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dav850
02-16-2010, 03:29 PM
Hey all,

There doesn't seem to be any subforum for modifications/member journals etc. so I hope this is an ok place to post this:confused:

I've always run IPD skid plates on my Volvos, which have served me well and saved my oil pan in more than one instance. However, I find they have some shortcomings that I have finally found time to address. Here's the first part of my project to add to the protective qualities of this product. By the way, this is for a Volvo 850, although perhaps it would useful for owners of earlier XCs, as I imagine the skid plates may be of somewhat similar design.

First-off, I decided to address the fact that the oil filter remains exposed and vulnerable to damage with the original design. I understand this allows easy filter removal during oil/filter changes, but I figured fabricating an easily removable extension would be a good idea, if not just a fun project to spend some free time and extra materials I had lying around on.

Here's a pic of the skid pate in it's original condition:

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods020.jpg
There's the cut-out at the top-left corner.

First, I made a cardboard template to base the aluminium extension off of:

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods022.jpg

Then I cut my piece out of some old sheeting I had lying around. It's a tad thinner than I would have liked to use, but it was Family Day, so most places were closed, and I didn't feel like spending more than time on this project.

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods023.jpg
I thought a clean line from the edges of where the original plate ends would be nice, but later learned it did not provide sufficient coverage, and left about 1/3 of the filter still exposed:o Anyways I carried on in my usual daze unaware[thumbup]

I left about an inch of overlap around the edges, and drilled some holes to bolt the new extension up to the original plate thru. I also letter-punched the extension to remind me what's behind it;)

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods033.jpg

Then, it was time to line-up the extension, centre-punch, and drill and tap some threads into the main plate to accept the Stainless bolts I used to secure it. I chose stainless, as first-off, I work on boats so I have lots of SS fasteners lying around, obviously they resist corrosion, and strength wasn't a priority as all they have to do is hold a very light piece of metal.

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods025.jpg

Next up was shortening the bolts, so they didn't protrude too far past the original plate and possibly poke the engine/filter if/when taking the next hit.

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods030.jpg

Finally (or so I thought:o) it was time to mount the new extension onto the skid plate.

http://i128.photobucket.com/albums/p182/davNF/cubaandskidplatemods034.jpg

Unfortunately, as I mentioned earlier, I failed to check my design over thoroughly, and realized the new cover provided only partial protection to the oil filter[cussing] Oh well, the hardest parts were done, and fortunately I had enough aluminium left over to quickly fab up a new cover, quickly and easily the next day using the old one as a template. Here's a few pics of the completed, final (maybe) version:

http://i128.photobucket.com/albums/p182/davNF/skidplatemods1002.jpg

http://i128.photobucket.com/albums/p182/davNF/skidplatemods1004.jpg

Well that's it for now, hope this wasn't completely boring and a waste of your time and bandwith:D Tomorrow's project: Drilling and tapping the subframe to accept some stainless bolts to positively fasten the pate to the front subframe crossmember (those stupid expanding rubber bolt thingies suck and keep falling out:()

Thanks for looking and stay-tuned for more updates!!!

Dav