New guy – 1962 Volvo PV544 mild custom
- This topic has 43 replies, 13 voices, and was last updated 1 month ago by Russ McLean.
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April 14, 2022 at 16:58 #73265Mild MitchParticipant
Wow, glad you’re back home. Cars, ain’t they fun?
April 19, 2022 at 18:00 #73272DavidParticipantWell Russ, the upside is it could be worse….you could play golf and be throwing clubs into the water out of frustration. At least the car is too heavy to throw into the pond. LOL Always something, isn’t it? Thank the Lord for AAA and the ride home….I’ve done that more than once, too. Glad it’s back home and ready for more “fun” projects ahead so it can fight another day. š
April 20, 2022 at 02:40 #73273Russ McLeanParticipantThanks for everyone’s kind words.
The following is somewhat out of the scope of customizing – But, is not the goal to drive our customs?
I finally got the drive train removed at 9:15 PM on Sunday night.Ā Clearance is tight around the bellhousing (measured 5/32 on an inch at the tightest spot) and the transmission.
I wasted several days attempting to configure a VW TDI engine swap.Ā Concluded that there is too much fabrication for a 77 year old to complete in a reasonable (“This is grandpa’s Volvo – He never could get it reassembled”).
I am currently chasing 5 speed overdrive transmission options(75 MPH at 4,000 RPM gets very tiring after about 3 states – Also not good for fuel consumption or engine life).Ā Fabrication mostly limited to the transmission tunnel – I “think” I can manage learn those skills.Ā The adapters can be purchased and the driveshaft modifications can be sent to a nearby driveshaft shop.
Russ
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
June 12, 2022 at 07:41 #73488John in PrescottParticipantRuss,
That Volvo project is very inspiring. I like what you did with the frenched headlights and tail lights.
I too have a 544 that I intend to make a mild custom. So far not much has been done; as you say life gets in the way.
Instead of the nerf bars Iām going to use some three ribbed bumpers, similar to the Briz bumpers, though at a lesser cost. Here is a picture of the one on the rear. It started out as an aftermarket ābillet aluminumā part intended for VW bugs. I used a hydraulic press to form the correct curve to match the body contour.Ā (More involved than that, of course.)
You have inspired me to get back to work.
John in Prescott, AZ
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You must be logged in to view attached files.June 12, 2022 at 18:24 #73490Russ McLeanParticipantJohn,
I love the look of the 3 rib bumper.Ā It is more of a custom look.Ā I considered the Briz bumpers – money was tight that month…Ā I used a Speedway nerf bar kit, which is more of a 1940’s – 1950’s hot rod look.
The frenching and fender skirts was done Ed Smoot of Smooth Engineering in Phoenix, AZ.Ā I simply did not have the skills and (at my age) did not have enough time left to develop those skills.
The engine in the picture is on an engine stand being disassembled.Ā So far, I’ve found a badly warped exhaust valve – which explains the 15 PSI compression reading.Ā Today, I need to plastigage the main and rod bearings, then pull the pistons to look for broken rings.Ā All work that I have never done before.
A rebuilt European T9 transmission (Ford Sierra) has arrived.Ā The snout is out for machining (the outer diameter needs to be slightly reduced to fit the Volvo throw out bearing).Ā The adapter and modified bellhousing are on order.
Russ
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
June 12, 2022 at 21:16 #73491John in PrescottParticipantRuss,
Where are you getting the transmission parts? I have heard that somebody makes the bell housing, adapter, etc but also that the individual was unreliable. What are you going to use for the clutch and linkage? This sounds like a good idea. Apparently if you want to put ANY different trans in you have to do some cutting up of the tunnel.
My plan is different. My Volvo originally had a B16 motor and has a 4.56 rear end ratio. Apparently the Ford Ranger rear end will fit in the 544 if you cut a couple of inches (I forgot the exact number) off one side.Ā As built it has one long and one short axle.Ā I went to the Pick-a-part and found a 3.73 positraction rear in a Ranger.Ā Of course it had to be the only east coast rusted out vehicle in the yard. All the others were desert vehicles and easy to take apart. Had to cut the u bolts with a battery Dremel tool. I stole the short side axle from another Ranger and substituted it for the long one.
Now it’s just a matter of narrowing the rear end, making appropriate brackets and figuring out some kind of adapter u-joint.
Calculations show the RPM at 70 MPH with the 4.56 is 4473, and with the 3.73 is 3659.Ā Don’t know if this is more or less work and money than changing the transmission however.
John in Prescott, AZ
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You must be logged in to view attached files.June 13, 2022 at 06:09 #73494Russ McLeanParticipantQuantum Mechanics, in Qxford, CT, imports and rebuilds the T9 transmissions.Ā I’ve heard the same stories on the adapter/bellhousing seller – I have my fingers crossed…
In 1962, the PV544 went to the B18 (1.8 Liter) engine and a 4:11 rear axle ratio.
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
July 16, 2022 at 09:10 #73578steven twitchellParticipantcool car. my Dad bought a brand new 55 Volvo and then traded it in for a 56 A year later because the 56 had a four speed. after in building a number of customs back in the 40s in the early 50s he didnāt do any more that I know of after the 52 Ford station wagon that was on the cover of October 1954 Rod and custom. some of his work is on this website under Al Twitchell.
kingman az by us66ā¦ mrspeedyt
July 19, 2022 at 06:12 #73585Russ McLeanParticipantSteve,
I checked out the pictures – Your dad had the 1952 Ford station wagon and a Volvo at the same time.
The image of my friend’s dad taking a PV544 uphill curve on the Mohawk Trail (RT 2, western MA) is forever burned in my mind.Ā He was well over the speed limit and leaned into the corner (just like theĀ pictures in the sports car magazines).Ā 5 years later, my first car was a PV544.
