780 Bertone - Nvrmnd - Volvo 745 Pickup Project

lookforjoe

True Classic
So, problem was not MCC head unit. Fuse blew agin the next day. Rechecked my wiring, and then remembered that I re-purposed the bl-gn signal for the AC relay for the PTC heater, as the new AC relay used two signal grounds instead of switched power. I unplugged the PTC, and so far the fuse has not blown, so perhaps it was just overloading that circuit.

added snaps to the wood floor to secure the plastic wagon cargo tray

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Changed the door handles for the later style, more reliable version. Since they are white, I think I'll leave the gate white & be done with it.

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Also painted the grab handles with SEM 15173 camel - thankfully the cap color does not match the contents

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lookforjoe

True Classic
Worked on the end caps this afternoon

set to align with outer top edge of taillamp

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put primer on them for now, no time to finish them until tomorrow

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Have to fill in the transitions with some more weld material

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figuring out the lower cap, hopefully get these welded tomorrow.

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kmead

Glutton for punishment
Worked on the end caps this afternoon

set to align with outer top edge of taillamp

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put primer on them for now, no time to finish them until tomorrow

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Have to fill in the transitions with some more weld material

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figuring out the lower cap, hopefully get these welded tomorrow.

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Nice.

Personally I would make the transition from the rail to the D pillar a more vertical return to the face of the faux rail at the end rather than the somewhat tortured expression (so it would be more like the tailgate side). You are the designer here so drive on :)

Lots of good work here to resolve a wide variety of conditions which were never intended to be capped. Congrats on getting near the end of another amazing project.
 

lookforjoe

True Classic
Nice.

Personally I would make the transition from the rail to the D pillar a more vertical return to the face of the faux rail at the end rather than the somewhat tortured expression (so it would be more like the tailgate side). You are the designer here so drive on :)

Lots of good work here to resolve a wide variety of conditions which were never intended to be capped. Congrats on getting near the end of another amazing project.

Thanks Karl - so more of a hard edge instead of the contoured transition? When I staggered the faux rail, I wasn't planning on widening the D post. If I had just run the rail into the cap, I wouldn't have ended up like this. I don't want to rework all that at this point, So I'll clean it up with some additional metal.

Today I added some material to the left cap (based on my previous plan), and made the cover plate for the right side. That's as far as I got - had to make the right cap twice, first one I had the depth all wrong for the gate depth.

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top view

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Feel pretty good about the overall look from the rear / side

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kmead

Glutton for punishment
Thanks Karl - so more of a hard edge instead of the contoured transition? When I staggered the faux rail, I wasn't planning on widening the D post. If I had just run the rail into the cap, I wouldn't have ended up like this. I don't want to rework all that at this point, So I'll clean it up with some additional metal.

Today I added some material to the left cap (based on my previous plan), and made the cover plate for the right side. That's as far as I got - had to make the right cap twice, first one I had the depth all wrong for the gate depth.

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top view

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Feel pretty good about the overall look from the rear / side

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Looking good. Drive on metal master :)
 

lookforjoe

True Classic
Cleaned up the left cap with a little more weld material, at this point I'm just going to use filler to smooth the visible dip left in the transition from faux rail to post

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kmead

Glutton for punishment
Looking good. A bit more filler in a few spots and you are ready for some color. Can’t wait to see it. Wish I lived closer I would have loved to be there to play through it all.

Nice job, you would hardly know there were so many parts glommed together.
 

lookforjoe

True Classic
It will be real pickup only when You will make a VOLVO on a gate like this. 😅

Yeah, I thought about that. My neighbor has one of those VW caddys (diesel, unmodified). I just don't have any way of stamping VOLVO into the gate :(

Today, I just mounted the new 225/45x15 BFG's for the back of the X1/9, so I can drive it to work tomorrow. Thunderstorms not expected until 3 or later, so should be a good drive to & fro. Scheduled the alignment for next Wednesday, so before I wear the tires out again...

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kmead

Glutton for punishment
I lIke this idea. Perhaps cutting the parts out of ABS and gluing them onto the steel using some of that incredible Fusor material or epoxy and fairing it in with Everfill.

It would complete the thing.

Locally I have seen a Passat pickup and a Jetta pickup. They were both surprisingly nice, they are built from fiberglass kit parts as I understand it.
 

lookforjoe

True Classic
I lIke this idea. Perhaps cutting the parts out of ABS and gluing them onto the steel using some of that incredible Fusor material or epoxy and fairing it in with Everfill.

It would complete the thing.

Locally I have seen a Passat pickup and a Jetta pickup. They were both surprisingly nice, they are built from fiberglass kit parts as I understand it.

I thought about getting acrylic letters & bonding to the gate, but it's just not going to look right. Unless the letters are spot-on for the Volvo font, it's gonna look like a$$, besides the fact that they will sit proud of the gate panel. Not sure if there is any way around it. I'd also have to level the panel & move the license plate & lights elsewhere. Under the bumper would look bad. I dunno. Can't see a practical solution now. Perhaps DTR I'll figure something out.
 

Janis

True Classic
You can cut with Laser from ~8mm sheet outer part, and inner part with litlle offset, then put another sheet or gate between them and wait for some truck to throw it under the wheels to get it formed :D
 

lookforjoe

True Classic
Worked on getting the bed finished up, so welding the pockets, refining the back end of the inner rail & D posts

seam sealer & secure right pocket
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filler on the rails

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fill, sand, fill, sand, spot putty on rail ends & posts

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pockets welded and sealed

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put some base coat enamel on the lower sections, tomorrow I'll hopefully do the final sanding & paint on the rails & posts

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cut & polished the tailgate, added the early (appropriate) V O L V O emblem back

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