flickr

another check for the bonnet line up
20160804_141326 by Benjamin Charlton, on Flickr

20160804_141334 by Benjamin Charlton, on Flickr

20160804_141551 by Benjamin Charlton, on Flickr

20160804_141554 by Benjamin Charlton, on Flickr

20160804_141557 by Benjamin Charlton, on Flickr

all ground down and neatened up
20160804_163116 by Benjamin Charlton, on Flickr

20160804_163121 by Benjamin Charlton, on Flickr

20160804_163124 by Benjamin Charlton, on Flickr

20160804_163135 by Benjamin Charlton, on Flickr

20160804_163138 by Benjamin Charlton, on Flickr

protective layer of paint
as you can see, filler will be in order and seam sealer, but all in all not that bad...???...
20160804_163848 by Benjamin Charlton, on Flickr

20160804_163855 by Benjamin Charlton, on Flickr

20160804_163900 by Benjamin Charlton, on Flickr

20160804_163911 by Benjamin Charlton, on Flickr

20160804_163925 by Benjamin Charlton, on Flickr

20160804_163937 by Benjamin Charlton, on Flickr

20160804_163945 by Benjamin Charlton, on Flickr

20160804_164007 by Benjamin Charlton, on Flickr

20160804_164010 by Benjamin Charlton, on Flickr

what do people think, this has to be the biggest job i have ever taken on

Ben

[bogbasic]

Epic effort. You'll be glad to get back to work - less stress. I'll be like you when I grow up ;-0

Only point I can add is that I found the wings dent very easily at the top when you're struggling to perfect the fit or leaning over the engine but it gives your car a certain patina of..... err, age ;-0

[benji1985]

Epic effort. You'll be glad to get back to work - less stress. I'll be like you when I grow up ;-0

Only point I can add is that I found the wings dent very easily at the top when you're struggling to perfect the fit or leaning over the engine but it gives your car a certain patina of..... err, age ;-0

Will be less stress. Oh well started so have to finish

The top of the wing "looks ok" I'll check it tomorrow.

Ben

[benji1985]

Good evening all, here is the next installment
05/08/16
As the lower windscreen is now done, I moved back to the sill and the rear wheel arch

Started by cutting away the rust on a piece of metal, i have no idea what this is called so i called it flappy bit
20160805_105011 by Benjamin Charlton, on Flickr
and painted everything i could get to with POR15
20160805_105013 by Benjamin Charlton, on Flickr
Made a new piece to replace the rusted away metal on flappy bit and painted in POR15
20160805_105022 by Benjamin Charlton, on Flickr
20160805_105032 by Benjamin Charlton, on Flickr

but before that could go in i had to rebuild the lower inner arch
20160805_125707 by Benjamin Charlton, on Flickr
20160805_125719 by Benjamin Charlton, on Flickr

while the POR15 was dryinig i decided to make a start on the inner sill, cut out all the rust and then decided to make a large piece along the bottom (bad idea!!!)
20160805_140506 by Benjamin Charlton, on Flickr
checking that it fitted, which it did not fit great
20160805_163545 by Benjamin Charlton, on Flickr
found out it was this area causing problems... or so i thought
20160805_163550 by Benjamin Charlton, on Flickr
20160805_163552 by Benjamin Charlton, on Flickr
at this point got a little grumpy, so left that bit and welded in flappy bits missing part...no longer flappy bit and cleaned up welds
20160805_163822 by Benjamin Charlton, on Flickr
20160805_163827 by Benjamin Charlton, on Flickr
sat a thought about the inner sill for the next couple of days......

06/08/16
today was nothing to do with the 340, the S80 needed its cambelt service and water pump....first time but went well
20160806_084201 by Benjamin Charlton, on Flickr

all went well

07/08/16
today was spent at the classic car show at Mount Edgcumbe, where there were 2 nice amazons a P1800ES and Matt's 340 (which looked really nice)

08/08/16
after spending the last 2 days thinking about the the inner sill and regaining some motivation from the classic car show, i set about undoing and removing the metal i added to the inner sill, and decided to build it up in stages
20160808_122409 by Benjamin Charlton, on Flickr
20160808_122411 by Benjamin Charlton, on Flickr
note to self.... missed a bit!!
20160808_122417 by Benjamin Charlton, on Flickr
this was the only bit from the original welding left
20160808_122420 by Benjamin Charlton, on Flickr
and then for the problem area
20160808_122424 by Benjamin Charlton, on Flickr

so this is where i am at now, hope to get the sill finished off in a couple of week as going to my parents for there birthdays on my next days off

keep an eye on this area

Ben

[bogbasic]

Epic work. Awesome and evil.

[volvomania]

Funny, I am doing exactly the opposite; I am scrapping a 1989 5-door with the intention of recuperating the maximum possible.
The car had suffered a head on collision at high speed and was left after the accident for approx 20 years in a forest behind a Volvo workshop.
Last year it was "rediscovered" and dumped on my driveway.
At present I have come this far:

and


I have already finished scrapping everything in front of the B-pillar, one spotweld at a time....
What is holding me up now is the disassembling of the inner wing/reinforcements/inner sill structures as these are overlapping and the spotwelds are not always that visible. It will be worth it as there is virtually no rust on these parts (except for some light surface rust).
I tell my colleagues at work that it is probably the cheapest form of stress relief

[benji1985]

Look quite good shape tbh, that last pic was helpful to see how the layers build up, what are the inner sills like?

Ben

[360beast]

The scuttle panel came up a treat and you should be very pleased with how well you got it to line up again