Duchess The Volvo 340 CVT

Post by **benji1985** » 11 Aug 2016 07:21 pm

360beast wrote:The scuttle panel came up a treat and you should be very pleased with how well you got it to line up again

thank you, it was a whole panel from a donor car, was 1.5mm out but wiper arms still go through nice.

Ben

Post by **benji1985** » 26 Aug 2016 10:33 pm

Hello all, sorry for the delay in updates. Wedding things are becoming more pressing now.

22/08/16
So today i finished patching up the inner sill and got it ready to be painted.

20160822_122907 by Benjamin Charlton, on Flickr

20160822_122921 by Benjamin Charlton, on Flickr
And mocked it up on the car ready, just to see how it went on

20160822_130720 by Benjamin Charlton, on Flickr

20160822_130725 by Benjamin Charlton, on Flickr
Then painted the inner sill and the inside of the rocker cover

20160822_144959 by Benjamin Charlton, on Flickr

20160822_145003 by Benjamin Charlton, on Flickr

20160822_145005 by Benjamin Charlton, on Flickr

20160822_145006 by Benjamin Charlton, on Flickr

20160822_145012 by Benjamin Charlton, on Flickr

20160822_145014 by Benjamin Charlton, on Flickr

20160822_145018 by Benjamin Charlton, on Flickr
also painted the inner inner sill

20160822_145037 by Benjamin Charlton, on Flickr

20160822_145039 by Benjamin Charlton, on Flickr

20160822_145041 by Benjamin Charlton, on Flickr

as you can see the POR15 is going off and there were little lumps in the paint

But left it there for today

23/08/16
Today was carrying on with the sill
cleaned the metal surfaces there were going to be welded and used the last of the weld through primer up

20160823_084024 by Benjamin Charlton, on Flickr

20160823_084026 by Benjamin Charlton, on Flickr

20160823_084028 by Benjamin Charlton, on Flickr

offered up the inner sill ready to be welded in to place

20160823_085331 by Benjamin Charlton, on Flickr

20160823_085333 by Benjamin Charlton, on Flickr

20160823_085334 by Benjamin Charlton, on Flickr
the inner sill was welded in place

20160823_103737 by Benjamin Charlton, on Flickr

20160823_103740 by Benjamin Charlton, on Flickr

then offered up the sill to see where the holes would need to be drilled and what it would look like, loosely fitted the rear door. Did notice that the sill would need to be pushed down in to place to allow it to fit right, but other than that it fitted quite well.
however as the por and weld through primer had run out, i didnt want to carry on with out doing it right, so my attention was drawn to the engine, it was a nice day and i had been wanting to paint the block for a while, so a good time to get on with it.

20160823_140004 by Benjamin Charlton, on Flickr

20160823_152251 by Benjamin Charlton, on Flickr

20160823_152330 by Benjamin Charlton, on Flickr

I feel the fuel pump lets it down....

after the inner sill was welded in place i put the wing back on to soo how it looked, sadly the mounting hole in the inner sill did not line up with the wing hold

not the end of the world as i have decided to put "nutserts" in and some of the screw holes just dont work

Anyway this is where she is up to.
Any comments please feel free

Ben

Post by **bogbasic** » 27 Aug 2016 02:45 am

1.4ever. Awesomer and awesomer. Fuel pumps, yes, summer better than others but you'll have it cleaned-up in no time.

Post by **benji1985** » 30 Aug 2016 08:24 pm

Good evening all, today saw a milestone for me, so hear goes.
30/08/16
Aligned the the new outer sill in to place and started to weld it on

20160830_095556 by Benjamin Charlton, on Flickr

20160830_095559 by Benjamin Charlton, on Flickr

20160830_102045 by Benjamin Charlton, on Flickr

20160830_102047 by Benjamin Charlton, on Flickr
thats the weld insides the doors done
all the other welds done, decided to run some beads of welds along the bottom because the after market sill seemed to be needing a bit of a push up to get it in the place and also my repair of the inner sill was not quite a straight and good as the factory

