Recommissioning a barn find Volvo P1800ES
Discussion
This is the second barn find car that's been offered to me this summer. The first was a Mini Cooper which I restored in 10 days. Mechanically that was pretty sound and needed a body restoration and interior. More details on that for those who are interested can be seen here:
https://www.pistonheads.com/gassing/topic.asp?h=0&...
I thought that was me done this summer, but this came along and it was just too good to refuse.
This project is the polar opposite in almost every way. This car is 100% complete and the bodywork and interior (albeit filthy dirty) is in fantastic shape. However mechanically it needs A LOT of work. It's absolutely huge and unlike the Mini, I plan to take my time over this project. I'll use this thread to post updates as they happen.
This car has been sat untouched and locked up in a garage for over 20 years. It was parked up because it had a slight misfire at the time and the previous owner just never got round to do anything to it.
After being told about it I had to go check it out, so this weekend we managed to roll it and inspect it further.
Allow me to introduce you to the Volvo P1800ES. I have never seen one on the metal before, in fact, I never knew these existed until now, but I have totally fallen for it's glorious looks, it's super retro styling and interior, the hefty 50 year old Swedish engineering and the wafty soft suspension that should make for a hilarious driving experience.
Here it is as we found it.
And after we managed to roll it out of the garage.
The back end has echoes of many modern Volvo models and the side profile reminiscent of a few recent estate models also.
And the front end it is classic P1800
So, there are plenty of good points about this car.... It's rare. According to the owners club register there's less than 50 left in the UK, but parts are readily available as it shares the same platform as the Amazon and regular P1800.
The bodywork is in top shape and should clean up very well. Same with the interior. It's all in very good order, totally complete and with a little love should look fantastic.
The car also comes with lots of spares including a new rear boot glass and even a genuine Volvo workshop manual.
However, there's a lot that's not good and largely a consequence of being parked and untouched for 20+ years, so essentially this is a recommissioning project rather than a restoration.
Even though it was parked with the handbrake off, it took 4 of us to crack it free and roll it out. The brakes are seriously pitted and need a complete overhaul.
I got a borescope in the petrol tank and the fuel is jellied and the tank rusted from the inside out, so it's going to need an entirely new fuel system.
As it's an end of run car it has the Bosch D-Jetronic fuel injection system. Whilst that's a good thing, I'm slightly dreading having to diagnose this if it's at fault.
I plan to be methodical and steady about recommissioning the old beast, so the first thing we did was pull the plugs and spray some Marvel Mystery Oil into the cylinders.
Next plan is to give it a proper clean up and then we'll move on to the fuel system, working our way forward to the ignition system and eventually attempting to fire it up. It also last ran on 4 star fuel... Who remembers that?! So it will probably need a cylinder head rebuild with hardened valve seats at some point.
There's plenty to do, but Autumn is fast approaching so I won't be able to do much mechanical work this year, but I'll be sure to update this as I go.
https://www.pistonheads.com/gassing/topic.asp?h=0&...
I thought that was me done this summer, but this came along and it was just too good to refuse.
This project is the polar opposite in almost every way. This car is 100% complete and the bodywork and interior (albeit filthy dirty) is in fantastic shape. However mechanically it needs A LOT of work. It's absolutely huge and unlike the Mini, I plan to take my time over this project. I'll use this thread to post updates as they happen.
This car has been sat untouched and locked up in a garage for over 20 years. It was parked up because it had a slight misfire at the time and the previous owner just never got round to do anything to it.
After being told about it I had to go check it out, so this weekend we managed to roll it and inspect it further.
Allow me to introduce you to the Volvo P1800ES. I have never seen one on the metal before, in fact, I never knew these existed until now, but I have totally fallen for it's glorious looks, it's super retro styling and interior, the hefty 50 year old Swedish engineering and the wafty soft suspension that should make for a hilarious driving experience.
Here it is as we found it.
And after we managed to roll it out of the garage.
The back end has echoes of many modern Volvo models and the side profile reminiscent of a few recent estate models also.
And the front end it is classic P1800
So, there are plenty of good points about this car.... It's rare. According to the owners club register there's less than 50 left in the UK, but parts are readily available as it shares the same platform as the Amazon and regular P1800.
The bodywork is in top shape and should clean up very well. Same with the interior. It's all in very good order, totally complete and with a little love should look fantastic.
The car also comes with lots of spares including a new rear boot glass and even a genuine Volvo workshop manual.
However, there's a lot that's not good and largely a consequence of being parked and untouched for 20+ years, so essentially this is a recommissioning project rather than a restoration.
