Duchess The Volvo 340 CVT

[benji1985]

Well life has got in the way of the restore for now.
next updates will be around my birthday on the 19th of may, new welder is coming, gas is sorted PPE is sorted, time to get the broken bolt/s out of the chassis

PS the 22nd of april she will be 28 years old

Ben

[bogbasic]

Good luck with it all, man - I look forward to the seeing how it goes. I couldn't help thinking this must be what snapchat is like (poor pun, sorry , but I've never used social remedia.... I agree that when something snaps, I always check who is in earshot ;-0 ;-0 ;-0 ;-0

[benji1985]

Good luck with it all, man - I look forward to the seeing how it goes. I couldn't help thinking this must be what snapchat is like (poor pun, sorry , but I've never used social remedia.... I agree that when something snaps, I always check who is in earshot ;-0 ;-0 ;-0 ;-0

"Snapchat" love it!

I am looking forward to trying my hand at a bit of fabrication, we shall see how it goes



Ben

[benji1985]

DUCHESS IS 28 YEARS OLD TODAY!!!

[MCHUDD]

Hi mate.
They are all getting on a bit now. My 2lt chuggle bus is now 33 and the daily 1.4 Banana is 35.
Cheers Mark.

[benji1985]

Hi mate.
They are all getting on a bit now. My 2lt chuggle bus is now 33 and the daily 1.4 Banana is 35.
Cheers Mark.

Aww i am going to get her a little cupcake and candle

[benji1985]

Good day all, Well i had a little bit of time today, so i could not resist in sorting out some of the parts.
the new vac hose arrived.
23/04/16
the new hoses were cut to size and clamped to the metal tube section for the air to the CVT unit
IMAG4121 by Benjamin Charlton, on Flickr
Also put the rubbers back in to the mounting frame for the CVT units
IMAG4118 by Benjamin Charlton, on Flickr

Found the old stud that were removed and compared them to the new ones
IMAG4119 by Benjamin Charlton, on Flickr

And lastly here are the hubs completed now with the new nuts (thank you Tom)
IMAG4122 by Benjamin Charlton, on Flickr

The new welder is on the way, the gas and regulator is sorted, new longer bolts are being sourced (Thank you Mac) and the tank cutter has been paid for, also the engine winch will be available and i have the new engine stand, I shall hopefully have everything ready for mid may and my holiday in june

Ben

[benji1985]

Hello all, next updates
18/05/2016
So today is the day I have been waiting for, the engine was unbolted and the hoist set in position, final checks made and it started to come out, my first engine removal
IMAG4147 by Benjamin Charlton, on Flickr
IMAG4148 by Benjamin Charlton, on Flickr
IMAG4150 by Benjamin Charlton, on Flickr
IMAG4154 by Benjamin Charlton, on Flickr
IMAG4155 by Benjamin Charlton, on Flickr
And it is out!!!!
Empty engine bay
IMAG4157 by Benjamin Charlton, on Flickr

Bellhousing undone and then removed
IMAG4159 by Benjamin Charlton, on Flickr

I then set about removing the clutch and flywheel, clutch cover came off along with the disc, as it came off i saw the flywheel mating face, and my face sunk and the words "Oh s**t" came out, the flywheel was well buggered, inspected the clutch plate to also find cracking.
IMAG4160 by Benjamin Charlton, on Flickr
IMAG4163 by Benjamin Charlton, on Flickr
IMAG4164 by Benjamin Charlton, on Flickr

Luckily and very surprise a 2nd hand flywheel was sourced but not just one 3 people had them

I have had the use of my father in law's impact wrench, this has made light work of these jobs, so i decided to tackle the front and rear engine mount bolts, lots and lots of heat and the 3 remaining front mount bolts came out (one as you know broke the other day) and the rubber bushes for the engine were also removed
IMAG4172 by Benjamin Charlton, on Flickr

The rear engine mount was a little more stubborn the 6 15mm bolts all came out, the other 4 17mm were harder, 3 of which did come out slowly and so much heat, sadly one decided that it would break the welds on the insert...

ran out time today so more to come over my birthday break, cant think of anything better to do on one's birthday

