Volvo 745 Pickup + 4.8l V8 conversion

bjwhite

True Classic
Wow. Looks like much work went into that example. Not a fan of the extreme dropped suspension, otherwise very cool!

When I look at the A-Traktor versions, I'm so happy NY doesn't impose build restrictions for modified vehicles (beyond the need to be safe & pass annual inspection).

I've never lived in a state that has yearly inspections. Seems so odd to me.
 

lookforjoe

True Classic
How about using one of these?

Many thanks Tom! I think I looked at something like that years ago, then promptly forgot all about it 🤪 - I found a brand that has the 10"+ 5" (still 5" depth, which I need) that can be connected together. That will work well, I hope!
 
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lookforjoe

True Classic
I've got an ancient one of those made out of metal.
Nice! Got a pic? I love to see old tools.

All I got done today was some wiring, no energy for anything more strenuous. Waiting for results of PCR test.

repinned the gate harness, JPT terminals

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left sufficient length to tuck the connectors in the middle area, in case there's no room on the outer left

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After that, I cut the rear harness to make the pass through connections. Spliced in an extra set of wires that can be used for the trailer connections, so I don't have to splice anything off the tail lamps. Also added the white wire back for the license plate illumination.

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6.3mm for the heavier wiring (4polePT), 2.8mm for everything else (6pole,2poleJPT), except the ABS which I used a TS060 sealed housing (used on later Volvos for engine temp sensors, so I have a bunch)

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Nice! Got a pic? I love to see old tools.

Here you go:

Contour Gauge - Front.jpg


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My Dad bought it some time during the 60s. It may have come from Job Lot Trading Company or one of those other stores big on tools in lower Manhattan around Vesey Street. Out of necessity, many moved a bit north when they built the World Trade Center. It was a pretty cool area to go looking for tools. There were also many electronics stores selling audio and communications equipment in the same area.
 

lookforjoe

True Classic
I've never lived in a state that has yearly inspections. Seems so odd to me.
Interesting - it had never occurred to me that there were states that didn't require some sort of safety (and emissions) testing. How do they make sure ppl aren't driving death traps? It's not as if you can rely on the individual to make sure their cars are safe to operate....
 

autox19

True Classic
Interesting - it had never occurred to me that there were states that didn't require some sort of safety (and emissions) testing. How do they make sure ppl aren't driving death traps? It's not as if you can rely on the individual to make sure their cars are safe to operate....
I am in one of those states. people do drive death traps. Cant say I wasnt one of them at least a few times in my life. had a VW bug that wouldnt lock up the brakes on loose pavement. did teach me to look way ahead in traffic, a good habit I still have today. I think 80% of the state would revolt if there were emission checks with all the hot rods around.

Odie
Michigan
 

lookforjoe

True Classic
Hope you're feeling better soon!!!

Both Ann & I tested positive last night in the at home tests, and my PCR test came back positive last night also. The at-home test I took on Sunday (negative) must have been too early to register. Last Wednesday the mask mandate was lifted for public schools, so way more than 1/2 the kids & staff were no longer masked from then on.

Only thing I did yesterday was make the 1/4 glass template - then the snow started. Archie is watching the snow fall.

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pulled out the rear door wiring, leaving only the speaker wires

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Interesting - it had never occurred to me that there were states that didn't require some sort of safety (and emissions) testing. How do they make sure ppl aren't driving death traps? It's not as if you can rely on the individual to make sure their cars are safe to operate....
In California, you can drive a death trap as long as it doesn't pollute. Only emissions testing (1976 and later).

I hope that you and Ann feel better soon.
 

Tom Ginefra

True Classic
Both Ann & I tested positive last night in the at home tests, and my PCR test came back positive last night also. The at-home test I took on Sunday (negative) must have been too early to register. Last Wednesday the mask mandate was lifted for public schools, so way more than 1/2 the kids & staff were no longer masked from then on.

Only thing I did yesterday was make the 1/4 glass template - then the snow started. Archie is watching the snow fall.