Even though it was parked with the handbrake off, it took 4 of us to crack it free and roll it out. The brakes are seriously pitted and need a complete overhaul.
I got a borescope in the petrol tank and the fuel is jellied and the tank rusted from the inside out, so it's going to need an entirely new fuel system.
As it's an end of run car it has the Bosch D-Jetronic fuel injection system. Whilst that's a good thing, I'm slightly dreading having to diagnose this if it's at fault.
I plan to be methodical and steady about recommissioning the old beast, so the first thing we did was pull the plugs and spray some Marvel Mystery Oil into the cylinders.
Next plan is to give it a proper clean up and then we'll move on to the fuel system, working our way forward to the ignition system and eventually attempting to fire it up. It also last ran on 4 star fuel... Who remembers that?! So it will probably need a cylinder head rebuild with hardened valve seats at some point.
There's plenty to do, but Autumn is fast approaching so I won't be able to do much mechanical work this year, but I'll be sure to update this as I go.
Thanks for the kind comments. From looking at others for sale, these seem to be a bit of an undiscovered secret in the classic car world and a good one doesn't cost too much. I'm not in this for the money, just for the fun of reviving an old abandoned car.
My thoughts when I first saw it was that it's ripe for an engine swap with something juicy, but I think I should try and get it running as it is.
The other good thing is it's MOT and tax exempt!
My thoughts when I first saw it was that it's ripe for an engine swap with something juicy, but I think I should try and get it running as it is.
The other good thing is it's MOT and tax exempt!
Challo said:
Looks a fantastic find, and good luck with the project.
What is the interior like? Any pictures for retro goodness?
I didn't actually get any shots of the interior after getting the car out, but I took this shot whilst it was still in the garage. Excuse the nasty steering wheel cover, that will get cut off soon to reveal the preserved bakelite!What is the interior like? Any pictures for retro goodness?
I'll take some interior shots when I'm next with the car. It's complete and I'm hopeful that it should clean up ok. There's a bit of mould on the dash and doors and lots of dust as the windows were left open.
Not much to add to this as we've been too busy to get back to the car.
We are planning to give it a full clean up very soon so I'll post an update on that with plenty of detailed pics when that's done.
In the meantime I managed to get some pics off of the borescope. I'm not quite sure what to make of these, but I think that considering this engine is approaching 50 years old, done 100k miles and hasn't been fired for 25 years; they don't look too bad. The camera amplifies the detail so it looks worse than it is.
A sensible restorer with unlimited time and funds would do a full engine rebuild first, but I think we're just going to send it and go for a start up once we have renewed the fuel and ignition systems!
I'm keen to know what any experts think of these.
We are planning to give it a full clean up very soon so I'll post an update on that with plenty of detailed pics when that's done.
In the meantime I managed to get some pics off of the borescope. I'm not quite sure what to make of these, but I think that considering this engine is approaching 50 years old, done 100k miles and hasn't been fired for 25 years; they don't look too bad. The camera amplifies the detail so it looks worse than it is.
A sensible restorer with unlimited time and funds would do a full engine rebuild first, but I think we're just going to send it and go for a start up once we have renewed the fuel and ignition systems!
I'm keen to know what any experts think of these.
Fastdruid said:
My approach would be to do an oil change first, then I'd stick a healthy squirt of engine oil down the bores. Take the rocker cover off and liberally dose everything up top with oil. inc down the pushrod tubes (if you can).
Then turn over by hand with the rocker cover off and ensure all the valves/rockers/pushrods move freely.
If everything seems to turn over freely then turn it over on the starter until you get decent engine oil pressure. Stick some rags over the holes to ensure you don't spray oil *everywhere*.
Then plugs in, fresh fuel and send it.
EDIT: The worst concern really is sticking rings, either gummed up or just with rust when you turn it over and they scrape the surface rust off the cylinder walls. It will drink oil and have low compression if they are stuck. Then again it may get better over time...or it may not. You can try some of the top-end detergent type things. Basically fill each cylinder with them, leave overnight, empty and then change the oil (as it will typically leak down into the sump).
Thanks for the feedback on the bore photos. I don't think they look too bad either all things considered.Then turn over by hand with the rocker cover off and ensure all the valves/rockers/pushrods move freely.
If everything seems to turn over freely then turn it over on the starter until you get decent engine oil pressure. Stick some rags over the holes to ensure you don't spray oil *everywhere*.
Then plugs in, fresh fuel and send it.
EDIT: The worst concern really is sticking rings, either gummed up or just with rust when you turn it over and they scrape the surface rust off the cylinder walls. It will drink oil and have low compression if they are stuck. Then again it may get better over time...or it may not. You can try some of the top-end detergent type things. Basically fill each cylinder with them, leave overnight, empty and then change the oil (as it will typically leak down into the sump).