20160830_120520 by Benjamin Charlton, on Flickr

20160830_120523 by Benjamin Charlton, on Flickr

20160830_120525 by Benjamin Charlton, on Flickr

20160830_120527 by Benjamin Charlton, on Flickr

cleaned up all the welds, looks really good, if i dont say so myself

20160830_134309 by Benjamin Charlton, on Flickr

20160830_134311 by Benjamin Charlton, on Flickr

20160830_134313 by Benjamin Charlton, on Flickr

20160830_134318 by Benjamin Charlton, on Flickr

looking good

20160830_134329 by Benjamin Charlton, on Flickr
all POR15'ed

20160830_141833 by Benjamin Charlton, on Flickr

While the paint is drying, i decided the paint the fuel pump and the distributor arm, as they let the nicely painted block down.
then i decided to look at the rear wheel arch and how i am going to get it in.

20160830_162728 by Benjamin Charlton, on Flickr

20160830_164033 by Benjamin Charlton, on Flickr

Not sure how I am going to do this...

20160830_165242 by Benjamin Charlton, on Flickr

20160830_165255 by Benjamin Charlton, on Flickr

20160830_165301 by Benjamin Charlton, on Flickr

So thats probably tomorrows job

more to follow

Post by **bogbasic** » 30 Aug 2016 09:09 pm

Epic work. I put my back wheels on this weekend ;-0

Post by **360beast** » 30 Aug 2016 10:17 pm

Don't forget to seam seal the sills and the wheels arches, these cars wouldn't have rusted so bad if the rust prevention and seam sealer were done properly at the factory. As for the wheel arch, I would cut the lip off of the blue piece where it is slotted over the black piece, then put it behind the black piece, drill holes through the black piece and plug weld it flush. Does that make sense? Can't explain what I mean properly.

Post by **benji1985** » 31 Aug 2016 10:17 am

360beast wrote:Don't forget to seam seal the sills and the wheels arches, these cars wouldn't have rusted so bad if the rust prevention and seam sealer were done properly at the factory. As for the wheel arch, I would cut the lip off of the blue piece where it is slotted over the black piece, then put it behind the black piece, drill holes through the black piece and plug weld it flush. Does that make sense? Can't explain what I mean properly.

Yes that does make sense, but for the rest of the arch Mac and others have told me to slot the new arch under the original metal so filler will on have to go down to the arch and not up the panel

Ben

Post by **Ride_on** » 31 Aug 2016 09:39 pm

Whatever you do weld it very slowly with lots of cooling, especially in the open area on the quarter panel.

Post by **benji1985** » 03 Sep 2016 09:13 am

next update
01/09/16
So today i got the wheel arch repaired and ready to go

20160901_112508 by Benjamin Charlton, on Flickr

20160901_112515 by Benjamin Charlton, on Flickr

20160901_112912 by Benjamin Charlton, on Flickr
fixed my little mistake when cutting out the arch

20160901_112511 by Benjamin Charlton, on Flickr
Then painted the area with POR15, while that was drying i tackled the peddle box

20160901_115132 by Benjamin Charlton, on Flickr
and the part of the door shut that needed fixed

20160901_131259 by Benjamin Charlton, on Flickr

20160901_134036 by Benjamin Charlton, on Flickr

20160901_134032 by Benjamin Charlton, on Flickr

20160901_140317 by Benjamin Charlton, on Flickr

I welded in the door jam part and cut away a bit for the new arch to butt up against..... i cut to much

screwed the new arch in to try and hold it all in place

20160901_164505 by Benjamin Charlton, on Flickr
as you can see i tried to repair my mistake, however i am not happy with it so will probably start again

20160901_164508 by Benjamin Charlton, on Flickr
and then the inside arch will need to be straighten and probably extended to meet the outer arch

20160901_164514 by Benjamin Charlton, on Flickr

20160901_164515 by Benjamin Charlton, on Flickr

20160901_164518 by Benjamin Charlton, on Flickr

but the door jam section is looking good i think?

