home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > projects & restorations

Reply
 
Thread Tools Display Modes
Old 08-29-2019, 06:03 PM   #1
IansPlatinum
Board Member
 
IansPlatinum's Avatar
 
Join Date: Jul 2018
Location: Texas
Default "Boat", the 1992 240 Wagon

Starting this thread primarily to organize my plans and goals, and document progress along the way.

I use this car mostly as a utility vehicle, like I would an enclosed (90s & early 2000s) Ford Ranger or Toyota Tacoma. It also gets used for any major travel outing or camping trip.
Therefore, my goals are primarily related to achieving durability, reliability, utility, gas mileage, & comfort.

Goals:
-maximize MPG while simultaneously maintaining utility and soft-road ability
-improve reliability and durability
-mild lift (1"-2" Front & Rear)
-improve traction
-add ancillary components to improve camping & travelling
-explore the US!

I have no desire to increase power or acceleration if it means a sacrifice in fuel economy (begin the boos and jeers of TB).

I acquired the vehicle July of 2018. I drove it around and instantly fell in love. I was hesitant to even try a 240 at first, because my first and only brick prior to this one was a 92 940T, which I didn't like very much (and soon after sold).


How it looked when I bought it... It had FWD wheels on that rubbed and were mounted with non-hub centric spacers in the rear (wobble wobble) and HOME MADE CUT DIAMOND PLATE spacers in the front... needless to say the highway wobble and vibration was real. I pulled the wheels after getting it to find that the rear OEM studs had been hammered out and replaced with longer ones that weren't a press fit into the hub... they just wobbled around loosely in the stud holes. Friction was the only thing allowing the lug to be tightened...



After putting the correct OE wheels back on (after sourcing good used rear hub studs and installing them)


And how it appears now, with powder coated wheels, some small spring spacers of front, overloads in rear, and goodyear tires.


Here's the work that's been done so far (pics to be uploaded soon):

Installed new Taxi control arms, superpro poly FCA bushings with zerks, and new ball joints (driver side is greasable moog unit, passenger side lemforder)
(checking for colinearity)

rear FCA bushing has 2 zerks, one that goes thru a hole on the bushing to the sleeve, another to fill the outer voids.


front FCA bushings have 1 zerk, required some clearance cutting on bushing.




IPD panhard rod drilled & tapped for zerks



New lemforder inner tie rods and moog greasable outer tie rods, new bellows

New Gates blue timing belt, tensioner, round tooth gear set, water pump, solid cam pin, new temp sender for ECU

New plugs, wires, dist, rotor. New coil (not installed, keep it in the trunk as a back up)

Refurbished injectors from GB reman (keep old injectors in trunk as spares)

Denso from Philski



Aluminum Yoshifab accessory bushings (beware, must add washers for late style PS pump- already pointed it out to yoshifab, they said they'd make me some proper length ones but then went silent... oh well, washers work too), new tensioner screws on all accessories, new Volvo brand drive belts




Intake manifold removed and power washed, then sand blasted on inside/outside

New carpet (aftermarket) - not a perfect color match but close enough





Adhesive anti-fungal closed cell foam added behind spare tire - idea from RWC's lumber wagon build. This wheel is now powdercoated silver with a new tire.


New driver's seat vinyl (swedish car parts)

5 New 195/75R14 Goodyear Wrangler AT tires, powdercoated OE 14" steelies




IPD front SS brake hoses (good thing I did!) & EBC redstuff pads, brembo rotors, typ200 brake flush



Helle supertones (want to repaint guards black... hate the red)

Bilstein touring shocks in rear, IPD overload springs

BAFTRs (adjustable torque rods assembled from greasable Johnny Joints & swedged tubes)


Radio replacement & relocation (took out crappy 2007 alpine radio, put in VDO unit)

Installed Gauges, VDO 360-028 pressure sender (M14x1.5, no adapter needed), vacuum tee


Inner window scrapers replaced

Front windows tinted with Suntek Ceramic tint, 25%, rears done under previous ownership, 10-15%


Changed instrument panel back face and gauge faces to older 80s style satin- the matte '92 gauge faces develop this weird residue and look like crap. The satin looks niiiiiice.... but my odometer is a little misaligned with the odo window now, cuts off the tops of the numbers and last decimal. Also installed Large Tach & small clock. Temp faker bypass


Custom over-axle exhaust. Mine would rattle on axle during high articulation.

Side-facing tailpipe (hopefully cuts down on hatch dirt a little...)

