making useful stuff (volvo tools, for a change)

[JW240]

2 stuck B230 crank pulleys and a broken impact gun motivated me to make this crank holder tool...

Start with a short piece of steel pipe, close to 90 mm (3.5") diameter iirc, it should fit in the crank pulley, mark the pieces that need to be removed with an old pulley and spraypaint. I used a hacksaw and a plasmacutter to remove steel.
http://img407.imageshack.us/img407/2723/p9213183br0.jpg

Join with some leftover box tube section (40x20x2 mm):
http://img517.imageshack.us/img517/2107/p9213189by6.jpg

Make a huge mess in the process:
http://img511.imageshack.us/img511/341/p9213188wl9.jpg

Ok weld, could have been a bit more consistent, I didn't use the machine for a month and forgot how much power this thick steel needs. Also a bit if contamination from a filler rod that was used to join steel exhaust pipe with stainless steel pipe. Anyway, it is strong enough :cool:
http://img291.imageshack.us/img291/458/p9213192qv3.jpg

How it works:
http://img407.imageshack.us/img407/8733/p9213194tt7.jpg
Works for both 8v and 16v engines (slightly different openings in the pulleys it seems). It was modeled after a 8v version.

What do you think? Post up some useful tools that you made, maybe we can make a list with useful designs to make.

[ozzy]

that my good sir is EXTREMLY usefull...justa shame theres only two pictures:-(

[JW240]

that my good sir is EXTREMLY usefull...justa shame theres only two pictures:-(

oh? maybe imageshack is acting up.... (5 pics loaded and visible here.....)

[volvo78244]

Nicely done JW, looks like a very handy tool.

[Fivehundred]

Looks good, though being a lazy sod I sniped mine off Evil Bay for 12 quid including postage and a new genuine Volvo Timing belt. The vendor didn't know how to fit said belt or how to use the tool after flashing the credit card at the local Volvo stealership:lol:

[JW240]

Looks good, though being a lazy sod I sniped mine off Evil Bay for 12 quid including postage and a new genuine Volvo Timing belt. The vendor didn't know how to fit said belt or how to use the tool after flashing the credit card at the local Volvo stealership:lol:

Those auctions are the best. that way i managed to snipe a complete 940 of ebay for the price of, ehm, lets say, renting the trailer was equally expensive :-D

evil bay is my main supplier. got the Esab AC/DC tig and many many more tools from it. Without it i couldn't have such a workshop (you don't want to know what a welder like that costs new :-P).

[Wagner]

Noice!

I do all sorts of special tools every change i get, but at least half of them are really not needed. I mean, i end up using more time making the special tool to reach some inconvinient bolt or something similar than to dismantle something that's on the way, and by taking it away the job would be 5 minute one. :)

I have a box full of wierd pieces of bent steel, and i've made at least a dozn punches, a few bearing pullers, some hooks and what not.

Most of them don't look all that nice though. And nice looking welds there on yours, no spatter what so ever. It is TIGged right?

Let's see, i found a few pics of the wierd things that i've made:
http://personal.inet.fi/koti/wagner/tools/vaihde.jpg
tool to position the shifter in 200-series, needed in the Getrag swaps.

http://personal.inet.fi/koti/wagner/tools/pihdit.jpg
pliers to remove the large snap ring found in Holsets, i've used them twice :-P

http://personal.inet.fi/koti/wagner/tools/teline.jpg
an engine stand in the making. They cost like 60 euros. ;-)

http://personal.inet.fi/koti/wagner/tools/vedin.jpg
general puller, this i've used plenty of times, it's way good!

[JW240]

And nice looking welds there on yours, no spatter what so ever. It is TIGged right?

Yup, TIG. Started welding with stick welding a long time ago, then mig, now tig :)
Lucky me i found the machine for a reasonable price otherwise i still would be using stick. Tig is the best process for me since i can switch between different materials without trouble (like MIG), it is usable for more delicate welding stuff and works good on thick stuff as well.
I do miss the point and trigger MIG stuff, so handy for (rusty) car bodywork, TIG is difficult, very difficult on that.

Noice!
I do all sorts of special tools every change i get, but at least half of them are really not needed. I mean, i end up using more time making the special tool to reach some inconvinient bolt or something similar than to dismantle something that's on the way, and by taking it away the job would be 5 minute one. :)

I have a box full of wierd pieces of bent steel, and i've made at least a dozn punches, a few bearing pullers, some hooks and what not.


It is the same here, although most of the time the people around me get impatient and i don't get the chance to finish the tool haha.

Those pliers look very beefy, good stuff. The gear puller is something i have to add to my collection as well.

This is one of the first pullers i welded, to remove the stuck windscreen wipers of my 240. Stick welded, the puller worked great.

http://img509.imageshack.us/img509/9445/pict4130bx8.jpg

http://img252.imageshack.us/img252/5520/pict4131cn3.jpg

a few quite ugly contraptions from my moped days are still in a box, they will be used again sometime. One of the last versions was quite nice, made of 3 very strong cylinder head bolts, washers, nuts and a piece of box tubing, worked good.