Skip to main content

Boot (Trunk) Excavation

As I suspect you are aware, issues with rot in the boot (trunk) of the Volvo 120 series are common and my Amazon is no exception. Over the years it has been 'repaired' a number of times and not always sympathetically.



I have made a start removing the filler and the patchwork of metal plates that make up the n/s and the floor next to the spare wheel well.  I've ground off some of the welds, chiselled and bent back the non-original metal. 




As I have already reported the lower rear quarter replacement panels are definitely not correctly positioned but I have successfully managed to uncover the original boot floor which although is in a very poor condition, does give me some points of reference for the rebuild.

Incidentally, a word of warning. I had to remove a lot of seam sealer and I really should have been wearing gloves. A slip with the scraper brought the session to a rapid conclusion. I was lucky not to end up in A&E.


Now that I have investigated more thoroughly, my repair panel budget might have to be revised. I was hoping to salvage the rear quarter sections as they are sound (i.e. not rusty), but I am not sure that I an going to be able to get them off intact and it also looks as if they are slightly misshapen towards the rear. New ones are available in two qualities, one being described as 'cheap repo', the other version suggested to be of better quality and fit, but at nearly twice the price. I'll reserve judgement until I've attempted to remove them.



Lower rear wing repair sections are a necessity though and now that I have also had a closer look repairing the existing spare wheel well is probably be more trouble than its worth. So I've added these to the shopping list, along with a bumper mount. 



There are issues with both rear panels. The inner has rusted on the bottom edge and although a replacement is available at around £100, I am on a budget here. It may be feasible to repair it. The outer panel has rusted through at a number of points along the bottom edge but this is more challenging to fabricate. A new panel comes in at around £200 and at this stage I still have reservations about removing it.  

I have totted up the cost of all these repair sections and the grand total is a shade over £600! More than I was hoping to spend, but I don't anticipate requiring any others for the rest of the vehicle. Realistically, if I can save either of the rear panels that will make a big difference to my budget and bring things in at a much more agreeable price. My plan is to attempt this before ordering any of the repair sections. If I succeed, then great, if not I will just have to bite the bullet and stomp up the extra cash.

 

With this is mind I have removed the inner panel using a Clarke spot weld drill kit, which worked a treat. I found with this tool I was able to separate the panels with little or no distortion. Maybe I'll do a demo/review at some point.


Looking at the outer panel from the inside, now that the inner piece is removed, I think that I am going to have to seriously consider replacing it.

Of course the real challenge is the boot floor itself. This I will have to fabricate as there are no replacement pressings available. I need to consider how I'm going to tackle that tricky looking recess that holds the fuel tank...


< previous post               next post >


Comments

Post a Comment

Popular posts from this blog

Volvo P120: O/S Boot (Trunk) Floor Pt. 2

  Picking up from where we left off, I had decided that I needed to create a controlled curve in the panel that I was creating for the front part of the O/S boot floor. I felt I needed a slip roller, or something similar. Researching available tools it soon became apparent that cost was disproportionate, given that it was entirely possible that I would never need this tool again, and so a 'DIY' solution was required. A couple of hours on YouTube and a root through the scarp metal bin... I came up with a plan. I used a couple of scrap bearings salvaged from Mazda Bongo idler pullys, two Ikea desk legs and an old HiFi speaker stand. The bearings fitted perfectly into the ends of the desk legs, great, so I then fitted some bolts and washers through the centre go the bearings as spindles. On the other end of the legs I found a couple more bolts that fitted snuggly into the plastic feet. Obviously not a robust solution, but I figured strong enough to last the short time required. I ...
Post a Comment
Read more

So What's the Big Idea?

Progress has been slow of late on Project Volvo. There have been a number of contributory factors; work, life, other projects.... However, my lack of posting should not be interpreted as a complete lack of momentum. There have been some developments, with the vehicle and with my thinking. When I started this venture, I never imagined that I would be looking for a show quality restoration, I wanted a usable car. What I was not so sure about was the 'focus' of the build; I have now made the decision to aim for a competition car. Volvo Amazon, Shelsley Walsh Hill Climb - 2017 This idea has been under consideration for quite some time. I have a close friend who competes in hill climbs and sprints in his 1967 4 door Amazon and I have attended numerous events with him. Through this we have become friends with a number of other Volvo owners who compete in the Volvo Owners Club Motorsport Challenge. '67 Amazon, Crystal Palace - 2015 At first I was happy to just string along and doc...
Post a Comment
Read more

Volvo Amazon Speedometer Facia Restoration

Back in May last year I started a process of refurbishing the speedometer unit from my Amazon. The speedometer itself was working fine, it was simply a matter of appearance; just like probably every other Volvo Amazon out there, the grey crackle coating on the facia had deteriorated and was peeling off. Many owners remove the coating completely and simply leave the brass finish, but quite frankly I don't like this look. I took the plunge and experimented with disassembling the binnacle (details in this earlier post ). I can now report that I have finished the task. The first challenge prior to painting the was what to do about the plastic warning lamp lenses (high beam, indicators, oil pressure and charge/amps). I wanted to remove them as I thought they would be difficult to mask effectively.  They are fixed originally by being melted from the back. They also each have a rubber shroud which being 50+ years old and subjected to heat cycles from the lamps, are somewhat discoloured an...
Post a Comment
Read more