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.

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

Looks really good, what defects do you have to tidy up?

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.

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.

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.
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.
Also Engine seems to be sitting on the steering bracket/rack. Not sure when this happened, original mount is a bit saggy

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

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.

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. 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.
Proper painted fuel cap finished with recoded rebuilt lock, reassembly is difficult, treat it like a tyre.
Essential tune player
Fix the engine height issues from the failed remaining 360 mount using 940 parts and fabricated chassis side.
Fixed the oil leak
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.
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.

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

Ben

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

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

Some more updates, getting the boot together.
Spoiler I had was rusted and broken.
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.

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.

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.