home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > projects & restorations

Reply
 
Thread Tools Display Modes
Old 08-15-2017, 11:41 PM   #1
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default Project Folvo I guess?? (5.0 240 wagon inside)

I have had a hankering for something different for the past year. I love V8 swaps and hell I love sleepers. Living in CT you would hear stories Paul Newman ripping around in swapped Volvos often but I never gave it much thought until now.

I decided between my shop connections and basic skills I can figure out a SBC swap in a RWD Volvo. I was only thinking SBC because of the great power you can get out of them and the plethora of knowledge on the swap itself.

I started looking for a cheap Volvo shell last week and almost immediately in Stafford Springs I noticed a 85 240 Wagon with a 5.0 HO motor in it!!! I didnt give anyone a chance to grab it before me and drove up there right away with a flatbed.



It didnt run and the interior was filled with trash. Im guessing a few rodents made their homes in this thing. The guy I got it from bought it as a project but never did anything with it asides drive it around a few times. He let it sit for a few years and attempted to fire it up recently with no luck. He claimed no spark but who knows. I brought a jump pack to just hear it crank over which it did.

He believed the motor swap was done by Converse Engineering however I couldnt find any paperwork in the mountain of documents about it. However it does look like a pretty clean install so its very possible.

The body is not in great shape in the rocker areas which hopefully can get addressed this winter. My biggest concern is what kind of shape the motor is in.



Garbage anyone? Believe it not there was some stock Volvo stuff in there NOS goodies an what not



Came with some stock Volvo wheels, not sure if they will hold air or look good though?


My inner Howie Mandel is going crazy right now....


More free stuff...


Continued below.....

Last edited by joedirt; 10-01-2017 at 01:24 PM.. Reason: me fail english
joedirt is offline   Reply With Quote
Old 08-15-2017, 11:47 PM   #2
BR1CKHOUS3
Machine washable
 
BR1CKHOUS3's Avatar
 
Join Date: May 2016
Location: Modesto, CA
Default

Very cool! Would be great to see you cure the rust problem and save it. Where is this located?
__________________
We don't do it for the glory.
BR1CKHOUS3 is offline   Reply With Quote
Old 08-16-2017, 12:15 AM   #3
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

The main reason I jumped on this brick....


Yeahhhh all the extra stuff it came with organized...and I didnt ask about the hairdresser's training doll head, I just shut the trunk and pretended I didnt see it when I loaded it up.


After a serious dewshing inside and out which it still needs again and again it was semi tolerable, now on to the cancer YAY.
Can you even buy replacement rockers and body panels for this thing???





The worst of it..my body shop guys are gonna love me but im hoping they will just kinda show me how to repair it and let me use the shop tools.



I found this mystery switch and also myself connectors hanging from the dash????


The filthy engine bay with lots of wires that I have no clue as to what they go to...


Behold the bone stock 5.0 in all its glory!!!!!







When we attempted to crank it over the starter solenoid stuck engaged so that was replaced. After connecting a jump pack and getting this thing crank it seemed like the motor was hitting something every once in a while. Even turning it by hand with a breakbar. I doubt that its one of the accessories but wont hurt to pull the belt and try it again.

We suspect that maybe a valve is stuck open or something along those lines from sitting for so long. So next task is going to be pulling the valve covers and making sure the valves all move. If that looks like its okay we cant see anything most likely pull the heads and manually crank it over. Luckily my buddy has a set of stock heads we can toss on for the time being to get it fired up.

Thats it for now until I get some more free time
joedirt is offline   Reply With Quote
Old 08-16-2017, 01:13 AM   #4
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by BR1CKHOUS3 View Post
Very cool! Would be great to see you cure the rust problem and save it. Where is this located?
I am in Connecticut home of snow, salt, and lots of oxidation!!
joedirt is offline   Reply With Quote
Old 08-20-2017, 07:21 PM   #5
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default Digging into the motor one curse word at a time

Soooo I think we nailed the reason the motor wasnt turning over smoothly lol. In between work and life I try to sneak in a few hours and there to wrench on this thing at a buddys shop.

