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Old 09-20-2017, 09:57 PM   #151
Stiggy Pop
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I want to see how the inspection goes. Mass is going to stricter ones in october I heard
Yeah, I know what you mean. I'm not really expecting any trouble, it's got a closed cab and all of the original safety equipment.

Worse comes to worst; I work in CT and my house is on the border... of the three plated cars I own only one has a sticker on it.
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Old 09-20-2017, 11:11 PM   #152
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Mine turned 35 this year - so in NC - no more inspections at all. They linked annual registration and safety/emissions inspection about 10 years ago here which meant, no annual inspection = no new annual sticker for the tag. ugh. But - no more! Free at last...
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Old 11-03-2017, 02:29 PM   #153
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We've been trying to make some time for this again. In no small part because woodstoves are running, leaves are down, and we're starting to think about storing cars, boats, mowers etc. Time to get this thing sealed up.

We jumped off the tailgate and started working on the hatch opening. We needed to build a lower 'dam' for the gate to close against and serve as a water barrier. We grabbed another piece of 90* 14gauge and started cutting...

Basic idea was to mimic and continue the lip of sheet metal which forms the stock opening. We cut a piece of the 90 to length and made slices to build in the curvature of the artful, pininfarina-esque shape of a Volvo 945 hatch.



With the piece tacked into shape, we then tacked it to the floor of the lip pointed out towards the hatch opening.



It worked out really well! You can see in the corner we made a slice up the lower piece and bent the lip up so it's a nice continuous line just like on a stock car. The corner here might not look polished and beautiful but I'm pretty proud of it - there's 10+ pieces of cut and shaped metal just in this picture to stitch all this together. Also, welding on folded over layers of steel with seam sealer in between them makes some nasty smoke...





The finished product - a fully gasketed hatch opening, utilizing the stock Volvo gasket!



The hatch pulls up well and the gasket makes good contact all the way around, so we're ready to seal up this welding and make a latch.

Going to work on some body prep this weekend - we're really pushing to get a couple coats of epoxy primer on the car to seal it up.

Thinking longer term... we had my brother in law's Lexus sitting around the yard for a few months, which was effectively killed by the mean streets of Boston. I love love love the way this car runs so I bought it for scrap. The b230ft is a little unloved and rough running and this thing is just sooo smooooooth.



maybe... maaaaaybe

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Old 11-03-2017, 04:30 PM   #154
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I wish I would've hung onto the 2J out of my IS back when I parted it. Great, smooth revving motor. Good luck!
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Old 11-03-2017, 05:05 PM   #155
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It just keeps getting better.
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Old 11-03-2017, 08:00 PM   #156
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how do you think it will feel to have the most well-built voltruck outside of scandinavia?
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Old 11-04-2017, 01:51 PM   #157
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how do you think it will feel to have the most well-built voltruck outside of scandinavia?
Is the bar that low?
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Old 11-04-2017, 03:16 PM   #158
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how do you think it will feel to have the most well-built voltruck outside of scandinavia?
Apart from coach built ones it's probably more well built than 99.9% of the ones here
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Old 11-06-2017, 01:57 AM   #159
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Is the bar that low?
you and tate even play humble the same.
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Old 11-06-2017, 03:53 AM   #160
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Wow that opening hatch is a nice touch. The 940 seats are very comfortable but the only downside is they don't have that quick release like the newer seat have to fold the back rest all the way forward. Would make it perfect to haul longer items.
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Old 11-06-2017, 01:59 PM   #161
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lets party
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Old 11-06-2017, 08:44 PM   #162
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you and tate even play humble the same.
I want to be just like Tate when I Benjamin Button back into my 20's.

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Wow that opening hatch is a nice touch. The 940 seats are very comfortable but the only downside is they don't have that quick release like the newer seat have to fold the back rest all the way forward. Would make it perfect to haul longer items.
Agreed. I will eventually put some sort of 2-door car seats in which flip forward.

