What did you do to your Volvo today? Topic is solved

[crasbe]

The dashboard kickpanel of my 1998 Volvo V70 I has a broken tab where it should be held in place by a screw under the steering wheel.
While the previous owner "fixed" that by screwing a drywall screw into the side of the kickpanel, I preferred a more lasting repair...

PXL_20240325_215722152.jpg (255.11 KiB) Viewed 2358 times

PXL_20240325_215746302.jpg (127.9 KiB) Viewed 2358 times

With Fusion 360 I created a 3D model which replicates the missing piece of the kickpanel and has a brim which will ensure a strong glue connection to the panel. In the profile of the model you can see that it follows the slight curvature of the panel as well, ensuring a good fit.

Screenshot 2024-03-26 012611.png (213.21 KiB) Viewed 2358 times

Screenshot 2024-03-26 012624.png (27.19 KiB) Viewed 2358 times

Due to the curvature it had to be 3D printed in a somewhat odd orientation, but it worked. This prototype is PLA, but the final version will probably be printed from ABS or PETG. PLA will start to become soft at around 60°C, which a black car (as mine is...) can reach on a very hot and sunny summer day.

PXL_20240325_234820544.MP.jpg (426.29 KiB) Viewed 2358 times

As you can see, it fits very nicely on the kick panel and I'm sure it'll be a very strong repair.

PXL_20240325_235226669.jpg (246.15 KiB) Viewed 2358 times

PXL_20240325_235301943.jpg (206.64 KiB) Viewed 2358 times

Of course, something like that is not designed first try, so this is the evolution of this repair part.
Leftmost is the little piece that was furtunately remaining on my kick panel, so I could get some reference dimensions from it. The first version was too small because I mixed up the inner and outer dimensions. The second version fit quite well, but didn't have the curvature yet, so the contact area was not good yet. The third version is a cutaway to see if the model curvature fits the actual panel. The last part is the final prototype

PXL_20240326_000751752.MP.jpg (199.5 KiB) Viewed 2358 times

The next repair will be on the dashboard, because the attachments for the kickpanel are broken on both sides...

PXL_20240301_194552966.jpg (239.14 KiB) Viewed 2358 times

Is that a common problem with Volvo V70s that this tab of the kickpanel breaks?
Or were the previous owners of my car just hacks who ripped the panel out instead of taking it out carefully?

If it's a common issue, I can publish the model files for the repair part.

[scot850]

Simple answer is yes it is a common issue along with several other plastic parts like the corners of the glove box.

I just did a similar repair using bits and bobs I had kicking around. Small strips of metal behind those 2 outer tabs for one. The advantage I had was that the whole dash was out anyway to repair the normally broken lower dash section firewall mounts. I used JB Weld black plastic for the repairs and it has worked well.

Your solution though is truly magnificent and many thanks for doing this and sharing! I could see others looking for this part and whatever solution you come up with for the 2 tabs.

Neil.

[brunocerous]

Could be fuel, spark or timing. You want to be sure not to crank too many times in case you are flooding the cylinder and then the CAT. Turn the key to Position 2 and push the Schrader valve to see if there is fuel squirting out.

Next check the cap & rotor. If it seems to look okay then remove the 2 screws to expose the injectors. Unplug the connectors and with the key in the Position 2 test to see if you have Voltage at the leads. Polarity doesn't matter when checking. If you have voltage then check spark to the plugs.

Timing would be the last to check.
.
98 Engine Compartment.png
.

Are you getting fuel? Almost sounds like a washed down cylinder.

Thank you, both! I don’t have a fuel pressure gauge (added to my list) but has fuel coming from the Schrader valve both times I checked. I unplugged the MAF sensor and then noticed that the small linkage arm with ball ends that comes off the throttle wheel was loose. (Why would this detach?) I disconnected and reconnected the spark plug wires, noticing that one seemed loose.

After about 20 seconds of cranking, it sputtered and finally started, with the tailpipe sending out a huge cloud of exhaust. Warming it to normal operating temperature, I turned it off, and it started a second time with no problem.

[brunocerous]

Is that a common problem with Volvo V70s that this tab of the kickpanel breaks?
Or were the previous owners of my car just hacks who ripped the panel out instead of taking it out carefully?

