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Old 12-27-2017, 10:26 AM   #76
dbarton
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Update time.

As I mentioned previously I decided to cut the vertical slots deeper. After cutting, I could see some jaggedness in the bottoms of the slots. I didn't know if it would show after painting, but either way, I didn't like it. So I mixed up a small portion of epoxy and carefully laid it along the bottom of each slot. It self-leveled and filled the jagged areas really well.

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'84 242ti, fourth owner, mine since 2003. Always garaged since brand new. Old-school rounds because I like. B21FT, SDS EFI/IGN, TD04HL-15G, T5Z trans with modded 0.73 OD, 3.91 diff, unmodified G80.
Volvo Ambivalence of Volvo Enthusiast Community: prancingmoose.com/#novolvo
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Old 12-27-2017, 10:28 AM   #77
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Thank you to Redwood Chair for sending me a sample piece of the 3M 1000 grit gold sanding pad.

As I mentioned, I was not happy with the paint finish from SEM trim black. It was not flat enough for the face plate and not really smooth enough either since it tended to lay down thicker that other flat paints. So I sanded it smooth again.

I picked up a small can of Testors Flat Black aerosol and sprayed a extra piece of PVC below as a test. A few thin coats. It makes for a very smooth, very flat finish. Then I very lightly polished an area you can see in the pic. It began to pick up a slight shine that I compared to an original Volvo dash piece. The match was very good.

So I sprayed the face plate and did the same treatment. The pic doesn't do it justice. It turned out nice.

Dave
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File Type: jpg repropod40.jpg (119.8 KB, 338 views)
File Type: jpg repropod41.jpg (126.9 KB, 337 views)

Last edited by dbarton; 01-06-2019 at 02:23 PM..
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Old 12-27-2017, 11:28 AM   #78
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That finish is very impressive and the slots looks good!
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Old 12-29-2017, 10:17 AM   #79
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Thank you.

UPDATE TIME:

I've been working on the mounting points inside the pod to hold the gauge plates. Using PVC primer and PVC glue when gluing PVC to PVC. Using Gorilla clear 2-part epoxy for plastics when gluing PVC to the ABS pod cover.

Dave
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Attached Images
File Type: jpg repropod42.jpg (124.6 KB, 300 views)
File Type: jpg repropod43.jpg (162.8 KB, 299 views)
File Type: jpg repropod44.jpg (94.6 KB, 299 views)
File Type: jpg repropod45.jpg (112.3 KB, 297 views)
File Type: jpg repropod46.jpg (198.5 KB, 301 views)

Last edited by dbarton; 01-06-2019 at 02:26 PM..
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Old 12-29-2017, 10:20 AM   #80
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This completes the pod except for the mounting of it to the dash. I have an old (cracked) dash I pulled out for the next steps. It will be a lot easier to figure out the mounting this way.

Also I see that I have some finish work to close up some gaps between the pod and dash.

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Old 12-29-2017, 10:32 AM   #81
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Looking good! That $300 pod that was in FS is looking more and more like a bargain.
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Old 07-29-2018, 06:55 PM   #82
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@dbarton, if/when you ever finish this amazing project, would you consider 3D printing repops?
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Old 07-29-2018, 10:00 PM   #83
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Quote:
Originally Posted by 855 T-5R View Post
@dbarton, if/when you ever finish this amazing project, would you consider 3D printing repops?
Eventually. Had a lot of other little projects plus my garage is an oven in the summer.
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Old 07-29-2018, 10:30 PM   #84
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Box fan????
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Old 08-09-2018, 02:01 AM   #85
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Dave, not trying to hijack the thread but slightly off topic inquiry (so @mods pls feel free to delete if necessary) to see if anyone ever reached out to the volvo240.be folks in Belgium who seemed to be planning on repopping these on their site here.

Quote:
We ar now offering this Volvo accessory as a remake.

so NEW but remake, I'll need orders like 4 -6 pieces then remaking them.