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pulled out the rear door wiring, leaving only the speaker wires

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I'm always impressed not just with the scope and quality of the work you undertake, but with your work ethic, as well. My family and I are all vaxed and boosted and with the exception of my wife "thankfully", we all got Covid at one point or another this year. And while my symptoms only lasted a few days, I wouldn't even think of trying to work on my car while I was sick. Kudos to you and best wishes to you and Ann for a speedy recovery.
 

kmead

Glutton for punishment
Both Ann & I tested positive last night in the at home tests, and my PCR test came back positive last night also. The at-home test I took on Sunday (negative) must have been too early to register. Last Wednesday the mask mandate was lifted for public schools, so way more than 1/2 the kids & staff were no longer masked from then on.

Only thing I did yesterday was make the 1/4 glass template - then the snow started. Archie is watching the snow fall.
pulled out the rear door wiring, leaving only the speaker wires
Crap, that is a pain. We suffered it at the beginning of the year when my idiot son‘s workplace went to no masks and he didn’t tell us.

Hope you are better soon.

I did want to say how impressed I always am by the electrical connector work you do, always the right crimped solutions and connectors.
 

lookforjoe

True Classic
Snow is gone & sun is out, so I worked outside for a few hours.

Worked on low effort pieces - started folding & tacking the cut B pillar layers so that nothing is left loose, and folded the edges that would interfere with the stake insertion, then cut & welded the first stake holder bracket . I'll finish it & clean up the welds later

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Figuring out how to fill the rear door - I decided I don't want to have a smooth panel covering the whole thing - it won't go with the rest of the bed. So, a filler piece to join door opening to inner door skin - approx 3/4" wide, will be butt-welded

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then contoured pieces to fill large openings, and join to the C pillar, and I'll fill the various small holes

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Cut some SS to make the reinforcement inserts for the rail caps: 48 x 3.5"; for a 2" vertical & 1.25" horizontal ( with a 1/4" folded edge)

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also folded some sheet (in background) to make the 1/4 glass lower lip

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So, back to one of my original layouts, just larger dimensions:

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This got complicated as I want to retain the inner & outer door upper lip - for the outer molding, and for the door panel should I decide to cut it down & make it work.. That means there has to be an open channel on either side of the glass frame lip along the door cap

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it will be welded to the door skin along the opening where the vice grips at located, and to the vertical pinch welds at each end

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(dropped on the right in this pic, it will sit level)

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lookforjoe

True Classic
Does that mean you are feeling better, Hussein ??

I was worried about you, my friend 😟

By the way....very cool project !!!!

Hello Doug! I was still pretty sick on Friday, so I only did a few hours of low effort stuff - I'm feeling much better today - planning on going back to work tomorrow - only requirement is 5 days quarantine from onset if fully vacc'd. I have to wear a mask for 5 days, but I still do that in class anyway, so no biggie. Couldn't do any outside work yesterday or today, too much snowfall yesterday & temps dropped back into the low 20's today 😫
 

lookforjoe

True Classic
Got back outside for a couple hours today whilst the sun was in the driveway. Still feeling kinda shagged.

Removed the rear door locks & handles to prep for welding, and made some more tagboard templates for the door filler sections, then cut a couple of the pieces from my wife's old roof section

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card filler strip to unite inner door skin to door sill/opening. approx 3/4" deep. Trying to keep all welds to butt joints whenever possible to avoid moisture traps

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lookforjoe

True Classic
small steps - got the upper inserts spot welded together after a bunch of fettling to get the fit right

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tacked in place - I'll weld the door side with the door open, then do the C pillar side after the door are welded shut

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cut the L & R forward door fillers, and center junction for bottom of door skin to sill

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nibbler tool worked the best for these more organic shaped pieces

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lookforjoe

True Classic
Cut out the cross braces & beams from the roof skin, so I can use parts of the skin for various areas.

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Cut out some more filler pieces

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The doors have a slight curve at the top where the handle is located, so I cut sections from the roof (8.25'x3.75") just inboard of the ridge.

Cut out the door cup, after scribing around the filler piece I made

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only minor filling after that

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ready to tack

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forgot to photograph it during the tack/weld steps - this is after I ground down the welds & put some primer on it

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I'll need to grind it a little more, then some minor filler

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pretty level across the panel - I'l happy with the results. I did get a little over zealous with the speed at which I worked around - I heard the panel pop in the area below the weld- it sucked in. I used the heat gun & a stick to massage it back out after.

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