Slow progress

Sorry for the lack of posts lately.  After my last post, most of the work done was just cutting more spot welds.  I haven't touched the car in several weeks because I have some other projects going on at the moment that are taking priority, but hope to be working on it again soon.  Slow progress is better than no progress.

Driver's floor pan pt. 1

If you looked through my previous pictures, you've seen that the floor boards on my driver's side were almost nonexistent.  Water had gotten into the car and caused rust to the point that very little metal was left.  A week or two ago, I roughly cut out the bulk of the rust with a sawzall cutting around the places where the pan was welded to the frame.  Today I started to cut out the spot welds holding the remaining floor in.  I've never needed to cut spot welds before, so it was a bit of a learning process.  I found that for most of the spot welds, it was easier to just grind them off instead of using the spot weld drill.  Because of the severe rust and pitting, it was difficult to determine exactly where each spot weld was and the spot weld bit didn't always cut where I needed.  I thought I made pretty good progress.

I think this may be the most difficult part.  This is the side of the reinforcement piece that goes over the transmission tunnel.  It sandwiches the floor pan between it and the frame below.  I'm guessing I'll have to remove it.  

Most of the floor pan is out and now you can see the frame below.  Still quite a bit to go around the perimeter, but this is a great start.  This pic shows how the pan is sandwiched by the transmission tunnel reinforcement piece.  

Added structural reinforcement

Its probably overkill for suck a light car, but I wanted to weld in some square steel tubing to reinforce things before I cut out the major sections of rust.  Not really an exciting step, but its something checked off the list.  

Two supports going each way should stiffen things up substantially.  

Parking Brake

I finally got to use a tool I've had sitting around for a long time... my spot weld cutter set.  I got a set of them a few years back to do a different car, but that car is now on the back burner.  I also have a spot weld drill, but due to clearance issues, I figured I'd just use the spot weld bits for this job.

If you've looked at the parking brake on these cars, you know its welded in.  Fortunately, or unfortunately depending on your perspective, mine was only attached halfway because the bracket was rusted through in several places.  I'm going to have to find someone who makes the bracket new or fabricate one myself.  The lever itself isn't in bad condition, but the rest of the components will need a full restoration.

You can't see the extensive rust from this side, but the other side is almost nonexistent where it meets the floor pan.

Warmer weather

Spring has finally started to arrive!  I've got to say, this is one of the latest springs I ever recall.  Winter just doesn't want to give it up this year.

I haven't gotten much done yet, but am finally starting to get back at this car.  One thing I've started is the wheels.  I haven't made a final decision on what wheels I'll use when that time comes, but at the very least, I'd like to have the wheels that came with the car ready in case I go that route.  My car originally came with steel wheels and hubcaps which I think is a good look.  Maybe that's because I was originally a Mopar guy and I like the Mopars with the body colored steel wheels.  Then again, maybe I'll convert to knock-offs.

Currently, I'm trying to find a good color match for the wheels.  Ideally, I'll get them powder coated, but that's assuming I find the right color.  I'm not against painting them, but that would be my second choice.  While I'm trying to get the color matched, I at least had the old tires removed.  They were in such sad shape that most of them had holes several inches long in them.

Ready for media blasting 

Got some new toys

I realize I haven't posted in a while, but its been too cold to do any work on the Volvo.  Once winter sets in, I only do work on cars if I absolutely have to.  Its no fun working with cold steel tools and car parts in a concrete and brick garage only to lose feeling in my hands and to get my knuckles busted open from the slightest mishap.  This is supposed to be fun, not punishment.

Despite the lack of progress on the Volvo, I have been getting some things checked off the to-do list.  First, I finally got a metal shrinker stretcher.  This tool should get a fair bit of use when fabricating patches for some of my Volvo's rusted body parts.  For example, I expect I'll be using it quite a bit to fabricate new sections of the trunk and hood gutters.  Since my car sat for so long, debris got lodged in these gutters which acted as a sponge for moisture, thereby rusting out sections in both the front and back of the car.

Also, I recently bought a blast cabinet.  I've been wanting one for years!  If I'm right, I'll be finding all sorts of uses for it.  I just bought one of the stand up Harbor Freight models, but I also did several of the upgrades you can find online for it.  I bought it knowing that some parts will wear out quickly and will need replaced soon, but for the price, that's not really a concern.  I'll upgrade them as they break.  It takes quite a bit of time to put it together, and even more to modify it, so don't think you'll have it up and running in a few hours if you buy one.  Plus, you may need to plumb it into your air compressor lines and you'll probably want to buy a dust separator so the debris doesn't wreak havoc on your shop vac.

Assembling the blast cabinet.  There are lots of parts of screws to deal with.  

Finally assembled and ready to clean its first part.