We have a suspicion that something in the valve train was a miss so I pulled the valve covers and noticed something odd with #7 cylinder's intake valve. It seemed like it was free floating almost like it was stuck.



My apologies for the huge and crappy pics. Eventually ill get a dslr again.



F this stupid stud...wouldn't come out with a extractor, since im replacing the heads anyway it got diced



Finally got to pulling that head on the driver side...








DING DING DING


So the next steps:
Inspect the head gasket throughly
Try to figure out why that valve stuck and the piston is loaded up with crap
I have a set of spare stock heads I can toss on for the time being

Pull the rest of the accessories and yank the other side apart
Have my mechanic take a look at the cylinder bores and if its worth it to put back together

Last edited by joedirt; 08-21-2017 at 12:49 AM..
joedirt is offline   Reply With Quote
Old 08-20-2017, 11:34 PM   #6
BillyMaysHere
Board Member
 
BillyMaysHere's Avatar
 
Join Date: Jun 2010
Location: San franpsycho
Default

replacement body metal http://www.skandix.de/en/spare-parts...eet-metal/393/
__________________
Quote:
Originally Posted by John V, outside agitator View Post
I am actually the gentlest and kindest of souls, you know that...I wish peace and happiness to everybody
Quote:
Originally Posted by Forg View Post
Was a sandals-and-socks elbow-patch-cardigan-wearing bearded college-professor 10mph-under-the-limit-in-the-fast-lane typical Volvo buyer from 1993 really caring about some sort of limited edition numbering?
BillyMaysHere is offline   Reply With Quote
Old 08-21-2017, 12:16 AM   #7
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by BillyMaysHere View Post
Awesome thank you
joedirt is offline   Reply With Quote
Old 08-21-2017, 06:46 PM   #8
BillyMaysHere
Board Member
 
BillyMaysHere's Avatar
 
Join Date: Jun 2010
Location: San franpsycho
Default


Alot of the stock OD units had ****ty wiring and the switch on the gear selector would fail so ive seen alot of "DIY" switches. As for the blue connector I forget but im pretty sure that it isnt used but here is a foctory "grren book" for your years electrical http://www.volvotips.com/service-man...rams-1985.html
BillyMaysHere is offline   Reply With Quote
Old 08-21-2017, 06:50 PM   #9
BillyMaysHere
Board Member
 
BillyMaysHere's Avatar
 
Join Date: Jun 2010
Location: San franpsycho
Default

^^^ found this, looks like it might be a neutral saety switch bybass https://volvoforums.com/forum/volvo-...t-thats-73465/
BillyMaysHere is offline   Reply With Quote
Old 08-21-2017, 07:09 PM   #10
M.H. Yount
Board Member
 
M.H. Yount's Avatar
 
Join Date: Nov 2008
Location: Charlotte, NC
Default

Following on FB too. Man, if the rust is that bad from the topside, I can't imagine what the bottom looks like. I believe I'd be gathering the useful bits from this one and letting the rest go. Look for a cleaner "donee"....
__________________
'82 242 6.2L; '17 Mazda3; '16 CrossTrek
M.H. Yount is offline   Reply With Quote
Old 08-21-2017, 09:22 PM   #11
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by M.H. Yount View Post
Following on FB too. Man, if the rust is that bad from the topside, I can't imagine what the bottom looks like. I believe I'd be gathering the useful bits from this one and letting the rest go. Look for a cleaner "donee"....
Im pretty stubborn however I know when to cut my losses. Truthfully the undercoating seems to have held up under neath. It has a few a ugly spots but not nearly as bad as you think. I dont mind spending some time this winter fixing it up at my buddy's body shop. But if I start poking around with a screwdriver to find swiss cheese then thats a different story.
joedirt is offline   Reply With Quote
Old 08-21-2017, 09:28 PM   #12
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by BillyMaysHere View Post