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lets party
I'll haul the keg. Crew's on deck



We did not make (many) sparks this weekend, just a whole bunch of dust. One of many, many days to come sanding this car.





switched to thin coats of Rage Gold to be blocked later on this week




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Old 11-06-2017, 08:56 PM   #163
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Dogs look bored - maybe need more sparks?

Can't wait to see the car/truck/ute in a coat a coat of primer so you can really see the lines.

I predict that your arms will be very tired of block sanding in the near future....
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Old 11-07-2017, 12:05 PM   #164
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So good, this is going to be awesome.
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Old 11-07-2017, 03:59 PM   #165
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I want to be just like Tate when I Benjamin Button back into my 20's.
step 1: chacos.
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Old 12-06-2017, 11:26 PM   #166
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We've been steadily putting time into the car as life allows, just not taking a ton of pictures. Doing a lot of blocking, and it's starting to come into shape. Took me a bit but I'm starting to get the hang of it. The Rage Gold sands really nicely.



This side of the car is pretty much there, little left to do at the bottom of the once-was rear door.



Cutting the fillet at the base of all the bed rail pieces is proving to be pretty difficult, but getting it close after a few shots.



I've had a lot of 940's come through the garage, and they've all got dinged up hoods. What gives?





Lotsa work but the results are not disappointing! This is our roof joint.

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Old 12-07-2017, 04:10 AM   #167
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Old 12-07-2017, 10:45 AM   #168
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Y'all are doing some top notch work, but I'd expect nothing less from you
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Old 12-07-2017, 12:44 PM   #169
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Something sort of Zen happened reading about blocking/sanding while listening to the Spice Girls sing 2 become 1....
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Old 12-07-2017, 04:34 PM   #170
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Loving the progress. You guys are doing great. Is it easy to reach the hatch latch while standing next to the bed? Also, does it lock the same as it did before?

Also, if that 2J goes in, I'll be even more jealous of you.
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Old 12-07-2017, 07:56 PM   #171
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Something sort of Zen happened reading about blocking/sanding while listening to the Spice Girls sing 2 become 1....
There's something sort of Zen about a few hours sanding after stressful days at work. Although we are usually listening to the Dead or Neil Young.

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Loving the progress. You guys are doing great. Is it easy to reach the hatch latch while standing next to the bed? Also, does it lock the same as it did before?
yeah it's easy to reach over and swing the hatch up, though we're talking about shaving the plate recess/handle area and putting some kinda low profile handles on the sides. Haven't built latches yet, hatch or tailgate. The hatch might only open from the inside. Just had a vision of an electric popper you could tap somewhere outside the car..

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Also, if that 2J goes in, I'll be even more jealous of you.
oh she'll go
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Old 12-07-2017, 08:00 PM   #172
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Originally Posted by Stiggy Pop View Post
yeah it's easy to reach over and swing the hatch up, though we're talking about shaving the plate recess/handle area and putting some kinda low profile handles on the sides. Haven't built latches yet, hatch or tailgate. The hatch might only open from the inside. Just had a vision of an electric popper you could tap somewhere outside the car..
Glad to hear it. The electric popper would be cool. Put some kind of button in the gas hatch or behind the license plate.


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oh she'll go
Since everything I do is a copy of you, you know you're making me build a ute with a 2JZ don't you? I don't have money for that, go easy on me.
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Old 12-07-2017, 08:25 PM   #173
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There's something sort of Zen about a few hours sanding after stressful days at work. Although we are usually listening to the Dead or Neil Young.
There's something sort of Zen about working with your son, relearning an old skill on my side, and watching your son learn something on his side.

It's been a good project because its "as time allows", and we try not to be in a hurry. I think to date, and its been a long run, we only had one bad night on the car, that left side f'n bed rail....
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Old 12-09-2017, 11:36 AM   #174
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Just curious, do you have a plan to let rain drain out of the bed or are you just going to always park it pointed up hill?

Loving the project, and thanks for sharing it.
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