1961 Volvo P1800 project, part 21


Rotisserie Apparatus: $1300.00
Used Spitzenagel Pneumatic spot weld drill: $149.00
Standing up straight while drilling out rocker spot welds: Priceless!

Repairing a rusty car is really simple:

You remove all the rusty parts and replace them with not rusty parts! Done! Right?? Right???!!


Oh my, what have I done now?? A huge hole. Remember the movie Wrist Cutters?? If not, watch it and you will understand.


Since this is a unibody car, I need to make sure it stays straight and square while I remove any supporting panels. I added these support beams just to make sure the body does not move while I remove this part.


Nice and shiny, eh? The jack supports were a bit weak as so I decided to replace the whole beam. It is often easier and even faster to replace the whole component rather then try to patch areas. Besides, it looks like a factory job.


Milestone?? I guess so. This is a card board template of the first piece of metal that is actually added/welded to the car. It is just the lower A-pillar support that attaches to the lower rocker panel.


Cleco. A metal worker’s best friend. You drill a small hole and then use these Cleco fasteners to hold the panel in place during fitting and welding.

1, 2 and 3!

The rocker assembly on a Volvo P1800 consists of no less than three components.


1. Bottensvällare: The first piece is the inside panel. The Swedes calls it bottensvällare and that directly translates to “bottom sweller” as it rises from the floor.


2. Subrocker

Connects the lower part of the A and B pillar.


3. Rocker panel. Hey, we finally arrived at the outer layer. The ironic part is that the rear quarter panel and front fender covers most of it but I am sure all this add a lot of strength to the P1800 body.


Just held in place with the aforementioned Clecos but hey, that looks like a genuine Swedish rocker! I need to tack it in place and then test fit the rear quarter panel and front fender before I dare button it up. Nobody said this was speedy work.

Mo later…