400 Series sidemarker install

[MistrThou]

Own a 7/9 series? Have a set of 400 side indicators laying around. Well you’re in luck. Here’s how to put them together. This system WILL require drilling into the inner and outer fender. If you don’t feel comfortable doing body work, or paying if you screw up, don’t attempt this modification. A good resource for the install can be found here:
http://forums.turbobricks.com/showthread.php?t=145126&highlight=side+marker+wiring

http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1061.jpg

Ingredients:
2x 400 series turn indicators with bulb sockets and wire tails
2x j-type machine screw nuts. 8-32.
2x 8-32 machine screws (small head with phillips works good, though black ones with a 3/32" hex are available) 3/4" length minimum
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1039.jpg
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2368.jpg
16 gauge wire
1x metal coat hanger
4x butt end connectors
4x piggyback connectors
2x bulbs for indicators (194)
Metal primer



Tools:
String or a plastic scraper
Heat gun (optional)
Drill
#2 Phillips Screwdriver
7/8” hole saw drill bit
7/32” drill bit

Forward
I’ve found a few others to have installed the marker lights “backwards”. That is, they put them on the opposite side of the car, for ease of installation.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2346.jpg
As seen in this picture , there are tiny arrows that should point forward. Thus putting the word “Volvo” towards the front of the car. The reason you need to drill for them, is that there is a mounting tab and a bulb socket on the back side that does not line up with existing hole. http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2347.jpg

It will be possible to cover up the holes drilled again by the original décor plate if for some reason you want to delete this modification, or move it to another vehicle.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1057.jpg


Installation
Begin by removing the old “Volvo” décor plate just rear of the front tire. Easy way I found was to use a piece of string and do a reciprocating motion to “saw” through the old foam and adhesive.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1037.jpg

You will most likely end up with a foam/adhesive residue left. This can be removed a number of ways. I just rubbed my finger over it repeatedly till it came up. You can also use a chemical adhesive remover. After doing so, you’ll end up with something like this:
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2344.jpg
*As a note: Some of my pictures look like there's adhesive left over. That's just the edge of the clear coat when someone repainted the car and didn't remove the emblems to do it proper.

The next step is to drill into the fenders for a hole to mount to, and to get clearance for the mounting tab and bulb socket.
I began by putting the j-clip into the existing hole as far rearward and centered as possible. I used that for my left to right guide. Centered, I drilled a hole for the machine screw.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1041.jpg
TADA:
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1042.jpg

Next, I measured the distance of the bulb socket from the screw hole on the indicator.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1043.jpg

Then I translated that measurement to the sheet metal and marked the closest edge with a chisel.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1044.jpg
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1045.jpg

The next step then was to drill an appropriately sized hole that would give enough clearance for the bulb socket to fit through. A 7/8” hole saw bit worked good. I used the mark from the chisel to be my guide for the inside edge of the hole saw. That left me with a hole like this:
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1047.jpg
As a note, the bulb socket would not clear the inner fender, so I drilled straight through that as well. The inner fender is not flat, so some skill was needed to cut through it at an angle.

The inner fender uncut is like this;
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1054.jpg

With those two holes now drilled, I could gently screw on the indicator and mark where the tab lined up. The tab is tapered with a little catch, that helps hold the front of the indicator in the sheet metal. Here’s the hole drilled with a machinists rule.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1055.jpg

With the holes all drilled, next came the wiring. I used a metal coat hanger to fish the wires between the inner and outer fenders. Theres a plastic plug under hood part way back that can be removed and the coat hanger straightened out with wire taped to it can fish back to the new holes you made.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1023.jpg
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1058.jpg
Here’s the coat hanger on the opposite side of the car. The plug is in the same place.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2355.jpg
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2356.jpg

Once the wires are run, connect them as shown:
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1059.jpg

For wiring, I followed the brickboard.com instructions. Here’s the schematic.
http://www.brickboard.com/FAQ/700-900/Images-Parts/SidemarkerWiring.gif
Other install info can be found here: http://forums.turbobricks.com/showthread.php?t=145126&highlight=side+marker+wiring

With the wiring and drilling done, next step is to place the bulb into the socket, the socket into the marker, snap it in place, and screw it in.