Edited by Fastdruid on Monday 28th September 17:42
My plan is pretty much as you say, but I'm going to fit a new fuel tank, fuel pump and filter first. The fuel is nasty and the tank rusting on the inside. I'm also planning a new ignition system before I go for a start including leads, plugs, rotor, cap, points, condensor and coil.
I have already sprayed some marvel mystery oil into the bores which is soaking in as we speak so I may give it a few turns with a spanner on the crank soon. Hopefully i don't crack a ring!
CharlesdeGaulle said:
What a wonderful car, and I'm in for the journey.
You say 'we', and the Mini thread featured your talented pal, so who is doing this with you? You're clearly very handy yourself, but is this a commercial deal or a bunch of blokes pitching-in free?
(Sorry for the nosiness; I love these threads but am a bit of a biff myself and have to pay everyone so the maths/affordability begins to not add up very quickly).
Thanks and fair question. The mini was done with my pal but that’s my car. He just helped on that. You say 'we', and the Mini thread featured your talented pal, so who is doing this with you? You're clearly very handy yourself, but is this a commercial deal or a bunch of blokes pitching-in free?
(Sorry for the nosiness; I love these threads but am a bit of a biff myself and have to pay everyone so the maths/affordability begins to not add up very quickly).
This car is being done with my brother who’s also a petrol head. He’s local and it’s a great excuse to spend time together and escape our respective families! We’ll have joint ownership of this... it will also splits the burden of inevitable incoming costs
e46m3c said:
Looking forward to seeing this progress.
Interestingly there was a car identical to this on a trackday at thruxton yesterday. Volvo are investing in this car for restomods and they were there with ohlin developing the suspension system.
That sounds interesting! Did you get an pics?Interestingly there was a car identical to this on a trackday at thruxton yesterday. Volvo are investing in this car for restomods and they were there with ohlin developing the suspension system.
Polestar have recently built a restomod coupe version with 400bhp.
https://www.carthrottle.com/post/the-volvo-cyan-p1...
Breadvan72 said:
What a delightful fraternal project, OP. I hope that it goes well. I sadly said no to a 1970 Volvo 145 a few months ago, because it had too much rust underneath, but I was very impressed by the engineering and build quality on that car. Hopefully that quality will shine through on the P1800 as you proceed with the recommissioning
Thanks! We're looking forward to getting stuck into this. I'm itching to get back to it, but work commitments and weekend arrangements are taking up all my time currently.It certainly is built like a tank. The doors close with a reassuring thump and clunk as they latch and even the bonnet release is 9" long metal lever under the dash that swings 90 degrees and locks into place. It's like latching a submarine door.
As far as condition goes, it seems to be in top order with only surface rot evident on a few suspension arms. We'll see what we unearth as we delve into it though!
Lord_Howit_Hertz said:
I’ve just read your Mini thread, and it has been one of my favourite threads in a long time. The finished car looks brilliant.
With this (I know it’s not the norm) but with it needing so much mechanically, would you not fancy 'modernising' it, rather than recommissioning it?
Thanks! The mini project was a lot of fun and only possible with the help of my friend and his workshop. If this was a rolling shell then maybe I'd consider something wild. I had thought that this would look great lowered on air ride with some nice dished 20" wheels and a modern straight 6 up front.With this (I know it’s not the norm) but with it needing so much mechanically, would you not fancy 'modernising' it, rather than recommissioning it?
The reality is I wouldn't have purchased this car if that was the case as I don't currently have tools, time or space for a project on that scale.
This car is complete and it deserves to be kept original. It wasn't that long ago I was tuning 90s Japanese turbo cars within an inch of their lives, but lately I'm only interested in return classics to original factory spec.
Paul S4 said:
Very interesting project there.
My father had a Volvo 122S 4 door in white with the solid red taillights, and IIRC it had the 2 litre twin carb engine.
I also had a 360 GLS in the late 80s with, I think, basically the same engine. That particular car was one of the best cars I have owned: that 2 litre engine was bulletproof, it ran completely dry of coolant one day on the motorway en route to work, after the AA man let it cool down we just refilled it with water and it was fine. Got the rad sorted and it ran for another 20,000 miles until I sold it.
Re the fuel injection, I would be tempted to convert it to a nice set of Webers, and a custom stainless exhaust system : a subtle yet probably more reliable/simpler fuelling system. And it would sound great.
I currently have a 2010 C30, which has similar design elements to your 1800ES, particularly the tailgate/window.
Looking forward to the journey with yours.
