1977 Volvo 242 project-b6304/T5

[rms]

Originally Posted by itlksez

Nice project!

I wish you weren’t on the other corner of the country, I’d gladly take that drivetrain off your hands.

Thanks! Yes, I’m learning it’s definitely easier to be a TB’er on the West Coast.

[rms]

So apparently the rear seat bottom is different between a 77 242 and a 90 244. The 90 (left) has some curves in it, while the 77 is flat. No problem, I swapped the 90 fabric onto the 77 foam and it fits perfectly. The seat backs look almost identical, so I don't anticipate any issues using the 90.

Also, had some more goodies show up from Ben and Taylor.

[volvoracer82]

Awesome! looks like a solid project. those later seats look like they are in good shape, don't look like they have the "gangster lean" going on. If you don't already know, take the locking mechanisms from the early seats and put them in the later seats so you have easier access to the back seats. I think there is a write-up on that mod somewhere.

[rms]

Originally Posted by volvoracer82

Awesome! looks like a solid project. those later seats look like they are in good shape, don't look like they have the "gangster lean" going on. If you don't already know, take the locking mechanisms from the early seats and put them in the later seats so you have easier access to the back seats. I think there is a write-up on that mod somewhere.

Thank you! Yes, I need to look into swapping the locking mechanism, or I may just swap over the better foam...TBD.

[rms]

Out with the old, and in with the SuperPros. Never seen bushings in such bad shape. I just love my HF 12ton press, it makes replacing bushings so easy!

[Vol242vo]

Are those BNE coilovers? Did you go standard or short? What inserts are you using?

[rms]

Originally Posted by Vol242vo

Are those BNE coilovers? Did you go standard or short? What inserts are you using?

They are STS coilovers, 2” shorter made for Saab 900 inserts. I have the Bilstein B6 inserts with 300lb springs...we’ll see how they do.

[240wagonguy]

Nice project. Consider your transmission choices. Deeworks makes the ones for a T5 and a CD009. With the T5 adapter you have to engineer the clutch actuation solution. The CD009 is already designed to use an LS1 throwout bearing. However if you are on a budget the cost is much lower with the T5. I joined a bunch of local mustang parts groups on facebook and eventually came up on a deal for a V8 foxbody T5.

[rms]

Originally Posted by 240wagonguy

Nice project. Consider your transmission choices. Deeworks makes the ones for a T5 and a CD009. With the T5 adapter you have to engineer the clutch actuation solution. The CD009 is already designed to use an LS1 throwout bearing. However if you are on a budget the cost is much lower with the T5. I joined a bunch of local mustang parts groups on facebook and eventually came up on a deal for a V8 foxbody T5.

Thanks, the CD009 looks to be ideal. However, I already have a spare T5 and the DeeWorks plate. I’m planning a Tilton hydraulic t/o bearing with the STS hydraulic clutch pedal. Hoping it all works together well.

[rms]

I was able to finish up the boxing on the front control arms and get them painted. Just need to push in the SuperPros and they’ll be all set. On a side note, the bushings on these are not easy to get out. I couldn’t press them out due to the shape of the control arm, so it resulted in drilling out the rubber and chiseling out the shell.

[Vol242vo]

They look great! What are you using for paint?

[rms]

Originally Posted by Vol242vo

They look great! What are you using for paint?

Thanks! Spray bomb satin black.

[rms]

I started boxing the rear trailing arms today.

[MikeJr.]

You live in Acworth?

[rms]

Originally Posted by MikeJr.

You live in Acworth?

Yes Sir.

[rms]

Pressing these Super Pro bushings in = not fun.

[rms]

This is really the only rot on the car. That said it’s pretty horrific, and the contours are going to make it hard to make from scratch. Anybody got a parts car 242 they want to cut this section out for me? Long shot...yeah.

[MikeJr.]

Originally Posted by rms

Yes Sir.

Have we met? We should meet up.

[rms]

Originally Posted by MikeJr.

Have we met? We should meet up.

We have not, and that’d be great. I’m new to the Volvo scene.

[Old Iron]

I need to find myself a 242 that someone has gone through like this. Great project.

[Turbo3er]

Looking really good so far. what's going back into it for drive train?

[rms]

Originally Posted by Turbo3er

Looking really good so far. what's going back into it for drive train?

Thank you. A 6 cylinder from a 97 960 with a Mustang T5 transmission is going back in.

[rms]

Today has me discouraged about using this b6304 from the 960. I pulled the majority of the wiring harness out, but to convert this to stand alone for the 242 is overwhelming. There is just so much wiring. I need to take a step back from that and continue to work on the chassis...there is still plenty to do.

[stevecole33]

Don't be discouraged by wiring. Landing wires from injectors, coils, etc to the ECU is easy. Making it pretty can be time consuming. Tuning is my current issue.

[DET17]

Originally Posted by stevecole33

Don't be discouraged by wiring. Landing wires from injectors, coils, etc to the ECU is easy. Making it pretty can be time consuming.

+1

I'll suggest you get the actual wiring harness for your 242, and the other for the 960 engine management. Work between the two wiring diagrams to determine exactly what needs to be connected. I want to believe that the vast majority of the cabin wiring, climate controls and such, simply need 12V, fuses and grounds to continue to function as designed. Where your marriage of systems will get complex is the dash cluster and connection to the engine. Getting speed, rpm functional with your ancient analog instrument cluster will present some challenges.... but has been done many times.

These projects are like eating an elephant: cut off a piece, chew, swallow.