• RWD
  • Resurrection of a 1961 Amazon 4 door

Hi All,

Ive had a few questions from the Volvo community so thought I'd better put up some progress!

This is the Amazon I'm rebuilding

Purchased of @Spac many moons ago with plans to harvest for parts such as an a long since looted M41 transmission, it's spent the last decade under a carport laying dormant - housing what appears to be a village of mice - waiting for its next purpose.

A thorough assessment of condition has called for some (relatively minor) rust repairs

Front and rear suspension rebuild including replacing the differential

Replacing the engine and transmission

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Bare metal respray and wiring work

Also brakes and interior...most of the car really!

carnut222

I know it goes without saying, but I love your work! :)

LOL I was thinking this was your dad’s post...but I’m sure your work is as awesome as his. :)

    carnut222

    https://ozvolvo.org/discussion/comment/192959#Comment_192959

    LOL I was thinking this was your dad’s post...but I’m sure your work is as awesome as his. :)

    Hahaha I do my best, so much to learn!

    Lucky to have an excellent mentor and get-out-of-jail free card with dad.

    This week's progress!

    Rear suspension installed

    Engine bay cleaned up and primed (now ready for colour once the paint is ready) and cross member installed

    Front suspension prepped and ready for install

    Head gasket replaced in old faithful restoring the air pumping goodness

    7 days later

    This week's progress!

    Front suspension installed (except for sway bar, need to extract snapped bolt)

    Discovered some floor rust. Removed factory black paper stuff, treated rust and sealed. Removed loads of old wiring that was in place for the no longer in use driving lights.

    Serviced a good pair of front calipers out of the Volvo spares archive. Gave @AshDVS some old brake and clutch flexible lines for samples to make up some fresh braided lines. Need to get some fresh rotors and rear brake pistons!

    Starting stripping panels in preparation for prime, smoothing out, and colour!

    11 days later

    This week's progress!

    Early style rims returned from sandblaster and primed ready for colour

    Custom HEL brake lines from @AshDVS

    Passenger side sill has some new metal and is in primer ready for further smoothing

    Engine bay has some colour

    Mike the vacuum has been putting in the hard yards keeping the dust down.

    Replacement windscreen has been sourced (maybe) - these appear to be much harder to buy than I expected!

    That pic of the tunnel with the 140 behind it is doing my head in LOL!

    My classic windscreen guy had no issues getting my screen 6 years ago. I hope they still are available.

      Vee_Que

      My classic windscreen guy had no issues getting my screen 6 years ago. I hope they still are available.

      I called a bunch of windscreen fitters including the place that has looked after me with 940s and my 145 to no avail as well as my local Volvo dealer and special vehicle divisions of O'Brien glass, all whom told me unavailable or I would have to purchase overseas or have custom glass made.

      After some eyewatering freight estimates kindly generated by the usual international Volvo parts suppliers and some more phone calls, I was thankfully put onto a windscreen wholesale mob in Queensland who had screens on the shelf for a very reasonable price and ordered some.

      Once I receive the screen I'll be able to report on quality and publish the part number for those chasing replacement screens themselves ?

      I was going to suggest Autoglasswarehouse.com.au but I don’t see the Amazon windscreen listed. I’ve bought a few 240 windscreens through them (picked up in Derrimut IIRC).

        carnut222

        I was going to suggest Autoglasswarehouse.com.au but I don’t see the Amazon windscreen listed. I’ve bought a few 240 windscreens through them (picked up in Derrimut IIRC).

        They were the winner! I was recommended to contact them, turns out they have a lot of stock yet to be listed online.

        9 days later

        Some more progress!

        Wheels painted and tyres installed

        Steering installed

        Dash painted

        Engine installed - note the world's prettiest fuel pump

        I'm having a play with using a 240 80A alternator with internal reg in place of the tiny external reg alternator I got the car with.

        Also discovered my plan to use a big 140 clutched fan wont be possible due to radiator clearance, so will install a 4 blade un-clutched fan and will investigate electric fan or some sort of custom fan shroud down the track if temperature gauge kicks up a fuss.

        I went straight to an electric fan mounted in front of an original copper radiator. Controlled by a Davies Craig electronic fan controller. Never have temp issues.

        I remember the excitement at this point of my 122 build. It's pretty awesome.

        6 days later

        I'll keep that fan setup in mind @Vee_Que - Thanks!

        Unfortunately the Derrimut windscreen depot has been declared a covid exposure site so my best laid windscreen procurement plans have been delayed. Best wishes to the workers there.

        The latest progress:

        Sills and door jams have been mended, smoothed out, primed, and painted

        Made up battery leads, got windscreen washer motor spinning again, installed replacement fuse box assembly and started roughing in where I want the engine bay wiring to go including replacing much of the charge circuit.

        Installed driveshaft and foam around gearstick hole

        It turns out throughout the Amazon production there were a variety of M40 gearbox output flange lengths. The gearbox I had originally prepared was too long for my selected driveshaft. Some careful measuring uncovered another M40 that was about 10mm shorter allowing the other pieces to slot into place.

        The car is now mobile under starter power!

        a month later

        @Essbos, I have been enjoying seeing the progression you are making on this. Makes me a bit embarrassed how little I have achieved over a lot longer period with mine.

        I was wondering if you prepped and painted the suspension components and if so, what you used on them?

        Thanks

          AdrianH

          @Essbos, I have been enjoying seeing the progression you are making on this. Makes me a bit embarrassed how little I have achieved over a lot longer period with mine.

          I was wondering if you prepped and painted the suspension components and if so, what you used on them?

          Thanks

          I've really enjoyed sharing it @AdrianH !

          I have also enjoyed the benefit of a well equipped working space and lots of help.

          For painting a preparation of suspension components: I firstly cleaned everything with parts cleaner, then had a local sandblaster remove any other paint & detritus, then applied POR15 sealant/paint. In hindsight I probably rushed the application of POR15 and the finish is probably not as polished as I ideally would have liked, however they will be well protected from rust and abrasion and that was the primary goal.

          For the crossmember after applying POR15, I let the paint set until touch dry then sprayed a light coating of primer. Left for about a week then applied even coat of primer than finished with machinery grey.

          Thanks for the response, will look into the POR15 product.

          I will need to clear a bit of room in my shed and get into the work on mine.