This has the B20F engine and from what I've read it has a thicker head gasket reducing compression and slightly lowering BHP. Apparently this improves drivability by not having peak power so far up the rev range and increases low down torque.My father had a Volvo 122S 4 door in white with the solid red taillights, and IIRC it had the 2 litre twin carb engine.
I also had a 360 GLS in the late 80s with, I think, basically the same engine. That particular car was one of the best cars I have owned: that 2 litre engine was bulletproof, it ran completely dry of coolant one day on the motorway en route to work, after the AA man let it cool down we just refilled it with water and it was fine. Got the rad sorted and it ran for another 20,000 miles until I sold it.
Re the fuel injection, I would be tempted to convert it to a nice set of Webers, and a custom stainless exhaust system : a subtle yet probably more reliable/simpler fuelling system. And it would sound great.
I currently have a 2010 C30, which has similar design elements to your 1800ES, particularly the tailgate/window.
Looking forward to the journey with yours.
I'll see how I got on with recommissioning and if the FI system refuses to play ball I may look into carbs as long as there's still good and consistent compression across the cylinders.
Saying that, if the engine is a basket case, it may be the first ever engine rebuild that I've done! They seem pretty straightforward to rebuild.
Thought I’d post an update on what’s been going on with the car as it’s been a while.
Working, families, emergency DIY at home and bad weather prevented us from getting to the car for the past month or so, but we found time this weekend to drag it out and give it a clean.
The car was parked up in 1994 so we were excited to remove 26 years of dust and grime.
This was just a first pass over the car to see what we are working with and it’s a lot better than we thought. The entire car is well preserved, it’s totally solid throughout and there isn’t a dent or scratch in sight.
We also found all the carpet, interior trim and missing brightwork to make it a 100% complete car.
The paintwork should look new with a bit of polishing and the brightwork should respond well to buffing. The carpets will get a good shampooing and should come up well too, and with a bit of love the interior should look equally good.
We also found time to siphon fuel out the tank to make it easier and safer to remove, fitted new tailgate struts as they were knackered and connected a new battery. We didn’t turn the car over as there’s still some way to go until we do that, but everything works. Wipers, all the lights, dash lights, stereo etc…
Oh… and the car was hiding a dirty little secret… It has an aftermarket sunroof which will no doubt upset the purists, but it’s a period correct mod and we quite like it.
I’ll let the pictures speak for themselves. Here it is before we cleaned it.
Working, families, emergency DIY at home and bad weather prevented us from getting to the car for the past month or so, but we found time this weekend to drag it out and give it a clean.
The car was parked up in 1994 so we were excited to remove 26 years of dust and grime.
This was just a first pass over the car to see what we are working with and it’s a lot better than we thought. The entire car is well preserved, it’s totally solid throughout and there isn’t a dent or scratch in sight.
We also found all the carpet, interior trim and missing brightwork to make it a 100% complete car.
The paintwork should look new with a bit of polishing and the brightwork should respond well to buffing. The carpets will get a good shampooing and should come up well too, and with a bit of love the interior should look equally good.
We also found time to siphon fuel out the tank to make it easier and safer to remove, fitted new tailgate struts as they were knackered and connected a new battery. We didn’t turn the car over as there’s still some way to go until we do that, but everything works. Wipers, all the lights, dash lights, stereo etc…
Oh… and the car was hiding a dirty little secret… It has an aftermarket sunroof which will no doubt upset the purists, but it’s a period correct mod and we quite like it.
I’ll let the pictures speak for themselves. Here it is before we cleaned it.
Edited by croissant on Monday 26th October 13:00
We first went over the bumpers with wd40 and wire wool which removed a lot of the pitting, but there is some permanent damage which we'll live with for now.
The interior just got a wipe down for now and then the exterior got a good wash. This was by far the most satisfying car wash I have ever done with each swipe of the sponge washing away the decades of grime that had collected.
There wasn't time to do anything else at this stage and we're going to focus in getting it running before we detail the car properly.
Here it is after cleaning:
The interior just got a wipe down for now and then the exterior got a good wash. This was by far the most satisfying car wash I have ever done with each swipe of the sponge washing away the decades of grime that had collected.
There wasn't time to do anything else at this stage and we're going to focus in getting it running before we detail the car properly.
Here it is after cleaning:
NomduJour said:
That looks remarkably straight under the muck.
Edit - even more so on a closer look, the sill bottoms look almost perfect. Wish mine had escaped 20 years in the barn as well...
The underside is just as well preserved. There's some surface corrosion on the suspension, but we'll tackle that in due course.Edit - even more so on a closer look, the sill bottoms look almost perfect. Wish mine had escaped 20 years in the barn as well...
