This weekends work on the 240

[ashvolvo]

It's a long weekend here (ANZAC day), so I've also scheduled to have monday off too, so now have a four day weekend.

We've been so busy working on customer work lately, so there's been no time to work on my 240.

The plan for this weekend is as follows -
* Fit front coilovers
* Cut towers and weld in Kaplhenke camber plates
* Fit our geometry and bumpsteer correction kit
* Modify the front bumper so that it can be easily removed
* Fit front tow hook.

Here's some pics so far

http://www.dvs.net.au/pics/apr0804.jpg

http://www.dvs.net.au/pics/apr0801.jpg

http://www.dvs.net.au/pics/apr0802.jpg

http://www.dvs.net.au/pics/apr0803.jpg

http://www.dvs.net.au/pics/apr0805.jpg

We'll have the LHS done tomorrow, the brakes bled and hopefully the front bumper and tow hook on.
Then ensure everything is fine, and get the ride height set and in for a wheel alignment on monday morning.

I'll post some more pics tomorrow night.

[m4ld0.^]

Your 240 is probably my favorite on the board. So sick.

[boosted]

Your 240 is probably my favorite on the board. So sick.

AND NOT IN THE COUGH COUGH WAY EITHER

[Vee_Que]

Awesome, glad to see your getting down to it, I like the weight saving int he front bumper too, I think I'll do that when I replace my front bumper too, how're you making it easily removable?

[OldSchoolEuro]

That is going to be one SICK car.

[blkaplan]

very nice!

[Volvo244GLE]

mmm sweetness. be interesting to see how you make the front bumper more easily removed. any particular reason for this?

shoot me a PM if your still up for sending me your old strut tops:-P

[crazy0000]

Those look awesome... Making me want to do coilovers so much more.

What would happen if you had the bumpsteer correction spacers on(tie rod), but didn't run the geometry spacers(ball joint)? Would it still correct the bump steer? or would bad things happen.

I ask because I think I remember someone running spacers on their 940 tie rods because they really lowered it.

[ashvolvo]

mmm sweetness. be interesting to see how you make the front bumper more easily removed. any particular reason for this?

shoot me a PM if your still up for sending me your old strut tops:-P

Almost the sole reason for making the front bar easily removable is that with the splitter fitted (it extends 90mm forward of the spoiler) I cant get up the ramps when getting a wheel alignment.

I thought you had a set of strut tops already, if you dont, shoot me your address via PM or email and I'll get them on their way to you.

[ashvolvo]

Thanks for all the compliments everyone.
Its now back on its wheels and everything went pretty well.
I did a quick lap of the black to ensure there were no issues and then took it out for a decent drive. It feels good, but certainly needs a wheel alignment.

Only ran into one issue -
I have 850T5 Columba wheels fitted with 25mm spacers up front and 32mm spacers on the back, however with the lower spring seat where I wanted to run it, it fouls on the tyre.
Simple solution was to fit the 32mm spacers to the front and I'll need to get another pair of 32mm spacers for the rear.

With a set of decent wheels with an appropriate offset this wouldn't have been an issue.

Here's the pcs from today -

http://www.dvs.net.au/pics/apr0806.jpg

http://www.dvs.net.au/pics/apr0807.jpg

http://www.dvs.net.au/pics/apr0808.jpg

http://www.dvs.net.au/pics/apr0809.jpg

http://www.dvs.net.au/pics/apr0810.jpg

http://www.dvs.net.au/pics/apr0811.jpg

http://www.dvs.net.au/pics/apr0812.jpg

We welded nuts into the back of the bumper bar posts and the bumper is now mounted via the allen bolts in the front. There's still the two 10mm bolts holding each end of the bumper to the guards, but its a lot easier to get on and off now, which is really what I wanted.
It'll also be handy to be able to remove the bumper to load the car onto a trailer.

It's now 25mm lower in the front than it was previously.
Heres some measurements and spring specs.

Before:
* Front springs - DVS spec 250lbs, 40mm lower than stock
* Middle of wheel arch to wheel centre - 360mm

After:
* Front springs - 450lbs 10" long coilover spring with helper spring, 65mm lower than stock
* Middle of wheel arch to wheel centre - 335mm

The geometry and bump steer correction spacers mean that the arm and rack ends are in the same place as they were before hand.

450lbs might be a little too firm, so I might try something around 400lbs or so, but I'll wait til the next track day to decide.

[blkaplan]

Before:
* Front springs - DVS spec 250lbs, 40mm lower than stock
* Middle of wheel arch to wheel centre - 360mm

After:
* Front springs - 450lbs 10" long coilover spring with helper spring, 65mm lower than stock
* Middle of wheel arch to wheel centre - 335mm

The geometry and bump steer correction spacers mean that the arm and rack ends are in the same place as they were before hand.

450lbs might be a little too firm, so I might try something around 400lbs or so, but I'll wait til the next track day to decide.

What dampers are you using? How much travel do they have? You might be able to get away with a 450x8 if you use a good spring like an ERS and if they don't have more then 6" of travel

[1stRaven]

Good job there. Looks good.

[ashvolvo]

Those look awesome... Making me want to do coilovers so much more.

What would happen if you had the bumpsteer correction spacers on(tie rod), but didn't run the geometry spacers(ball joint)? Would it still correct the bump steer? or would bad things happen.

I ask because I think I remember someone running spacers on their 940 tie rods because they really lowered it.

bad things would happen :-P

[ashvolvo]

What dampers are you using? How much travel do they have? You might be able to get away with a 450x8 if you use a good spring like an ERS and if they don't have more then 6" of travel

They're Koni Sport #8641-1245.
A shorter spring with the perch up considerably higher might work well.

[RedFridge]

Nice work ma man.
As always...love the ride.