For the 200

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Old 08-09-2018, 02:08 AM   #86
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Dave that's looking great

$19.99 shipped?
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Old 12-10-2018, 01:25 AM   #87
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Looks great, I want one! 3D print reproductions would be the way to go.
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Old 01-06-2019, 12:54 PM   #88
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Quote:
Originally Posted by 855 T-5R View Post
Dave, not trying to hijack the thread but slightly off topic inquiry (so @mods pls feel free to delete if necessary) to see if anyone ever reached out to the volvo240.be folks in Belgium who seemed to be planning on repopping these on their site here.
This and others will likely be out of reach for a TBer's budget. Anyone here can do what I've done for a lot less and get nice results. If you have the money to burn, by all means, buy a repro.

And speaking of results, I'm finally done with mine. Anyone still wanna see pics?
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Old 01-06-2019, 01:00 PM   #89
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Since my last update, I began making the mounting plate for the speaker grill location. This is the same 1/4 inch gray PVC that I mentioned before. Got from McMaster Carr.

It cuts easy with a fine blade sawzall and can be shaped with a bench grinder or belt sander.
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Old 01-06-2019, 01:05 PM   #90
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My first idea for the mounting screws involved threaded rivet nuts below, but I changed my mind later, since the back two, how they stuck up like that, interfered with the main cowl piece laying flat on the plate.
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File Type: jpg repropod49.jpg (91.1 KB, 121 views)
File Type: jpg repropod50.jpg (87.7 KB, 120 views)
File Type: jpg repropod51.jpg (109.1 KB, 122 views)
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Old 01-06-2019, 01:10 PM   #91
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Then I decided to simply press in some M6 flange nuts into the holes I had. Those holes are about 3/8 inch.
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File Type: jpg repropod53.jpg (125.7 KB, 125 views)
File Type: jpg repropod54.jpg (78.7 KB, 123 views)
File Type: jpg repropod55.jpg (108.9 KB, 122 views)
File Type: jpg repropod57.jpg (81.8 KB, 122 views)
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Old 01-06-2019, 01:15 PM   #92
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Mounting plate progress . . .
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Old 01-06-2019, 01:18 PM   #93
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Made some brackets from 1/4 inch PVC and epoxied them to the cowl.
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File Type: jpg repropod61.jpg (174.7 KB, 121 views)
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Old 01-06-2019, 01:20 PM   #94
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Then some final assembly. I also slotted the base plate so wires or connectors can pass through.
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File Type: jpg repropod63.jpg (198.1 KB, 119 views)
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Old 01-06-2019, 01:31 PM   #95
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and done!
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File Type: jpg repropod65.jpg (136.6 KB, 121 views)
File Type: jpg repropod66.jpg (124.9 KB, 123 views)
File Type: jpg repropod67.jpg (125.1 KB, 120 views)
File Type: jpg repropod68.jpg (182.2 KB, 123 views)
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Old 01-06-2019, 01:45 PM   #96
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Yet again, how much for me to ship my to you and this be done?
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Old 01-06-2019, 02:37 PM   #97
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Quote:
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Yet again, how much for me to ship my to you and this be done?
If I had all that extra time on my hands, I would think about it. I can't count the number of tongue lashings from the better half after bringing in plastic grindings on my shoes and clothes. So it's a no for now.

But my point in putting so much detail into this thread is for those of you to start on one of these yourself. If there are any questions or missing details, photos or measurements that need to be added, I'll add em. I have some other projects to get out of the way, but I'll post more pics after I add gauges and mount this in my 242. I guess I'll mount my radio in the upper spot when I do that.
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Old 03-29-2019, 08:23 AM   #98
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Completed and mounted in my 242:
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Old 03-29-2019, 09:42 AM   #99
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The problem with most flat black paint is it goes chaulky over time. Matte black bicycles are painted with gloss paint and matte clearcoat. Ihave used this on many projects with good results.
https://www.krylon.ca/products/matte-finish/
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Old 03-29-2019, 11:14 AM   #100
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Quote:
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The problem with most flat black paint is it goes chaulky over time. Matte black bicycles are painted with gloss paint and matte clearcoat. Ihave used this on many projects with good results.
https://www.krylon.ca/products/matte-finish/
Nice tip. I'll try that sometime.
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