Installed rear muffler (car came with it removed & straight piped, highway drone SUCKED)

Headrest inserts (will reupholster in blue eventually but black is pretty inconspicuous for now)

Relocated O2 sensor and added bung for wideband

Updated computer to 9XX series ECU

Mann air filter, replaced airbox (old one had crack AFTER filter), PCV system, vacuum lines

Silicone radiator hoses & coolant flush

12L ATF flush - volvo dex III fluid


New volvo motor mounts (old ones weren't that bad... oh well)


New OD relay & fuel relay

New fuel pumps (both) and filter, good thing too... in-tank pump had a ripped sock, didn't work, and wasn't even plugged in.




AC recharged with redtek 12a (hydrocarbon), high pressure switch bypassed (to enable constant pusher fan use while snowflake switch is on)

Acoustic foam on exposed sheet steel to reduce cabin noise

Optima yellow top - for when I install cabin evac fan


And work to be done in the near future:

install Ben's spherical TABs
rear pads & rotors (currently warped)
Hatch hinge re-alignment (maybe replacement too...) & wire harness replacement
preemptively replace CPS, keep old one in trunk
have rear axle rebuilt & install Trutrac LSD, driveshaft U joints
Install rear lift springs & vanagon shocks
Ben's extended coilovers & strut mounts
redesign trailing arms & spring perch
install STS hd center support bearing
New battery cables
Install inverter
install cabin evac fan setup
sand down rust near hood hinges and below battery tray, respray with color matched white
replace rattly knock off front muffler with either straight pipe or glasspack or other
roof racks / roof basket
LH 3.1 conversion
T-cam & reshim, rear cam plug & retainer
taxi ball joint plate


spare gas tank sealed & repainted
__________________
'96 854 Platinum - "Trusty"
'92 245 - "Boat"
'71 145 - "Rusty"

Sold:
'73 1800es - "Sunny"
'92 940T
'98 S70 T5
'99 S70 GLT

Last edited by IansPlatinum; 08-29-2019 at 07:44 PM..
IansPlatinum is offline   Reply With Quote
Old 08-30-2019, 10:23 AM   #2
IansPlatinum
Board Member
 
IansPlatinum's Avatar
 
Join Date: Jul 2018
Location: Texas
Default

Glam shots from march:

Some glamping in Austin



Only one to attend volvo meetup that got cancelled due to rain :(

IansPlatinum is offline   Reply With Quote
Old 08-30-2019, 10:30 AM   #3
basicbrick
Board Member
 
Join Date: Jan 2019
Default

real nice pictures and attention to details.
__________________
98 P80 NA: sold
86 240 sedan m46 sold
92 245 wagon, NA, white, non op
92 940T donated, now has LS swap
97 850 NA Wagon
89 244+T beige from Oregon
93 945 Regina
basicbrick is offline   Reply With Quote
Old 08-30-2019, 11:57 AM   #4
Centsableone
SNAFU - BOHICA
 
Centsableone's Avatar
 
Join Date: Oct 2011
Location: Memphis, TN USA
Default

Nicely Done!
__________________
1983 245T, 1986 244, 1990 745T, 1990 245, 1982 4- speed 245D,
Currently: 1992 244

Sale and Purchase Feedback


Centsableone is offline   Reply With Quote
Old 09-02-2019, 10:09 PM   #5
IansPlatinum
Board Member
 
IansPlatinum's Avatar
 
Join Date: Jul 2018
Location: Texas
Default

Some good wagoning this weekend at Hagerman wildlife preserve
IansPlatinum is offline   Reply With Quote
Old 09-14-2019, 06:29 PM   #6
IansPlatinum
Board Member
 
IansPlatinum's Avatar
 
Join Date: Jul 2018
Location: Texas
Default

Not much today, just an oil change and engine bay scrub & shine.


T-cam procured, up next is a cam swap, shim job, new rear plug & retainer, etc... maybe even an adjustable cam gear
IansPlatinum is offline   Reply With Quote
Old 09-14-2019, 07:44 PM   #7
smoothdurban
I do my own stunts
 
smoothdurban's Avatar
 
Join Date: Jan 2013
Location: LaSalle ON
Default

Looks good Ian. Hopefully that T cam met your expectations.
__________________
1983 242 Turbo w m46 142,000 km's B230FT LH2.4
1991 240 Wagon w m47 Winter DD 440,000 km's!
2005 S40i Sedan w M56 Summer DD with 140,000 km's

Last edited by smoothdurban; 09-16-2019 at 06:40 AM..
smoothdurban is offline   Reply With Quote
Old 09-15-2019, 11:49 PM   #8
IansPlatinum
Board Member
 
IansPlatinum's Avatar
 
Join Date: Jul 2018
Location: Texas
Default

Quote:
Originally Posted by smoothdurban View Post
Look good Ian. Hopefully that T cam met your expectations.
It was packaged very professionally and I'm sure it will give me the low end oomf I'm looking for.

