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Old 09-13-2020, 09:44 PM   #51
Vol242vo
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Brilliant idea with the painters tape and washers. I skimmed through the last few posts, are you powder coating or spray? It all looks fantastic.
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Old 09-13-2020, 11:09 PM   #52
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Brilliant idea with the painters tape and washers. I skimmed through the last few posts, are you powder coating or spray? It all looks fantastic.
Thank you for the kind words. Ive been doing the washer and tape thing since I was a kid; back in my slot car days.

I am rattle can spray painting with etching primer and Rustoleum. Before painting Im sandblasting wherever possible. I.e. if it will fit in my blast cabinet. I prep all parts with acetone immediately before painting to ensure any lingering oil residue is removed. Paint consists of light coat of primer and 2 coats of color. After the finish coat of paint cures sufficiently to be able to handle I bake at 325F for 30 minutes. At assembly time I try to keep my hands clean and pre-fitting parts before painting helps to assure that they go together w/o interference. The resultant finish has proven to be quite durable.
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Old 09-15-2020, 07:26 PM   #53
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Does anybody know whether or not these two plugged holes have threaded nut plates behind them on my '73 145? I'm referring to the 2 plastic plugs on the cowl between the windshield washer reservoir/pump and the wiper motor, circled in the pic below:


They are pretty well aged and I think that I would destroy the plugs by attempting to remove them. If they are threaded I can use them to provide anchor points for a future A/C hose support.
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Old 09-20-2020, 10:59 PM   #54
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Does anybody know whether or not these two plugged holes have threaded nut plates behind them on my '73 145?
Unfortunately, no; they don't.

Your progress on this car is quite awesome, and I'm following with interest.
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Old 09-24-2020, 12:53 AM   #55
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Unfortunately, no; they don't.
Thanks for the info. Not to worry, there are plenty of other existing holes, screws and bolts on the firewall to use to secure the A/C return hose from the evaporator to the compressor. Thanks to your response I have gone in another direction that will work out well I think. At least I hope that it does.

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Your progress on this car is quite awesome, and I'm following with interest.
Thank you very much.


I had a bit of time at the shop this afternoon so I took advantage of the opportunity and made a plan for the A/C hose routing. With that in mind I made a few new parts, some brackets and hard lines:


Top to bottom they are:
1) Support bracket for the return hose to the Compressor from the Evaporator
2) Aluminum hard line from the Receiver-Drier to the Evaporator (to go through the cowl)
3) Steel hard line from the Compressor to the Condenser (to route around the steering gearbox and under the battery tray))
4) Aluminum hard line from the Receiver-Drier to the Evaporator (to get around the air cleaner
5) Aluminum hardline from the Evaporator to the Compressor (to exit the cowl)
6) Revised E-fan lower mount brackets

With the routing laid out I can now order the proper fittings. I'll be placing a parts order with Cold Hose in the morning. Once received I can move on to get the hoses final-fitted (hopefully), crimped and installed.

With any luck I'll have A/C working by wintertime.
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Old 09-24-2020, 08:23 PM   #56
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I spent a little time working on the Banana today. I placed my parts order with Cold Hose this morning. I hope that I got everything that I need because they're all the way on the other side of the country from SoCal. I also installed the new support bracket that attaches to the cowl and will keep the A/C return line from the evaporator back to the compressor properly located and not rubbing on a bunch of other stuff. A nice by-product is that the stiffening flange on the back side of the bracket also provides a convenient little cable tray area to clean up and more effectively control all of the wires that traverse the cowl from the driver's to passenger side of the engine bay. I added a few holes to the bracket to allow convenient placement of cable ties in the future.

Here is the new support bracket installed:


Since the new A/C compressor is very close to the brake master cylinder I already have re-routed the positive battery cable to run a bit further down so that there is no risk of contact with the compressor. I decided that a new support / guide bracket was in order to replace the original Volvo bracket. The new bracket routes the starter wire below the power brake vacuum reservoir instead of along side it.

Here is the new starter wire support / guide bracket:


And now with a proper grommet to better insulate the wire from chafing damage:


I will make a new battery-to-starter motor lead wire in the next couple of days as the original one that is still functioning could stand a fresh connector at the battery end. I'll make a fresh ground lead at that time as well. You know, as long as I am in there..... Haha.
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Old 11-12-2020, 01:10 AM   #57
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It's been pretty hectic around here for the past few weeks, leaving zero time to play with the Bad Banana. However that changed this past weekend as I needed to do a bit of preparation / maintenance for a short get-away drive up to the Central Coast area with a few buddies. Nothing too major needed attention except for a new fuel pump. The original unit has been acting up a bit over the summer, requiring a light wrap with a massive object to bring it to life every now and then. While it never rains here in SoCal, it did, of course, rain this past weekend when I needed to be outside to change the fuel pump. Good thing that it was relatively dry on the creeper under the Banana! Haha.

The OEM Bosh fuel pump in-situ:


Since the OEM Bosch pump is no longer available I searched the interweb a couple of weeks back and found a suitable substitute in terms of pressure and flow rate to support the D-Jet EFI system. I went to the Rockauto website and looked up their recommended replacement pump, a Delphi p/n FD0011 at $104 plus shipping. Review of the Info tool on the Rockauto website showed the Delphi pump to be rated at 58PSI and 32GPM. I did a bit of searching and came up with a less expensive option with nearly identical specifications. I chose a Powerco p/n E8445 rated at 45 - 65PSI and 35GPM for a much more reasonable $64.92 delivered. It came with appropriate 5/16" diameter barb fittings, screw lug crimp-on electrical connectors and a pair of mounting clamps. I tossed the spring hose clamps.

