Made a bit of progress over the last few days. Rebuilding doors while on your knees isn’t too fun! I should have made up a stand to do the job properly...may do so yet.
I got the driver’s door power window mechanism and power lock motor installed (required for remote lock/unlock that I plan to add). Also removed the chrome bright trim around the frame and installed the black trim from the 93. Swapped over all latch/lock/lock rods hardware from 93 and also installed the extra foam weatherstrip on the window frame, and swapped in the window channel seal and door perimeter seal from the 93. Reinstalled front door...it was a bitch to get it aligned. Probably should have installed rear door first. May need to adjust once I do that. Still debating about whether to install the master power window switch panel with the 4 switches or just install a single switch for the driver’s door...saves wiring.
Got started on the rear door - removed all seals and the chrome upper frame trim. Swapped out all latch/lock/rods and lubed everything. 2 spot welds holding the outer panel have popped where attached to the base of the upper frame, so will need to tack those again or pop rivet if I can do that without interference to the glass run channel seal.
Also did some more work on the dash wiring harness. Pretty much got it routed back in place. I need to figure out how to re-wire the harness for the M46 instead of the automatic OD. I have a manual relay, so I assume it’s pretty straightforward, plus installing the jumper on the park/neutral switch.
Did some digging in my cruise control bits box. Didn’t realise how much stuff I’ve hoarded, including multiple cruise control actuators, throttle spools, stalks, computers, you name it! Guess it’s good to have but when you buy stuff thinking you need it only to find out you already had it, that’s not good! ;) May have to offer some bits up for sale.
Need to run wires through the firewall for the cruise control vacuum motor, plus the vacuum line for the cruise brake/clutch cancellation switches, plus make up mounting bracket and install switches. Also need to run some extra wires for oil pressure gauge and ambient temperature gauge.
Need to make a decision on the radio. I think I’ll either go retro OE Volvo radio, or possibly use an old Sony pull-out radio I had for nostalgic reasons. However, I’m unsure if the US-spec radio will tune to the Aussie frequencies. Seem to recall I had to get a new radio for my ES when I brought it out here as it would only tune to the odd frequencies, or it stepped up in increments of 0.3 Hz???
The workshop is looking like a disaster area with boxes of bits, bits, tools, rags, etc spread everywhere. Is it worthwhile saving the 93 door shells? If not I think I’ll throw them in the 93 body and send it to scrap.
Some pics to follow.