If it's a common issue, I can publish the model files for the repair part.

This is amazing! Every one of my P80 vehicles had this issue. I’d love a copy of the file, if it’s not too much trouble.

[bmdubya1198]

The dashboard kickpanel of my 1998 Volvo V70 I has a broken tab where it should be held in place by a screw under the steering wheel.
While the previous owner "fixed" that by screwing a drywall screw into the side of the kickpanel, I preferred a more lasting repair...
PXL_20240325_215722152.jpgPXL_20240325_215746302.jpg


With Fusion 360 I created a 3D model which replicates the missing piece of the kickpanel and has a brim which will ensure a strong glue connection to the panel. In the profile of the model you can see that it follows the slight curvature of the panel as well, ensuring a good fit.
Screenshot 2024-03-26 012611.pngScreenshot 2024-03-26 012624.png


Due to the curvature it had to be 3D printed in a somewhat odd orientation, but it worked. This prototype is PLA, but the final version will probably be printed from ABS or PETG. PLA will start to become soft at around 60°C, which a black car (as mine is...) can reach on a very hot and sunny summer day.
PXL_20240325_234820544.MP.jpg


As you can see, it fits very nicely on the kick panel and I'm sure it'll be a very strong repair.
PXL_20240325_235226669.jpgPXL_20240325_235301943.jpg


Of course, something like that is not designed first try, so this is the evolution of this repair part.
Leftmost is the little piece that was furtunately remaining on my kick panel, so I could get some reference dimensions from it. The first version was too small because I mixed up the inner and outer dimensions. The second version fit quite well, but didn't have the curvature yet, so the contact area was not good yet. The third version is a cutaway to see if the model curvature fits the actual panel. The last part is the final prototype
PXL_20240326_000751752.MP.jpg


The next repair will be on the dashboard, because the attachments for the kickpanel are broken on both sides...
PXL_20240301_194552966.jpg



Is that a common problem with Volvo V70s that this tab of the kickpanel breaks?
Or were the previous owners of my car just hacks who ripped the panel out instead of taking it out carefully?

If it's a common issue, I can publish the model files for the repair part.

I'd also love this file! This is a super common problem, I've tried to fix mine many times in many ways, but this is the best looking and appears to be the most effective.
I've glued a washer there previously, but that hasn't held up very well.

[ZionXIX]

Nicely done!

[crasbe]

Thanks for the feedback and the kind words. Since this seems to be a bigger issue, I'll start a new thread in the evening and will publish the files on Printables.

[abscate]

Are you getting fuel? Almost sounds like a washed down cylinder.

Bdub for the win.

Youve won lifetime of Taylor Swift downloads for your Miata!!

[MoVolvos]

Could be fuel, spark or timing. You want to be sure not to crank too many times in case you are flooding the cylinder and then the CAT. Turn the key to Position 2 and push the Schrader valve to see if there is fuel squirting out.

Next check the cap & rotor. If it seems to look okay then remove the 2 screws to expose the injectors. Unplug the connectors and with the key in the Position 2 test to see if you have Voltage at the leads. Polarity doesn't matter when checking. If you have voltage then check spark to the plugs.

Timing would be the last to check.
.
98 Engine Compartment.png
.

Are you getting fuel? Almost sounds like a washed down cylinder.

Thank you, both! I don’t have a fuel pressure gauge (added to my list) but has fuel coming from the Schrader valve both times I checked. I unplugged the MAF sensor and then noticed that the small linkage arm with ball ends that comes off the throttle wheel was loose. (Why would this detach?) I disconnected and reconnected the spark plug wires, noticing that one seemed loose.

After about 20 seconds of cranking, it sputtered and finally started, with the tailpipe sending out a huge cloud of exhaust. Warming it to normal operating temperature, I turned it off, and it started a second time with no problem.

.
Great you got it going! Do you think it was the one loose spark plug wire as the linkage arm still provided throttle input?
.

[xanthefin]

After first test I think i need adjust Speed conversion slightly.
I belief this is from VSS sensor? I need pull ABS fuse and go verify.
Screenshot_20240324_165431.jpg

It was VSS so if ABS is bad can monitor VSS via automatic gearbox as alternative speedo.


Then made today short video Key programming on P80 platform (+ C70 and 40 series up to 2004?).