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1963 Volvo 544
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of work done
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06/05/07: Rust at the bottom of the door |
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Replacing rusted bottom door flange |
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Door being chemically stripped |
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Door stripped-like factory new-no abrassives used |
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Rusted strip removed from door bottom. Shows new flange welded on |
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Door bottom blasted and weld thru primed. Ready for new door skin bottom |
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New door bottom tacked on |
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6/06/07: Front crossmember still complete-in process of disassembly |
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Differential removed and being cleaned for painting |
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6/11/07: Hans and Brad priming parts |
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Suspension parts blasted and started priming |
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6/18/07: AIR BORN! At last, on the way to have the main body painted |
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The car will stay on the rotisserie until final painting. Chassis parts can be reinstalled after painting |
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6/20/07: Front suspension parts out and broken down for processing |
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Front brake parts off and ready |
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6/21/07: Front brake parts |
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Parts processed for front suspension |
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6/26/07: Front king pins cleaned and ready for paint-these parts are painstakingly cleaned since there are working parts, no abrasives can be used |
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Rear support rods sand blasted, ready for primer and paint |
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7/19/07: Firewall primed, filled, sanded and ready for paint |
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Frame: driver side ready for paint |
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Under trunk where trunk floor was installed |
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Firewall and front frame in self-etch primer |
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Frame and firewall in self-etch |
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Front frame in primer-paint started |
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Trunk interior being prepped |
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Interior around rear window getting body work |
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7/25/07: Under floors being painted. Holes taped so overspray from painting inside floors wont impact under floor finish |
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Firewall painted interior in process |
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All inside and under parts done, on its way back to have mechanicals installed before exterior painting |
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7/23/07: suspension parts finished and ready for reinstall |
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7/25/07: Engine cross member with suspension assembled, ready for reinstall into body |
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View of brake backing plate |
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View of front cross member and suspension |
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7/26/07: Hans, Denis and the car |
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View of interior from trunk |
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Cross member done and ready to be installed |
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View of crossmember reinstalled on frame |
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7/30/07: Front brakes done...and a thing of beauty! |
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Remaining parts in self etching primer, ready for black paint |
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8/01/07: Sand blasting rear end |
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8/06/07: Rear end assembly and support arms reconditioned and ready for reinstallation |
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8/07/07: Rear brake assembly rebuilt-to better than new! I've seen a lot of good restoration work, but this is as good as it gets |
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Rear end and brakes back together |
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Brake and clutch assemblies back in place. All new bushings, sleeve, zirc fittings...EVERYTHING! |
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Running the stainless stell brakeline around the cross member |
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Doing all of the work on the rotisserie-the only way to go! |
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8/08/07: Brake master cylinder showing the stainless steel brake lines going in |
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Front end done-all brakes and suspension completed. Red paint has a protective coat on which washes off at the end of the job! |
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8/20/07: Heater air distributors box as found-these parts were painted only minimally at the factory-who wants to breath air passing through rusty |
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duct work?! |
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8/21/07: Transmission mount renovated including new transmission mount-see the beautiful stainless steel fuel line?! |
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Emergency brake handle-wow, we found the correct original pale blue/grey color! |
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Emergency brake pivot assembly-now BETTER than new! |
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Refurbished cabin air control box-fresh air at last! |
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Cabin air control box-here is that fabulous 544 under dash pale blue/grey |
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Heater box casing-like new and ready for installation |
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10/04/07: Wheels, trued and reconditioned (sand blasted and painted)-better than new now!! |
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