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Hi,
As part of our ongoing father-son Volvo rebuilding adventure, we're planning on salvaging some good rear floor sheet metal from our donor car. Son suggested using a torch (yikes!) based on a friend's experience; based on that same friend's experience, I am leaning towards something like a "sawsall" with a metal-cutting blade.
Problem: I don't own said "sawsall"
Problem: Father's Day is too far away
Possible solution: Craftsman hand-held scroll saw with metal-cutting blade?
As near as I can tell, I'll only be cutting single-layer sheet steel. Do you think the possible solution (scroll saw) will work?
Any BTDT on other approaches--or things to avoid?
FWIW, the father-son part has gone real well, and I would recommend it. We had a really good spring-break together. We both learned a lot--and not just the more colorful aspects of the English language . . . .
Best Regards,
Steve A-
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When I did this, I used a Sawzall. Worked like a champ.
Use this opportunity to justify the Sawzall of your dreams. And if you're really persuasive, maybe you can sneak a nice MIG welder into the deal, too...
--
Don Foster (near Cape Cod, MA)
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Don,
Thanks for the advice--just returned from tool shopping (as opposed to buying, at least for tonight). Currently have my eye on a nice cordless sawsall . . .
You're right, a MIG welder would be good too. A buddy got one for Christmas and has pretty much welded together every loose piece of metal in his garage. He said I could borrow it if I ever needed it, so now might be the time . . .
On another subject, how long do you think a stock AW-70 would last with a B21FT if I dialed the boost back a little bit. The 4+OD in our project needs some work, and I happen to have a good auto-box and related parts (cooler, etc.) out back. Son doesn't know how to drive a stick--yet--and thought I could get him started with the auto while fixing the manual. I also have a line on an AW-71 (L maybe) from a 940 Turbo, but would like to keep the $ aspect of this under control.
Thanks again for the advice.
Best,
Steve A-
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Here's what you tell wife: "Gee, Honey, if I buy a saw to cut out the floor, then I obviously need a welder to install it..."
The tranny should last a good 300k if you don't abuse it.
Don't forget that you'll also need the flexplate, driveshaft, and all the shifter stuff. If you have a donor, then you should be OK, But if you only have the tranny, then you'll spend time and $$$ hunting down all the stupid little stuff.
Personally, I think you and son would be better off if he learned to drive a stick. It might take less time and be less trouble than installing the A/T...
--
Don Foster (near Cape Cod, MA)
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Don,
Thanks for the quick response.
We have all of the parts needed (unless the B21FT has a diffent ECU for the automatic)--the shifter cover is even the right color . . .
We tried the "learn to drive a stick" from the start in my wife's 91. Didn't work out so well--the dog got car sick and I wasn't feeling too well myself (can't even remember why we had the dog with us . . .)
Anyways, he's been using another old Volvo (mine) to learn on and is getting pretty good. I figure by the time he gets his license I can maybe have the 4-speed rebuilt.
I KNOW he's planning on learning to drive a stick someday, as he hopes to inherit the old 914 parked in the garage (though with any luck it will be a LONG wait).
Thanks again,
Steve A-
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posted by
someone claiming to be Dino
on
Mon Apr 28 13:31 CST 2003 [ RELATED]
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Steve,
While I don't have any direct experience cutting auto sheetmetal, I can only tell you NEVER PASS UP AN OPPORTUNITY TO PURCHASE A NEW TOOL!!! There are a number of recipricating saws on the market that can be had for around $100. Mine gets lots of miscellaneous use around the house, (just not the car...yet) Come to think of it I have always fancied those full french sunroofs with the simple canvas cover!
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Dino,
Good advice. Funny, I hadn't thought about a recip-saw and one of those big sunroofs for a while--not since X traded my paid-for 76 Volvo 242 (with ipd bars, cibies, etc) for a Renault Le Car back in 1980 . . . . The Renault had one of those canvas-covered sunroofs--probably a good thing I didn't have the sawsall . . . .
Thanks!
Steve A-
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Hey Steve, I replaced a pan in my 83 last year and I took a battery powered sawall with several metal cutting blades to the junk yard, and I used it for about half of the job and ended up using a chisel and hammer for the other half. Don't go out an buy a tool for this job...a chisel works just fine. Bring two good sharp cold chisels and some leather gloves. Its less work than chopping down an 8" tree and just as fun!
Cliff
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Cliff,
In addition to the project, I have a couple of trees to take out--will probably save what remains of my strength for that job. I've been needing a recip-saw for a few years and have been puting it off. Now might be the time . . .
On the other hand, I could give the chisel, gloves and BIG hammer to the kid and let him go at it . . . .
Thanks!
Steve A-
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A torch is certainly the most dramatic way to cut sheet metal. It's even more dramatic if the undercoating and fuel tank are still on the donor vehicle. Cutting torches usually make a mess of thin sheet metal, so I wouldn't recommend it.
A plasma cutter is the best option, also the most expensive.
A scroll saw (a.k.a. jig saw or saber saw) will work just as well as a Sawzall. Remove hard obstructions, such as the drive shaft and exhaust - the blade will break if it hits them.
An abrasive metal cutting wheel on a circular saw or angle grinder will also do the job. Lots of noise and sparks is always fun - eye and hearing protection required.
I usually use some combination of Sawzall, angle grinder and snips to cut sheet metal. Whatever method you choose, cut the donor material a few inches larger then you need, and trim to fit with snips. It's much harder to add metal than take it away.
-Ron
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Ron,
Thanks for the advice--already been out looking at saws. Son's friend lit off the undercoating on his car last summer; almost a BTDT.
Appreciate the tips on the obstructions; everything is already removed--we took the old car completely apart in 4 days.
A cutting wheel is a good suggestion too. I would probably go that route if my son were going to be there to observe (like you said, it's quite a show), but I think he'll miss the cutting.
Thanks again for the advice.
Regards,
Steve A-
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