I had to fab a mounting plate to interface the new pump to the Volvo's pair of vibration isolator mounts as well as source a 1/2" - 5/16" barb hose adapter (not shown in the bench top pic) to neck down the fuel tank feed hose to the new pump's 5/16" inlet as well. I also replaced the factory fuel pump connector with a 2-pin Delphi Weather Pack connector on both the pump and the Volvo's chassis harness, taking care to install the sockets on the powered chassis side harness and pins on the pump side of the connection. While I wanted to route the cable above the hoses (It's always best practice to route wiring above fluids, specially flammable ones) there just wasn't room to make that a reality in the tight confines of the factory pump location.

Here's the new rig on the bench prior to installation:


The extra hose tie wrapped to the fuel feed hose is to isolate the U-bend from the edge flange of the fuel tank which is in ver close proximity as well as to provide a bit of anti-kink protection on the relatively tight radius of the required hose loop.

And here is the new pump installed prior to re-fitting the factory splash guard plate underneath:


I have road tested the installation for the past 3 days to the tune of about 130 miles and all is working properly --- I hope that this substitute pump turns out to be a winner in terms of reliability.

Tomorrow afternoon I'm gonna knock off work mid-day to get ready for an early Friday morning start on our back country drive up the coast. We plan to spend a couple of nights in Cambria, a night in Solvang and then home to San Diego. We're targeting several great roads on the drive including, but not limited to, Cerro Noroeste Road, Prefumo Canyon and See Canyon Roads, Old Creek Road, Santa Rosa Creek Road, Hwy 1, Nacimiento - Fergusson Road, Tepusquet Road, Foxen Canyon Road, etc. The cars on the trip are a '63 Porsche 356, a '73 Pantera, a '69 Alfa Super and the Bad Banana. A nice little Euro-centric international group.

This will be the first time I've been out on a drive since returning from an epic adventure drive down the length of the Baja Peninsula to La Paz, Mexico back at the end of February / beginning of March. We'll be practicing social distancing, wearing masks and each of us solo in our cars, albeit with 2-way radios. We're thinking that traveling solo and carrying food and drink in the cars will be less risky than venturing out to the grocery store. At least we hope that is the case! At any rate we're going and thinking that this will be a great break before the winter holidays. And my first real opportunity to take the Bad Banana on a spirited long distance drive.

Last edited by escondidoron; 11-12-2020 at 01:16 AM..
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Old 11-17-2020, 02:06 PM   #58
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How did it go? I totally would have been down with meeting up. Should check these posts more often!
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Old 11-19-2020, 12:39 AM   #59
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Lots of projects going on here presently. Upon return from our weekend holiday yesterday I had a free evening and reassembled my Ford T-9 transmission that goes into one of our other cars with significant assistance from Lucy. Given that some have used this gearbox on early Volvos I thought that there might be some interest here in this project so I made a brief video summary of the reassembly highlights:






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How did it go? I totally would have been down with meeting up. Should check these posts more often!
I'm sorry that we missed you. Maybe we can meet up next time. As for how the trip went, I think that this video will give you a better feel for Day 1 over my feeble attempts to convey the experience through words:


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Old 11-20-2020, 05:48 PM   #60
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Ah very nice. All my stomping grounds! (Born and raised in SLO, lived in this county my whole life). Thanks for the insight on the T9, have always been curious about those.
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Old 01-29-2021, 07:41 PM   #61
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Sorry for the corniest comment ever, but here goes... THANKS for the awesome pics! My 145 has been in boxes forever, and your pics are so incredibly clear that I've used them to help re-situate so many little things like engine bay hose and line clamps, wire routing, and all those random bits that fall out of the clearly marked ziplocs over the years and accumulate in the bottoms of random boxes.

Seriously, thanks, because it seems like all the pics I took during disassembly are blurry, glared, or cropped in just such a way that I can't see what I need to see to get mine off jackstands, back together, and out of the garage.
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Old 01-29-2021, 10:54 PM   #62
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Seriously, thanks, because it seems like all the pics I took during disassembly are blurry, glared, or cropped in just such a way that I can't see what I need to see to get mine off jackstands, back together, and out of the garage.
Thank you for the kind words. I am happy that I have been of some help to you.

If you ever need any additional pics for your project feel free to let me know. I would be happy to help.
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Old 03-18-2021, 12:09 AM   #63
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I was very much saddened to see this news this morning. I was aware that Sabine was fighting cancer but was optimistic that she would pull through. Sadly that is not the case.

Sabine Schmitz Dies at age 51.

Two memories stand out for me beyond her BMW 'Ring Taxi driving, DMAX and Top Gear TV presenter roles, and 24Hrs of the 'Ring victories;

1) Transit Van at the 'Ring


2) I was lucky enough to meet her on one of my visits to the 'Ring. While wandering thru the paddock, er, parking lot, at the 'Ring, she saw me and walked up to me to look at my T-shirt. Upon inspection she introduced herself, as if I didn't know who she was, and asked me in jest if I didn't think that she should get a royalty. She then produced a Sharpie and autographed my shirt! A truly delightful moment.
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