Volvo Gen II Hood Hinge Mount Repair
RandyA had a problem with his hood. The mounting point for a hood hinge had separated from the fiberglass. Not wanting to purchase a replacement hood, Randy created a new mounting plated to attach the hood hinge.
With the hood open I decided NOT to try removal of the hinge or hood. The torque rods sort of scared me because I know how much energy they have when let lose improperly. I could not gather any help today. It was a "by myself" job. So, I decided to leave everything "as is" and built on to what I had to work with. It was apparent that the hinge plate had some earlier problems - there was a piece riveted onto the bottom. No epoxy resin in my workshop, only polyester. Besides, it was too cold to set up strong enough to do me any good today. I had the broken piece of fiberglass (or SMC) poked back up into the hole it broke out of so I saw no immediate need to glue it back together.
I took a lesson from the Gen 1 Volvo's that ran the support up the side. Just like Brad Dadles said, there was a metal plate inside that I could grab onto.
These are photos of the repair. Click on the photos to enlarge them.
Figure #1 - I ended up using my trusty little Chinese plasma cutter and some scrap angle and plate to form and weld up an offset Z bracket that would attach to the hinge and then run up the inner side of the hood.
Figure #3 - Then I welded the lower part of the new support to the hinge arm knowing the sole 1/4" bolt would not hold up.
It is pretty darn solid now and once I replace the sheet metal screws with rivets I don't think it will give me any more trouble.
IMHO - the OEM design on the Gen 2 (mine) was not nearly as strong as the Gen 1 design. Wonder why they changed????
It took every bit of 5 hours.
Now I need to do a PM on the other side with the same type of bracket.