Alot of the stock OD units had ****ty wiring and the switch on the gear selector would fail so ive seen alot of "DIY" switches. As for the blue connector I forget but im pretty sure that it isnt used but here is a foctory "grren book" for your years electrical http://www.volvotips.com/service-man...rams-1985.html
Now that I recall in the pile of crap in the trunk I found what looked like a odmeter gear unit that had a matching blue connector on it...thanks for the link ill have to mess around with the switch once its back and running.
joedirt is offline   Reply With Quote
Old 08-21-2017, 10:11 PM   #13
BillyMaysHere
Board Member
 
BillyMaysHere's Avatar
 
Join Date: Jun 2010
Location: San franpsycho
Default

85 should be gear driven, but since its swapped idk
BillyMaysHere is offline   Reply With Quote
Old 08-22-2017, 11:58 PM   #14
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by BillyMaysHere View Post
85 should be gear driven, but since its swapped idk
Im gonna post up a picture of what im talking about to be sure. As this is alllll new to me.


Also my bro in law does powder-coating and hydrodipping so those bland stock valve covers are getting something done to them just dont know what yet . Also was gonna sandblast and powdercoat those boat anchor exhaust manifolds because they look terrible. Getting the family discount as im not pumping any money into this beast until im confident in it.

Come to think of it I wonder how those Virgos would look powdercoated maybe black....
joedirt is offline   Reply With Quote
Old 09-11-2017, 11:02 PM   #15
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default boring with a side of progress

Nothing super exciting but I love the idea of using this post to keep track of what im doing...

So heads came off they were pretty ugly all over. A buddy of mine had a set of freshened up stock E7 heads which suck for performance but will get me by for now. He was nice enough to just give them to me, hell we even ported the exhaust ports because why not lol.

Its a mess at the moment


I apologize for the crappy picture quality eventually ill get a decent DSLR.


Installing the emission's block off "kit" on the back of the heads


Heads are in...setup these studs to assist with keeping the lower intake in place with a ton of silicone in between the heads, because the hell with those cork gaskets. Also new water pump because that one that was on it was not looking too hot.


Lower intake is in...hopefully I loaded up enough silicone guess well find out when it runs Also new thermostat...


Got the boat manifolds all sandblasted up. Had one snapped stud and one stuck 02 sensor which ill have to work on this week when I have time this week.




So right now I need to source a stock fuel rail and injectors. The old stuff on this motor was really crappy looking. And the old fuel was not kind over the years im sure. Not worrying about

Need to get the exhaust manifolds powdercoated.

Also we wanted to get the motor on TDC and noticed something odd, the harmonic balancer was not pointed at the mark and was off. The rubber was deformed and broken on it. Gonna most likely pull it and swap it for a known good one my buddy has to be safe.
joedirt is offline   Reply With Quote
Old 09-17-2017, 09:38 PM   #16
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Found some stock injectors/rail for free that should hold me over for a bit.
Found the balancer was semi shot as the TDC mark was totally off and the rubber was ugly, luckily got another balancer for free.

Need to get those things in and get the valve covers back from the powdercoater. Noticed the radiator was pretty terrible looking so might have to think about one of those soon, I think its the factory volvo radiator but need to confirm it.

Maybe it will run before it snows lol
joedirt is offline   Reply With Quote
Old 09-18-2017, 07:01 PM   #17
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Injectors and harmonic balancer are in


Last edited by joedirt; 10-01-2017 at 01:26 PM..
joedirt is offline   Reply With Quote
Old 10-01-2017, 01:33 PM   #18
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Motor is basically all together...



Needs:
A shorter belt with AC but no Smog
Few random vacuum lines gotta be capped and what not
Radiator
O2 sensors


Biggest issue right now is the fuel pump in the tank is not kicking on. We checked the wires a found no power going to the black wire with the key on. It does kickover with starting fluid however in order to get it into the shop we gotta try to get it running on fuel. Plan is to get juice going to the wires in the tank and get a walbro 255 in it. Bypass the inline fuel pump and just run the intank pump.