Edited by NomduJour on Monday 26th October 12:59
It sucks to be sat at a computer through the week attending to client needs. I just want to be back at the garage and tinkering away!
Next jobs are to crank the engine by hand, lube up the rockers and valves, change the oil and filter, remove the fuel tank, pump and filter and replace with new items, and then blow air through the fuel lines then pump fresh fuel through until it runs clear.
Breadvan72 said:
Nice! I've never seen another on the road before. I actually quite like the wheels too.
I've been looking at wheel options, but go full circle and want to stick with the originals. I might be tempted to band the wheels at some point and add a couple of inches to them though.
NomduJour said:
Might be useful (last time I pulled mine out, the auxiliary air valve was the issue):
https://jetronic.org/en/d-jetronic/72-troubleshoot...
That is going to be SUPER helpful! Thank you. I've not come across this site before https://jetronic.org/en/d-jetronic/72-troubleshoot...
It really is a glorious machine. From the moment I first saw it I saw its potential and had to have it. The weather looks dry here on Friday so I've taken the day off and got a big parts haul on the way which I'm expecting today. Updates to follow sooner than anticipated hopefully.
Breadvan... you're first in line if we decide to sell
Breadvan... you're first in line if we decide to sell
I've not yet seen another wheel I prefer so the steelies will be staying. They'll eventually get a repaint and some new tyres.
In the meantime I had a quick go at cleaning the leather seat bases. Still some way to go and I need to find a product that can really get some moisture back into these.
Anyone got a good recommendation?
My big parts haul has arrived also! New fuel tank, pump, filter, injector rebuild kit, water pump, thermostat, entire ignition system, belts, full service kit and more. Enough to keep me busy for a while and hopefully all I need to get it fired up.
In the meantime I had a quick go at cleaning the leather seat bases. Still some way to go and I need to find a product that can really get some moisture back into these.
Anyone got a good recommendation?
My big parts haul has arrived also! New fuel tank, pump, filter, injector rebuild kit, water pump, thermostat, entire ignition system, belts, full service kit and more. Enough to keep me busy for a while and hopefully all I need to get it fired up.
Edited by croissant on Tuesday 27th October 16:02
Paul S4 said:
That car looks amazing after a decent wash !
IIRC the trim parts were stainless steel ?
Re the wheels, I would keep the original steel ones, never heard of 'banding' wheels but I guess if done professionally they would look really good andf allow some wider modern rubber....
Then you can lower it a bit ....! Or Not !!
Just a thought, if it were my car I would have a look at removing those rear bumper over riders to 'clean up' the rear end, and that long tailpipe would look better (IMHO of course !!) if it were a nice stainless modern backbox. Of course there is probably a good reason why they protrude like that ( probably to do with aero and not sucking fumes back or something )
Years ago I had my first 'proper car', a 1973 MGBGT, and my first job on it was to remove the front over riders ( one was bent anyway when I bought it !) and replace with some new chrome bolts. It made such a difference to the front aspect. So thought it would look good on your car, especially as there are none on the front of your Volvo.
Very interested on the progress of this lovely car, as mentioned previously my current car is a descendent of your car....a C30 !
The trim around the windows is stainless but the bumpers are chromed mild steel. Not sure on the headlight rings or front grille. I'll tackle all the brightwork once it's on the road and whatever I can't get looking good I'll replace.IIRC the trim parts were stainless steel ?
Re the wheels, I would keep the original steel ones, never heard of 'banding' wheels but I guess if done professionally they would look really good andf allow some wider modern rubber....
Then you can lower it a bit ....! Or Not !!
Just a thought, if it were my car I would have a look at removing those rear bumper over riders to 'clean up' the rear end, and that long tailpipe would look better (IMHO of course !!) if it were a nice stainless modern backbox. Of course there is probably a good reason why they protrude like that ( probably to do with aero and not sucking fumes back or something )
Years ago I had my first 'proper car', a 1973 MGBGT, and my first job on it was to remove the front over riders ( one was bent anyway when I bought it !) and replace with some new chrome bolts. It made such a difference to the front aspect. So thought it would look good on your car, especially as there are none on the front of your Volvo.
Very interested on the progress of this lovely car, as mentioned previously my current car is a descendent of your car....a C30 !
I've seen a set of original wheels on ebay but they're collection only and up in Hull. If I can get them delivered at a reasonable price I may get them, then I'll have a set of originals and a second set to have banded. I could potentially add 2-3 inches and fit wider tyres all round. Should give a more modern slant to the original equipment and I could even go or a staggered look.
There's also 30mm lowering springs available which I'm tempted by!
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