850 bumper on a 940

[Dr Dokeh]

Now updated with lots of pictures and stuff!

Inspiration comes from Jocke's beautiful 940 (http://www.volvo940turbo.dk/) and his guide which was kindly translated by Alex Buchka at http://forums.turbobricks.com/showthread.php?t=100728

"How to"

First things first, start by removing the front bumper cover like so...

This job is MUCH easier to do with the bumper off the car. There are two 15mm bolts either side holding the bumper bar to the bumper shocks.

The top trim piece is held on by six sprung clips that must be pushed downwards and then out to release. The trim then simply slides off the bumper, exposing seven push rivets. There are 14 of these total on the upper and lower parts of the bumper beam, remove them in any way you see fit (I used a screwdriver and hammer, 13 out of 14 came out without breaking!) The number plate will also have to come off, the two parts then separate.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02336.jpg

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02337.jpg

You’ll then be left with a bare bumper beam which must be bolted back onto the car. The holes in the bumper shocks are conveniently elongated, put it as high as it’ll go and then tighten the four 15mm nuts down nice and tight.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02338.jpg

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02339.jpg

The 850 bumper is actually two parts, the upper grey piece and the lower body coloured spoiler. They’re clipped together and simply pull apart if you start pulling at one edge. Test fitting and mounting is easier if you just use the upper piece.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02355.jpg

With the bumper cover placed onto the bumper beam, get it all lined up straight and you’ll see that it hits some protrusions on the fenders/wings on either side.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02340.jpg

You’ll need to trim the bumper at these points so it fits flush.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02342.jpg

I got a bit overzealous here, and although it doesn’t actually show once the bumper is on, the less cut out the better!.

With that done, the bumper can be pushed into the desired position, and some side mounting holes drilled. There’s a convenient bracket on the inside of the 850 bumper that goes right up to the 940’s sheet metal.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02345.jpg

Mark a point here and drill a hole, I used a piece of angle steel here as I had no washers large enough to cover the hole, this is probably for the best as it’s a lot more rigid.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02346.jpg

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02347.jpg

CAUTION!!!! I’d seriously suggest you remove the battery while doing this, as going through it with a drill might be a bit nasty.

With the sides aligned and secure, you can start on attaching the bumper to the bumper beam. I started by marking out a line where the headlights and grille came to, then drilled five evenly spaced holes making sure they were behind the line.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02351.jpg

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02353.jpg

For now I've used regular bolts, but plan on using flush mount button bolts like these painted grey.

http://www.boltmotorcyclehardware.com/images/M6fairing.gif

Not done yet is some support for the lower part of the bumper, as there’s a ~5cm gap between the beam and the bumper. While this is not completely necessary I feel that the more rigid the mounting, the better. I plan to get some more steel and make some brackets that go from the underside of the bumper beam to the bumper. Updates will follow.

Once it’s all secure and you’re happy with the mounting, clip the lower spoiler back on and admire your lovely new bumper!

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02355.jpg

Although it's a remarkably good fit, there are some small issues...

As mentioned in Jocke's guide, there's a small gap showing either side. It's not THAT noticable, but fiberglassing it over is a fairly trivial job. I want to respray this bumper dark grey anyway.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02354.jpg

Then there's the whole 'sticking out' issue, I think it looks like it sticks out more mainly because there's not 2" of trim along the top of the bumper to break up all of the greyness like there is with a 940.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02360.jpg

I can't hold a camera and a ruler straight at the same time!, that's about ~3.75"

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02361.jpg

And with the 850 bumper, about 4.5" max.

And some decent pics as promised.

http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02356.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02357.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02358.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02359.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02362.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02363.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02364.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02365.jpg
http://homepages.nildram.co.uk/~drdoke/940/850bumper/Dsc02366.jpg

Yay!

[Fake-R]

eek. I'm not feeling it. Sticks out way too far, IMO.