20/05/2016
So today i set about striping out the engine bay and separating the parts of the rear engine mount, steering rack off.
IMAG4173 by Benjamin Charlton, on Flickr

broken bolt and broken insert
IMAG4175 by Benjamin Charlton, on Flickr
IMAG4177 by Benjamin Charlton, on Flickr

the torque rod mounts need a good clean...
IMAG4178 by Benjamin Charlton, on Flickr
IMAG4179 by Benjamin Charlton, on Flickr
IMAG4180 by Benjamin Charlton, on Flickr


So my pile of parts is started for powder coating
IMAG4181 by Benjamin Charlton, on Flickr


So i have this wire... what wire is this for, has a earth wire going to the negative battery lead
IMAG4193 by Benjamin Charlton, on Flickr
IMAG4194 by Benjamin Charlton, on Flickr

What is this and what does it do?
IMAG4196 by Benjamin Charlton, on Flickr

decided to take a pic of the CVT unit (think primary) it has some pitting on the drums.
IMAG4197 by Benjamin Charlton, on Flickr

So this is where we are at now, next break is some more stripping, interior is coming out and the engine bay, underbody and floor plan all going to be wire brushed and POR15'ed

so more to come

[bogbasic]

Awesome work. That field must be worth a bob or two.

[Ride_on]

The electronic module is for fuel cut on closed throttle decelerating. Wire is probably ground for the outer sheath of the speedo perhaps for RFI/ESD reasons.

[benji1985]

good evening all, the past couple of days have been very busy.
so here's the next installment in the duchess saga....
25/05/16
As my new welder has arrived I decided to attempt to try and weld on a nut to the remaining broken bolt in the chassis, and i am happy to say that it worked, the remaining bolt is out!!!
IMAG4200 by Benjamin Charlton, on Flickr

The bumpers are dismantled so the metal parts can be cleaned up
IMAG4201 by Benjamin Charlton, on Flickr

I then started to dismantle the interior:
first the seats came out, then the center console
IMAG4206 by Benjamin Charlton, on Flickr

IMAG4209 by Benjamin Charlton, on Flickr
IMAG4210 by Benjamin Charlton, on Flickr
IMAG4211 by Benjamin Charlton, on Flickr
IMAG4224 by Benjamin Charlton, on Flickr

Then the carpet came out
IMAG4226 by Benjamin Charlton, on Flickr
Notice the amount of slim coming out of the foam
IMAG4227 by Benjamin Charlton, on Flickr
The sound deadening started to flake off revealing some more surface rust
IMAG4231 by Benjamin Charlton, on Flickr
lucky it is not to bad at all
IMAG4232 by Benjamin Charlton, on Flickr

another look at the scuttle panels show that the rust underneath could be bad.... this will be tackled
IMAG4233 by Benjamin Charlton, on Flickr

I decided to run a tap through all the engine mounts holes in the chassis whilst doing this found some more rust on the chassis
IMAG4235 by Benjamin Charlton, on Flickr
IMAG4236 by Benjamin Charlton, on Flickr
IMAG4237 by Benjamin Charlton, on Flickr

So all in all a busy day, in total there are 7 rust spot that are going to need to be tackled, so not really that bad, but I can assume that there will be more just waiting to show itself.

26/05/16
Today was planned to strip the rest of the interior out,
Rear seatbelts
IMAG4239 by Benjamin Charlton, on Flickr
Front seatbelts
IMAG4242 by Benjamin Charlton, on Flickr
Instrument cluster surround
IMAG4249 by Benjamin Charlton, on Flickr
wiper stalk
IMAG4255 by Benjamin Charlton, on Flickr
light stalk
IMAG4257 by Benjamin Charlton, on Flickr
clock..... this is my wiring, bad Benji....
IMAG4258 by Benjamin Charlton, on Flickr
IMAG4259 by Benjamin Charlton, on Flickr
Glove box
IMAG4260 by Benjamin Charlton, on Flickr
Lighter.... again wire fun there....
IMAG4262 by Benjamin Charlton, on Flickr
center console and bits all removed
IMAG4267 by Benjamin Charlton, on Flickr
IMAG4268 by Benjamin Charlton, on Flickr
Dash removed
IMAG4269 by Benjamin Charlton, on Flickr
Heater matrix - also found a bent wire that controls the air flow
IMAG4270 by Benjamin Charlton, on Flickr
wiper motor
IMAG4271 by Benjamin Charlton, on Flickr

getting there
IMAG4272 by Benjamin Charlton, on Flickr

the inside of the scuttle panels....
IMAG4273 by Benjamin Charlton, on Flickr

wiring removed
IMAG4275 by Benjamin Charlton, on Flickr
IMAG4276 by Benjamin Charlton, on Flickr
IMAG4277 by Benjamin Charlton, on Flickr
IMAG4278 by Benjamin Charlton, on Flickr
IMAG4280 by Benjamin Charlton, on Flickr

