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Volvo 940 GLE Caravan Project - Underway!
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Fred
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Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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Did a tiny bit of work to it: Peeled a bit of thin flakey bog out of the left sill and black zinced the exposed surface rust and a couple of other random bits. Studied the rear end suspension and space required for a queen sized mattress. Then removed the lower torque arm saving a massive 1.7kg: https://twitter.com/FredCookeNZ/status/ ... 2772410368 
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Sun May 21, 2017 5:34 am |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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Regarding building a non-differential rear axle for this thing: - 73.4-73.5 whatever standard is OD
- 29.4-29.5 axle spline ID
If I can find a sealed or unsealed bearing like this that isn't taper roller and doesn't require spacing to be proper for the inner, I can just run two bearings and no spool at all. Idea courtesy of em_knaps :-) Not sure why I didn't think of that, but I didn't. :-p Having had a look now, the exact size is only available in taper roller bearings, not self-aligning ball bearings. The standard ID is 30mm which would likely be OK with 0.5mm clearance to the spline, but the nearest OD is 70mm. So some sort of sleeves would be required to get to a suitable bearing situation in terms of securing them in the housing and running cleanly on the splined shaft ends. Volvo diff bearing details tweet: https://twitter.com/FredCookeNZ/status/ ... 8469828608
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Sat May 27, 2017 6:04 am |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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Moved it again tonight, last date was 22nd May, and I guess the next date will be 29th May :-)
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Sun May 28, 2017 11:45 am |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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And again tonight, prematurely: https://twitter.com/FredCookeNZ/status/ ... 7746307072 A few things are going on with this project: 1) This weekend I'll be in possession of another Volvo 7/9 diff, possibly open to be used as donor for the caravan so I can take the G80 from it and put it in the sedan 2) In a few months I want to move it to the land the wife and I bought and use it for holiday accommodation there :-) So then, I'd like to at least get the rear suspension chopped and relocated, and the final axle into it, and the floor lowered and replaced and a queen size mattress in there :-)
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Tue Jul 18, 2017 11:15 am |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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And again this coming Sunday or next Monday: https://twitter.com/FredCookeNZ/status/ ... 1401860101 And the diff is in strange condition, might have a usable R&P or not, but the free-spool will be good for this: https://twitter.com/FredCookeNZ/status/ ... 9178411008
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Tue Jul 25, 2017 12:41 pm |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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Ring gear is rusted pretty badly, so is likely a piece of junk to be recycled, now :-) I'll use the spool, bearings, housing. I'll chop off unrequired brackets etc, and ditch the backing plates. I'll chop the front of the nose off and weld a plate over that, too. Brakes will go back onto it after they come out of the 740 sedan, probably, as I'll probably keep the current lower-mileage caravan ones for the 740. May try to pull it to bits tomorrow, otherwise one evening next week, or next weekend. Pics: https://twitter.com/FredCookeNZ/status/ ... 0586572800https://twitter.com/FredCookeNZ/status/ ... 2094223360 
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Sat Jul 29, 2017 8:11 am |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Tue Aug 01, 2017 12:02 pm |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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More caravan progress in another thread: viewtopic.php?f=15&t=2789&p=43744#p43744
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Sat Aug 05, 2017 12:38 pm |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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Caravan progress by screw up and confusion and downsizing of others. Ie, I've repeatedly said that a queen size mattress could fit into this thing. Wrong. 1400 or maybe 1380 is what I have available width wise. Which by chance is about the size of a double bed, at 1370mm. Oops. And it just so happens that there are four beds available and up for grabs right now, two queens, and two doubles. One of the queens will replace our nearly fifty year old super uncomfortable king base with topper and make the wife and I a lot happier. And one of the doubles will end up in this, possibly as soon as Friday. So that'll be good to see. :-) Reference: https://en.m.wikipedia.org/wiki/Bed_size
_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Mon Aug 07, 2017 11:29 am |
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Fred
Moderator
Joined: Tue Jan 15, 2008 2:31 pm Posts: 15073 Location: Home sweet home!
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_________________DIYEFI.org - where Open Source means Open Source, and Free means Freedom FreeEMS.org - the open source engine management system FreeEMS dev diary and its comments thread and my turbo truck!n00bs, do NOT PM or email tech questions! Use the forum! The ever growing list of FreeEMS success stories!
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Tue Aug 08, 2017 6:11 am |
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