Progress update:Ā S-l-o-w…Ā 3 out of 4 exhaust valves were recessed into the head (several thousand miles at 4,000 RPM is the probable cause).Ā I bought stainless steel (“racing”) exhaust valves and the head is at a machine shop to get hardened valve seat inserts and a rebuild.
Surprisingly, there was minor wear on the bearings and cylinder bores look good (I need to inspect them closer).Ā No problems spotted with the rings – again, need to inspect closer.
I am debating just honing the cylinder bores, polishing the crank, installing new bearings, and throwing the short block together (with a new gaskets and oil pump).Ā I’ve never done this before – figure that age 77 is a good time to learn.Ā Just bought a (cheap Harbor Freight) set of micrometers.Ā I “might” have to read the service manual first <wink>.
Russ
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
January 22, 2023 at 21:10 #74331Russ McLeanParticipantThe project is slowly moving forward (Stumbling forward).
Hold my diet Pepsi…Ā The engine and transmission fought us for a while.Ā The engine hoist was hitting the roof truss and the oil pan would not clear the front panel.Ā Some juggling of jack stand heights was required…
The 5 speed T9 transmission (Ford Sierra) is longer than the stock M40 Volvo transmission.Ā Then add 1 inch for the adapter.Ā It is also wider.Ā Some surgery on the transmission tunnel and floor pans was required.Ā I finally got the engine (a mock-up engine, the “good” engine is out for a rebuild) and transmission in the approximate location.Ā The engine is properly located on the motor mounts.
The next task is to do a mock-up install of the water pump, engine fan and radiator.Ā Then jack up the transmission to make the engine fan parallel with the radiator.Ā At that point, I can build a cross member for the transmission mount.
The shop has a couple of electric heaters that can be turned on – it will slowly warm up to the mid 50’s F degrees.Ā I live on the Mexican border of Arizona.Ā The altitude is almost 4,800 feet and the near by mountains are over twice that high.Ā It gets cold here at night.Ā Some times my 78 year old body says “maƱana” (Local definition: “Not effin today”)
Russ
- This reply was modified 1 year, 2 months ago by Russ McLean.
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
January 22, 2023 at 23:36 #74333John in PrescottParticipantRuss,
Looks like you are on your way again. How are you going to actuate the clutch, hydraulic? Where did you get the adapters from?
You have inspired me to get to work again on my Volvo 544.
John in Prescott
January 23, 2023 at 20:41 #74340Russ McLeanParticipantJohn,
Adapters are from Vintage Performance Developments in Syracuse, NY
http://www.v-performance.com/products/transmission.html
The T9 pilot shaft is approximately 0.36 inch shorter.Ā I will need to order the optional 0.625 inch thick pilot bearing.Ā As mentioned in the above link:Ā “In order to use the Volvo release bearing, the transmission input shaft sleeve is slightly reduced in diameter by turning on a lathe.”
I bought the optional modified bellhousing.Ā The clutch fork comes out in the stock location, so the stock clutch release linkage “should” work.
Modifying the linkage “scares”me a little.Ā I installed a Wilwood remote filled brake master cylinder (2 circuit) that uses the stock brake actuator rod.
There is not much space left for a clutch master cylinder.
The PV544 drive shaft tunnel is too narrow for the 5 speed overdrive transmission.Ā Surgery is required – the tricky parts are minimizing the cuts and adding strength back into the floor pan.
More work is required to fabricate a transmission mount.Ā Today is a āmaƱanaā day.Ā The predicted high is 38 Degrees F, the 2 electric heaters in the shop won’t do the job.Ā Tomorrow looks like 51 Degrees F.
Russ
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
February 24, 2024 at 04:06 #75251steven twitchellParticipant1955 my dad bought a brand new Volvo sedan. traded in Ā his customized 1952 Ford ranch wagon.Ā then bought a new 56 Volvo that had the 4 speed transmission. That didnāt last long either. a new 1957 fiat 600 multipla followed. dad was thinking weird back in those days. Ā butt the fiat lasted longer than the Volvos. In 1961 he bought a used english thames window van. Ā 1963 he bought a used Corvair Greenbrier window van 4speed. 1964 he got a company car. a four door chevelle sedan 283 powerglide. he did buy Mom a 1951 Chevy 4dsd with powerglide.
- This reply was modified 1 month ago by steven twitchell. Reason: Just noticed just noticed i posted a couple years ago about the volvos he bought new. i guess my brain is fried
- This reply was modified 1 month ago by steven twitchell.
kingman az by us66ā¦ mrspeedyt
February 24, 2024 at 18:30 #75254Russ McLeanParticipant13 months later, an update.Ā Lots of “Life had other plans” has occurred.Ā I eventually got the Volvo B20 engine back from the machine shop.Ā More “Life had other plans” occurred, so the engine sat on the shop floor for a few months – long enough that I forgot a critical re-assembly step – replace a damaged plug on a oil gallery.
Installation and cam break-in had a few problems – It took me a couple of times to get the rocker cover gaskets right (oil leak).Ā First test drive (about 25 miles) went well, the overdrive operation was very smooth – EXCEPT – it used about 3 quarts of oil…Ā Eventually, I remembered that I forgot to replace the oil galley plug (sometimes this 79 year old misses a “few” details…).Ā The plug is behind the flywheel, the engine and transmission have to be removed.Ā I am currently in another “Life had other plans” moment – maybe next month…
Russ
1962 Volvo PV544 mild custom. A 55 year old dream come true - with much help from Smooth Engineering in Phoenix, AZ (Many thanks to Ed Smoot).
Still trying to navigate this site.I am the frequently deleted TrailerTrashToo on the HAMB, a little nervous if I am "on-topic" here.
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