[2fast242gt]

eek. I'm not feeling it. Sticks out way too far, IMO.

sticks just as far as the stock bumper, looks great!!!!! do you know how well the rear will fit? sideskirts will be fun..

[VolvoPunch]

I like it, looks good now just paint it.

[Dr Dokeh]

I did kinda agree with you there Brett, but after going back and forth many times between both of my 940s with a tape measure I realised that it only sticks out a teeeeeensy bit more than the stock bumper.

It doesn't look as silly as a 240 with commando bumpers :-P

[impulse922]

looks great, much better than the 940 over on VS where the guy is attempting a whole 850 front end conversion...

[turbowagoneer940]

lookin' good!!!

who killed your tire?:-P

[Fake-R]

sticks just as far as the stock bumper, looks great!!!!! do you know how well the rear will fit? sideskirts will be fun..
really? This picture just killed it for me:
http://homepages.nildram.co.uk/%7Edrdoke/940/850bumper/Dsc02330.jpg

I did kinda agree with you there Brett, but after going back and forth many times between both of my 940s with a tape measure I realised that it only sticks out a teeeeeensy bit more than the stock bumper.

It doesn't look as silly as a 240 with commando bumpers :-P

haha, good to know, and I agree about those commandos.

[SteveP]

Like it, Steve...

Smartens the front end up alot :)

[244tiCanuck]

Hmm... I think I'm gonna start looking for an 850 front bumper.

[turbowagoneer940]

i can just imagine how a battery of 4x1000's Hella will look on that bumper!:oogle:

[Dr Dokeh]

Updated!

[dirtbike]

I'm liking that lots Steve, it'll look sweet with the matching rear.
Would a S90/V90 rear be any easier?

Laters
Nick

[shellshock]

Awesome. I just might do this now!

How goofy does the car look with the 850 bumper on front and the stock 940 bumper on the back? Could i pull it off?

[triton]

would it work out the same on a 90 745? if so i may consider doing this, wonder how hard a rear bumper would be EDIT reread the original, lots of cutting for rears lol

[VQ]

It's tempting to do to my 760 as the current front bar is stuffed, combined with s90 side skirts and trim and handles and 850 rear bumper...

[suterman]

nice work steve, wtf happened to your tyres?

[Dr Dokeh]

It's not often you see a tyre with rust on huh? :-P

That's the result of a heavily abused tyre with exposed cords plus a slow puncture being left for 11 months.

[hockey930]

Don't know if I love it, but very cool. I am surely glad this has been posted!

[Chris_R]

Some of the 9 series cars had a flat chrome (stainless?) trim piece on top of the bumper, but under the lights... I wonder if that would fit on your bumper and eliminate the gap.

[matt b]

You're doing it better than this kid:
http://volvospeed.com/vs_forum/index.php?showtopic=88293

[Chris_R]

Yeah, I think that car is for sale on TB now.

[Sir Psycho]

Do you have any more information on this? Did the rear bumper ever work, or do you have pictures of how it all looks now?

[hokman]

good look, bumper sticking out far is popular on custom cars in japan

[1990_740turbo]

im thinking aboutdoing this to my 90' 744ti lots of 850s in the yards

[aStrauss]

any shots from farther away, so we can get the full effect? looks cool from what i can tell so far!

[Karlos_UK]

bump for wanting pics ;-)

[Sir Psycho]

Check my project thread.

[Karlos_UK]

yours was ok, this one is more comprehensive

no offence matey :)

[Sir Psycho]

What do you need to know?

Screw the upper part of the 850 bumper into the 940's core support and attach the lower trim.

[Karlos_UK]

erm thank you i guess :wtf:

i was after the pics hosted by the op. i know the basics of it.

[Sir Psycho]

Did you follow the links in the OP?

[Karlos_UK]

yep

again, no intricacies

[Airfrix]

Bump for pics !

(plz use other upload site than before, like imageshack.us because it wont delete pictures after X time)