20160901_164521 by Benjamin Charlton, on Flickr

the peddle box and peddle are looking better too now

20160901_165415 by Benjamin Charlton, on Flickr
as does the painted fuel pump and and distributor

more updates to come next week then it is my wedding so wont be anything till late October

Ben

Post by **benji1985** » 07 Sep 2016 07:13 pm

Good evening all, another update and a big milestone for me

07/09/16
So today the new rear arch was started (i forgot to take photos as a started it sorry).
Positioned the arch and drilled some holes through the body and then welded the arch to the body

20160907_121818 by Benjamin Charlton, on Flickr
welded the lips together

20160907_121821 by Benjamin Charlton, on Flickr

20160907_121825 by Benjamin Charlton, on Flickr

20160907_121829 by Benjamin Charlton, on Flickr
repaired my little mistake and also added a flap so the missing part of the sill can be fabricated

20160907_121836 by Benjamin Charlton, on Flickr
cut out the new peice to finish of the sill area and welded it all up

20160907_151038 by Benjamin Charlton, on Flickr

20160907_151045 by Benjamin Charlton, on Flickr
painted it over with some primer

20160907_165558 by Benjamin Charlton, on Flickr

20160907_165559 by Benjamin Charlton, on Flickr

20160907_165601 by Benjamin Charlton, on Flickr

decided to cut away the inner ache that i made as is was not neat and would not have met the outer arch, so once the outer arch was in I made some inserts

20160907_165611 by Benjamin Charlton, on Flickr
and the same on the rear side

20160907_165616 by Benjamin Charlton, on Flickr
the lower back edge

20160907_165620 by Benjamin Charlton, on Flickr
ready for some filler
I am quite pleased with how it came out, just hope it all looks as good once the car is back together

20160907_155817 by Benjamin Charlton, on Flickr

20160907_170634 by Benjamin Charlton, on Flickr

20160907_171330 by Benjamin Charlton, on Flickr

Please feel free to let me know what you think

Ben

Post by **bogbasic** » 07 Sep 2016 09:51 pm

Epic and awesome work - I never knew you were into arch-welding ;-0

Post by **benji1985** » 10 Sep 2016 11:35 am

Good day all, a small update today
09/09/2016
I finished off the peddle box

20160909_173235 by Benjamin Charlton, on Flickr

20160909_173238 by Benjamin Charlton, on Flickr
and i also started using the filler to tidy ou the arch, it is far from finished yet but only had a few hours to play

20160909_173252 by Benjamin Charlton, on Flickr

20160909_173259 by Benjamin Charlton, on Flickr

20160909_173308 by Benjamin Charlton, on Flickr (the circle is maker where i know there is a low)

20160909_173319 by Benjamin Charlton, on Flickr
this bit is going to take some time to get right

thats all for now, have got one more day on the car before the wedding in less than 2 weeks.

will keep you updated

Ben

Post by **benji1985** » 10 Oct 2016 09:47 pm

Good evening all, so it has been a while (2.5 weeks) since I have done anything to the car due to my wedding and honeymoon. But today i was right back on it..
10/10/16
I start today with bracing the door apertures and made a start on the other sill to be removed

20160914_153745 by Benjamin Charlton, on Flickr

20161010_094908 by Benjamin Charlton, on Flickr

Then removed the outer layer near the rear wheel arch, was presently surprised to find that there is very little rust compared to the other side

20161010_101829 by Benjamin Charlton, on Flickr

20161010_101834 by Benjamin Charlton, on Flickr

20161010_101837 by Benjamin Charlton, on Flickr
then proceeded to remove the outer and inner sill

20161010_134831 by Benjamin Charlton, on Flickr

20161010_134839 by Benjamin Charlton, on Flickr

20161010_134843 by Benjamin Charlton, on Flickr

with the inner sill removed i was able to repair the section in the inner "inner" sill

20161010_143847 by Benjamin Charlton, on Flickr

20161010_143852 by Benjamin Charlton, on Flickr

20161010_150143 by Benjamin Charlton, on Flickr

20161010_150147 by Benjamin Charlton, on Flickr

Then i cleaned up the inner "inner" sill and POR15 it.

20161010_150153 by Benjamin Charlton, on Flickr

20161010_151536 by Benjamin Charlton, on Flickr