Also, I hit the mecca of 240 mileage today:

IansPlatinum is offline   Reply With Quote
Old 09-17-2019, 02:01 PM   #9
Estateman
K-Jet or Bust
 
Estateman's Avatar
 
Join Date: Jan 2018
Location: Dallas, TX
Default

Quote:
Originally Posted by IansPlatinum View Post
Not much today, just an oil change and engine bay scrub & shine.


T-cam procured, up next is a cam swap, shim job, new rear plug & retainer, etc... maybe even an adjustable cam gear
Wow... that engine bay looks incredible. You're gonna have to teach me how to do that! Why did you choose a T cam for this one? I've got an A cam and adjustable timing gear sitting in the garage waiting to go in myself.
__________________
88 245 - M46 3.73 Gears
>>FEEDBACK<<
Estateman is offline   Reply With Quote
Old 09-17-2019, 02:11 PM   #10
R-Pow3R3d
Master of Disaster
 
R-Pow3R3d's Avatar
 
Join Date: Sep 2018
Location: Pittsburgh, PA
Default

What'd you use to do the engine bay cleaning?
__________________
1990 745 Turbo Intercooler
2004 V70R M66
2007 XC90 V8 Sport
R-Pow3R3d
R-Pow3R3d is offline   Reply With Quote
Old 09-18-2019, 04:30 PM   #11
IansPlatinum
Board Member
 
IansPlatinum's Avatar
 
Join Date: Jul 2018
Location: Texas
Default

Quote:
Originally Posted by Estateman View Post
Wow... that engine bay looks incredible. You're gonna have to teach me how to do that! Why did you choose a T cam for this one? I've got an A cam and adjustable timing gear sitting in the garage waiting to go in myself.
T cam for low end torque. Y'all can tease all y'all want, but this engine rarely gets revved over 3K. It's a utility car / highway cruiser / camping car, not a racer. The T cam is supposed to result in larger dynamic compression & expansion ratios and shift power band a little lower, sacrificing high end revvability.

Will also probably install phenolic intake manifold spacers to reduce charge heating, which also helps with low end torque, but I'll have to delete my EGR system when I do that because the pipe won't line up any more.

Quote:
Originally Posted by R-Pow3R3d View Post
What'd you use to do the engine bay cleaning?
Just CRC degreaser, rinse with water (pressure washer is the best option), dry, and gunk engine shine. Be sure to remove battery first. Wipe off engine shine from painted surfaces with a dry cloth. It helps that I also sand blasted the inside and outside of the intake manifold when I took it off to service the PCV system, and have cleaned it before several times. That's the biggest one. Just repeat and regular cleanings, maybe once every 3 months. IPD belly pan helps keep the dirt out too.

If you use the pressure washer, be sure to follow up with a leaf blower on all electronic connectors to make sure there's no standing water. Also best to do it on a sunny day and let it sit for a bit to dry.
IansPlatinum is offline   Reply With Quote
Old 09-18-2019, 05:12 PM   #12
R-Pow3R3d
Master of Disaster
 
R-Pow3R3d's Avatar
 
Join Date: Sep 2018
Location: Pittsburgh, PA
Default

Quote:
Originally Posted by IansPlatinum View Post
Just CRC degreaser, rinse with water (pressure washer is the best option), dry, and gunk engine shine. Be sure to remove battery first. Wipe off engine shine from painted surfaces with a dry cloth. It helps that I also sand blasted the inside and outside of the intake manifold when I took it off to service the PCV system, and have cleaned it before several times. That's the biggest one. Just repeat and regular cleanings, maybe once every 3 months. IPD belly pan helps keep the dirt out too.

If you use the pressure washer, be sure to follow up with a leaf blower on all electronic connectors to make sure there's no standing water. Also best to do it on a sunny day and let it sit for a bit to dry.
Good stuff, thanks! I'm pretty fearful of turning the pressure washer on towards the engine bay of a car from the 90's (let alone my 04). I have considered using the foam cannon, though.
R-Pow3R3d is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


All times are GMT -4. The time now is 05:33 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.