Rotisserie Chicken…ahem…Volvo

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Short up-date but it took half the weekend to make the brackets that attaches to the car.

My grocery store keep telling me that their rotisserie chicken is the bestest. I can only assume it is because it is evenly done. Just like this Volvo will be evenly done all around because…rotisserie!

1961-volvo-jensen-p1800-in-rotisserie

To be able to repair and replace floor boards while standing up sounds like Ergonomic Bliss to me. All the sheet metal is in so it is time to start cutting!

 

1961 Volvo P1800 project, part 19

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With the body back from stripping some less than professional repairs came to light.

1961 Volvo Jensen P1800 door lousy bodywork

This door had a scrape on it and the honorable Drill, Bondo & Squirt Inc. drilled 200 holes and then filled with bondo. I have ordered new door skins.

 

1961 Volvo Jensen P1800 quarter panel more beautiful bodywork

Looks like the same body shop did this fine work on the right quarter panel.

 

1961 Volvo Jensen P1800 quarter panel bodywork

Also, check out this classy job on the bottom. Initially, I thought about just patching the bottom but theĀ heat and general distortion from welding when installing a patch will always require some filler.Also, you end up with an unsightly looking seam inside the trunk. The plan is to replace the complete quarter panel for a factory looking job.

 

1961 Volvo Jensen P1800 drilling spot welds

In order to remove the panels I have to use a spot weld drill bit. This is tedious work and NOT so fun. To make things easier, I ordered a professional pneumatic spot weld drill.

 

1961 Volvo Jensen P1800 NOS fender

Can you imagine going to the local Volvo dealer and pick up an NOS front fender for a P1800??!! I just did. My local Volvo dealer had this 664372 on the shelf. The tag shows a stocking date on 1995!

 

1961 Volvo Jensen P1800 brazing

Before I remove any panels I am taking tons of pictures. Here you can see that the front fender was brazed in place. So basically the P1800 fenders are welded, bolted and brazed!

 

1961 Volvo Jensen P1800 rocker fender seam

Here is another seam that will be important to duplicate. The seam between the rocker panel and the fender. Small detail but filling it would not look correct.

 

1961 Volvo Jensen P1800 quarter panel front

This is another thing worth noting: The factory used lead to cover the spot welds on the quarter panel at the B-pillar. Normally car manufacturers are not “hiding” the spot welds in a location like this. This is just part of the documentation, I plan to duplicate this.

1961 Volvo Jensen P1800 right side quarter panel removed

Here goes nothing! Well, actually, it is something…the first quarter panel is off.

 

1961 Volvo Jensen P1800 right inner wheel well

The inner wheel well looks very nice except the very lower corner. I can just do a spot repair in that area.

 

1961 Volvo Jensen P1800 quarter panel spot welds

It was hard to see the spot weld on the outside on this panel so I cut the panel out and left a half inch or so. Now I can clearly see where the welds are located and I can drill them out.

 

1961 Volvo Jensen P1800 ye olde quarter panel

Ye olde quarter panel

1961 Volvo Jensen P1800 high spotwelds

Problem: When you drill out spot welds with the spot weld drill bit it will leave part of the weld in place so you have to dress and grind the surface so you have a smooth attaching point for the new panel.

 

spitznagel

Solution: The world famous Pneumatic Spitzenagel Spot Weld Drill Apparatus. This tool will remove the spot weld completely and you can set the depth so it does not disturb the remaining flange. You gotta love good tools.

Speaking of helpfulĀ apparatus…I ordered a rotisserie rack so I can work on the car in comfortable positions and not break my back while working on this car. Can’t wait to get it set up! If chicken is good on rotisserie cars must be too!

All I have to do now is remove and replace the other rear fender, rear back panel, rear support panel, rear side support panel, rocker panel, sub panel, rocker sill plate, front fenders, floor boards, battery box, bla, bla, bla!!! Easy right??