[crazy0000]

Sorry for being ignorant.. But what gains do you get from running a helper spring, when you could just run a longer spring with the same spring rate?

[smosit]

fuggin' sweet! looks good, fancy suspension or not!

have fun,

[ashvolvo]

This morning there wasnt much left to do except give it a quick oil and filter change, and give it a quick wash.

Theres still a couple of things to do before its complete though -
* Wheel alignment (booked in for tomorrow morning)
* clean the engine bay and tidy up around the welds in the towers with drip-check
(No idea if its called that in the US - its a flexible goo stuff that you cover seams with)
* Fit tower to firewall braces
* Fit strut tower brace.

Heres some pics from today -

http://www.dvs.net.au/pics/apr0813.jpg

Heres the difference in ride height.
On the left: 1993 240 wagon with Kings Springs. 30mm lower than stock
On the right: 1990 240 sedan with coilovers. 65mm lower than stock (F) and 40mm lower than stock (R).


http://www.dvs.net.au/pics/apr0814.jpg

http://www.dvs.net.au/pics/apr0815.jpg

http://www.dvs.net.au/pics/apr0816.jpg

http://www.dvs.net.au/pics/apr0817.jpg

And at home in the backyard, just washed.


I'll remove the front bumper again and take it in for an alignment tomorrow morning.

[ashvolvo]

Sorry for being ignorant.. But what gains do you get from running a helper spring, when you could just run a longer spring with the same spring rate?

The helper spring is not of a significant rate, so with the car on its wheels the helper is fully compressed.
The idea is that with a helper spring, the main spring doesnt become untrapped at maximum suspension travel.
I think its unecessary, but wanted to try it out and actually see the benefits of having a helper spring with our own eyes.

[shaved240]

is the tie rod spacer something you guys sell? I need a tie rod spacer made for my 50mm ball joint spacer. Can you make something like this? I know your ball joint spacer is 25mm or something

[Vee_Que]

Nice Ash, glad you finally got around to it, the rake looks awesome and I bet the handling is going to be a lot better.

[xrayjeeper83]

whats the use of the tow hook like that? does it tie into the frame or something else?

car looks sweet

[ashvolvo]

is the tie rod spacer something you guys sell? I need a tie rod spacer made for my 50mm ball joint spacer. Can you make something like this? I know your ball joint spacer is 25mm or something

Yes, it is.
http://www.dvs.net.au/240.html
However, the rack end spacer we sell wouldnt be suitable for your 50mm ball joint/LCA spacer, it'll be too short.

Strength is a concern with longer spacers, both for the ball joint/LCA spacer and the rack end spacer.
Drop me an email if you like and we can discuss it further and look at making something suitable for you.


whats the use of the tow hook like that? does it tie into the frame or something else?

car looks sweet

Previously, the car had no rear tow hook, as the exhaust exits on the RHS where the tow hook used to be.
Some of the clubs that run the track days I compete in are now specifying you need a front and a rear tow hook, so we installed one in the rear bar.

As you know, on a 240 the front tow hook is mounted to the chassis rail, accessible through the front spoiler.

Since we had two tow hooks and I'm always a little concerned about damaging my spoiler/splitter when towing by the factory one, we fitted the left over one to the front.

Both mount through the skin of the bumper, through the aluminium inner and into the bumper bar posts.

[Krisverde]

I truly am jealous of your car. Nice work.

[2fast242gt]

ash i love your car. i may copy your removable bumper idea.. i have the same probblem with my body kit.

[dl242gt]

Nice work on the latest upgrades Ash! Your car is one of my favorites and I always like to see the latest efforts.

Now, when are you going to put a turbo engine in that beast? Nothing wrong with a high power n/a engine. But you know, turbos are so much fun.:oogle:

[2fast242gt]

me likes my N/A engines lotz

[ashvolvo]

I truly am jealous of your car. Nice work.

Thanks heaps. I'm really really happy with it, and more so since getting an alignment done this morning. :)

ash i love your car. i may copy your removable bumper idea.. i have the same probblem with my body kit.

You wont regret it, it really does make life SO much easier.

I removed the bar to get an alignment done this morning, seriously it took 2 minutes and nothing was hard to get at.

http://www.dvs.net.au/pics/apr0818.jpg

Nice work on the latest upgrades Ash! Your car is one of my favorites and I always like to see the latest efforts.

Now, when are you going to put a turbo engine in that beast? Nothing wrong with a high power n/a engine. But you know, turbos are so much fun.:oogle:

It's on the list of things to do, but it'll be a high compression, low boost arrangement.
I've got the bottom end here (B230FB with squirters and B230E pistons), as well as a box of parts for the head but the head still needs machining, a cam, valves, etc.

I'll get the ECU done before its turboed though, and the get the new head fitted to the current B230F bottom end, run it for a while, then swap the new bottom end in and turbo it.

me likes my N/A engines lotz

Me too.
I should make some more power with it before I go to the dark side though. ;-)

[Midgie245R]

Damn Ash, looking really really nice there mate. Your old man was showing me the coilovers when I popped in. Lovely piece of work.

[Crazychopstick]

Tiiiiiiight.

I need to remount my tow hooks too.

[ashvolvo]

Damn Ash, looking really really nice there mate. Your old man was showing me the coilovers when I popped in. Lovely piece of work.

Thanks, we've been working on them for long enough, so to have them fitted to the car is great, it helped out heaps with working out bugs for 'customer' versions, when we're ready to offer them.

Tiiiiiiight.

I need to remount my tow hooks too.

Cheers,
The ones we used actually came from Valley Motorwerks in the US.
http://www.vmwerks.com/proddetail.asp?prod=towtabs

We still need to sort out a strut brace for it, the one we offer will work but would need to be removed to change alignment settings. Since I'm lazy, I'll just design top plates that are a little different.