Video of it running but running roughly on starting fluid
https://photos.app.goo.gl/Z6ZpsyPHVLA42DfI3
joedirt is offline   Reply With Quote
Old 10-14-2017, 08:35 PM   #19
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

"car ran a few years ago"...more like a few hundred years ago. I got all excited that my DW200 came in the mail on time to work on the 240 this weekend. Pulled the fuel sender with a ghetto rigged puller and found rust rust rust. The old gas in there didnt look too hot either so gonna source a gas tank/sending unit.

joedirt is offline   Reply With Quote
Old 10-14-2017, 09:04 PM   #20
M.H. Yount
Board Member
 
M.H. Yount's Avatar
 
Join Date: Nov 2008
Location: Charlotte, NC
Default

Well, I guess that mess in the tank was predictable.
M.H. Yount is offline   Reply With Quote
Old 10-14-2017, 11:00 PM   #21
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by M.H. Yount View Post
Well, I guess that mess in the tank was predictable.
Don’t mind me just restoring a super common car lol. Definitely wouldn’t be easier to buy another.
joedirt is offline   Reply With Quote
Old 10-22-2017, 11:13 PM   #22
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Hoping to have some extra money this week to order a tank (rock auto) and sending unit (rock auto maybe as well). Plan on loading up the fuel tank with some kind of undercoating or something to protect it. Shame I have a DW200 sitting on the shelf waiting to be installed. Still have to run a new fuel pump relay straight from the mustang ECU since the stock Volvo stuff is a bit of a mess.

Winter in the around the corner and I would love to have this thing driveable to make it into the shop before old man winter shows up

Last edited by joedirt; 10-22-2017 at 11:22 PM..
joedirt is offline   Reply With Quote
Old 10-28-2017, 06:47 PM   #23
Old Iron
I Roll
 
Old Iron's Avatar
 
Join Date: Jun 2009
Location: Dela-Where?
Default

Cool project, it’s not often you come across a swap like this sitting for sale!
__________________
Turbobricked
Old Iron is offline   Reply With Quote
Old 10-28-2017, 07:09 PM   #24
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Quote:
Originally Posted by Old Iron View Post
Cool project, it’s not often you come across a swap like this sitting for sale!
Totally had to grab it since I dont have LS1 swapped volvo money yet lol. The 302 is such a simple motor that I had a feeling even if I had to do major motor work it still would be pretty cheap to get it fired up.

Current status:
Just got a new aftermarket tank (which im gonna undercoat before install, that thing will rot out in no time if not), a used but working fuel sender from a member here (Jack), a DW200 and the stuff to run a separate relay for the single intank pump.

Just need free time to do it all


joedirt is offline   Reply With Quote
Old 11-06-2017, 05:49 PM   #25
joedirt
Board Member
 
joedirt's Avatar
 
Join Date: Aug 2017
Location: Beacon Falls, CT
Default

Progress!

Got this thing to run on its own somewhat now. Got the new tank and all that stuff installed. Bypassed the stock inline pump and filter (there is a filter under the hood). However the line cracked a little bit and will have to be re made under the car. Wired in a new fuel pump relay because I have no clue where the stock ford one is lol.

Found that the timing was off by one tooth but despite it being pretty off it fired up. Didnt have oxygen sensors in and a bunch of vacuum leaks on top of it. Also found a really beat up 2 piece driveshaft and since I had a stock mustang 1 piece driveshaft laying around thats going in, just need to get my hands on a adapter.



https://www.youtube.com/watch?v=ie5CL94WFoE
joedirt 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 04:00 AM.

Powered by vBulletin® Version 3.8.9
Copyright ©2000 - 2017, vBulletin Solutions, Inc.