Voila,
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1026.jpg
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF1060.jpg


Final touchups
Here I added a black screw to each side as a suggestion.
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2371.jpg
http://i162.photobucket.com/albums/t246/MistrThou/Red%20944ti/DSCF2372.jpg

-Travis

[wisturbo]

Nice write up Travis!! :cheers:

[orie]

Vgood, i will be doing this soon. :)

[buzz]

Can I have my lights back? :rofl:

[MistrThou]

Can I have my lights back? :rofl:
:wtf::omg::grrr:

[n. rippe]

Did the adhesive come off? I have a set to install, I'm thinking soaking that area for a couple of days with goo-gone before I try and take off the emblem.

[MistrThou]

I literally just rubbed my fingers across the adhesive and it sorta balled up/rubbed off.
The remnants you're seeing on mine is the edge of the clear coat when someone repainted that side.

[MistrThou]

Will my pictures be uploaded to the forum, or do I need to keep that photobucket account open (no big deal)?

[CHESH740R]

Very nice write up you've done there, if anyone else is interested in installing these, i have several sets of these 400 series side markers available that i grabbed whilst in the junkyard.

$20 shipped via airmail to your door will get you a set, PM me for details.

[pinguin]

Travis, the only change I would make would be black screws

[MistrThou]

Travis, the only change I would make would be black screws

Store didn't have em. My wife said she had black nail polish, but when I checked, she didn't. I may go buy some still.

[psy]

very nice, just to add though I just installed mine using spring loaded butterfly nuts works great didn't drill anything and they don't sit that much further up.

[MistrThou]

very nice, just to add thought I just installed mine using spring loaded butterfly nuts works great didn't drill anything and they don't sit that much further up.

What did you do with the small black plastic tab?

[psy]

What did you do with the small black plastic tab?

you mean the little push in part? if so I just cut it off to make it all flat, marker sits perfectly flat and I haven't touched it almost 2 years.

[Chris_R]

Great write-up - thanks!

Could you not remove the front nub and use double-sided tape to install them without drilling?

Maybe epoxy in the head of a black screw (or an LED) into the screw hole?

[MistrThou]

Great write-up - thanks!

Could you not remove the front nub and use double-sided tape to install them without drilling?

Maybe epoxy in the head of a black screw (or an LED) into the screw hole?

You either need a hole or to nip the nub off. Remember the bulb has to go through a hole.

[MistrThou]

Edited:
Changed screw size and added identification pictures.
Changed bulb number to 194
Added post-black-screw pictures at Eugene's suggestion.

I'll give it a few more days, then submit it to dana.
Anyone know if I need to upload the pictures to TB? Or can I leave em photobucket?

[MistrThou]

you mean the little push in part? if so I just cut it off to make it all flat, marker sits perfectly flat and I haven't touched it almost 2 years.

Great write-up - thanks!

Could you not remove the front nub and use double-sided tape to install them without drilling?

Maybe epoxy in the head of a black screw (or an LED) into the screw hole?
Same sort of ideas. But I didn't like how far forward or rearward it would have put the markers. I liked using the "stock" area which the decor plate was in.

[BlueSwede]

Cool write up.. does anyone know of any other badges(VOLVO) with the turn signal integrated into them..these may be the ones I have been looking for but for some reason I remember ones that kinda look like the fender badges on old 242's.

[psy]

Cool write up.. does anyone know of any other badges(VOLVO) with the turn signal integrated into them..these may be the ones I have been looking for but for some reason I remember ones that kinda look like the fender badges on old 242's.

To my knowledge these are the only ones, As to answer the other question about how to mount them I used double sided issue with that is when you need to take them off its a pain as you have to retape them and take a chance to mess up the paint.

[MistrThou]

To my knowledge these are the only ones, As to answer the other question about how to mount them I used double sided issue with that is when you need to take them off its a pain as you have to retape them and take a chance to mess up the paint.
Yup, I just unscrew the one screw and pop the front tab out to replace the bulb.

[BlueSwede]

Same sort of ideas. But I didn't like how far forward or rearward it would have put the markers. I liked using the "stock" area which the decor plate was in.
How about on a 240, will not drilling put these way off?
Anyone with pics of these on a 200 series???.
This is actually one of the last "external mods" I wanted to make..well besides a paint job..

[MistrThou]

How about on a 240, will not drilling put these way off?
Anyone with pics of these on a 200 series???.
This is actually one of the last "external mods" I wanted to make..well besides a paint job..
:e-shrug: Never owned anything that wasn't a grandpa mobile.

[Anatoli]

very nice.
i have installed saab amber lights on my 95 940 a while back.
i chose to have a flashing set up.