All the front wiring removed
IMAG4282 by Benjamin Charlton, on Flickr

Brake servo
IMAG4284 by Benjamin Charlton, on Flickr

Pedal box
IMAG4285 by Benjamin Charlton, on Flickr

Steering column
IMAG4286 by Benjamin Charlton, on Flickr

removed the foam
IMAG4287 by Benjamin Charlton, on Flickr
IMAG4288 by Benjamin Charlton, on Flickr

the front end stripped
IMAG4289 by Benjamin Charlton, on Flickr

Found some more rust
IMAG4290 by Benjamin Charlton, on Flickr

Rear wiring removed ----> light clusters
IMAG4293 by Benjamin Charlton, on Flickr

Fuel tank expansion and petrol cap
IMAG4294 by Benjamin Charlton, on Flickr

I decided to removed all the sound deadening, chipping didnt work...... blow torch worked , all deadening removed
IMAG4295 by Benjamin Charlton, on Flickr
IMAG4296 by Benjamin Charlton, on Flickr

more rust!! this patch is where the front seatbelt bolts in
IMAG4299 by Benjamin Charlton, on Flickr

My future grandparents cleared out a large shed to put all the parts in, so with a big move from lots of little places in to one, I had a look at chrome windscreen trim, i lifted the edge to see how bad it was going to be to get out.
it started to come out quite easy, I used two flat edges to lift the trim
IMAG4300 by Benjamin Charlton, on Flickr
using the "U" shape part under the edge of the trim
IMAG4301 by Benjamin Charlton, on Flickr
IMAG4302 by Benjamin Charlton, on Flickr
Tools
IMAG4303 by Benjamin Charlton, on Flickr
ran the tool around and the trim came out in two pieces (meant to be two)
IMAG4304 by Benjamin Charlton, on Flickr

So far so good, more to come next week as i am on holiday

Ben

[bogbasic]

Epic work!!

[benji1985]

Epic work!!

Thank you

[benji1985]

Good day all, yesterday was a bit of a slow day, but did manage to get some more stuff done all in prep for the sills to be cut out and repaired.
04/06/16
Started off with dismantling the front bumper to retrieve the chrome (and put it some where safe)
IMAG4325 by Benjamin Charlton, on Flickr

I then removed all the door cards
IMAG4326 by Benjamin Charlton, on Flickr

My new sills await (Thank you Dia)
IMAG4327 by Benjamin Charlton, on Flickr

set the better half the job of removing the glue.... it didnt work... stronger measures were needed
IMAG4328 by Benjamin Charlton, on Flickr

Stripped down her new doors.... just need to find the rear drivers door now, all these doors are in really good condition, few very minor rust patches
IMAG4329 by Benjamin Charlton, on Flickr
All the chrome trims came off nice, thank you bogbasic for pointing me in the right direction
IMAG4330 by Benjamin Charlton, on Flickr

set about removing all the sound deadening from the back..cue blow torch
IMAG4331 by Benjamin Charlton, on Flickr
IMAG4332 by Benjamin Charlton, on Flickr

Stronger solvent cleaner was used to removed the glue and paint and rust and finger tip after melting gloves and maybe a few brain cells...
But it worked the glue was removed
IMAG4333 by Benjamin Charlton, on Flickr
IMAG4334 by Benjamin Charlton, on Flickr
IMAG4335 by Benjamin Charlton, on Flickr

also the axle stands were moved of the jacking points and is now resting on the chassis with some wood in between.

so Tuesday i hope to removing the passenger doors and brace them up and start to remove the sill and examine the inner sill, need new rear wheel arches too now.

So until then watch this space

Ben

[bogbasic]

Epic work again. What are you going to replace the sound-deadening tar material with??