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Old 05-17-2020, 10:09 PM   #26
atomicdeathmonkey
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So a bit more dirty work today!

I cleaned out the expansion tank and realized that the nice clean coolant is actually in the system, there was just a gunky residue in the tank itself - coolant was grand in the pipes beneath it - I've to make up a bracket to hold the tank but should be grand!

I had a closer look at the wiring and ended up cutting out the bad bits to get started on repairing what's there. There's not too much wrong with the harness except where it seemed to be sitting an inch from the turbo - don't know who thought that was a good idea but we'll get it sorted.

20200517_172837 by V G, Flickr에서

These were the crispy bits!

and the connector from behind the dash to the engine bay was fubarred!

20200517_172901 by V G, Flickr에서

20200517_204057 by V G, Flickr에서

I chased it back throught he dash and snipped it off once I found good wire.

One side of the connector is grand, the other is in pieces - I think I'll replace the lot with a junkyard 8 pin waterpoof connector or just buy new 8 pin connector and put it all together properly.

20200517_174215 by V G, Flickr에서

I also found this thing lounging around in free space in the engine bay - looks like it's vacuum related? either way, it's not doing much with all the holes in it right now - essential or can I delete it ? - I may recreate it using a can of tomatoes from the pantry :D


20200513_184347 by V G, Flickr에서

Also I couldn't help myself - need to get some 5x108 to 5x5/5x 127mm adapters to make it work but should look nice !
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Old 05-17-2020, 10:14 PM   #27
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20200513_184353 by V G, Flickr에서

There were some grooved discs and standardish looking bilstein struts in there !

20200513_184032 by V G, Flickr에서

20200513_184045 by V G, Flickr에서
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Old 05-24-2020, 11:39 PM   #28
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20200523_215840 by V G, Flickr에서

So this is going to turn into a harness that connects the dash to the engine :D

20200523_215835 by V G, Flickr에서

Went with a molex connector for simplicity as I wanted something better than the original volvo stuff, went with 18awg tinned copper wire silicone so very easy to work with and good for 200 degrees - hopefully It's up to the job as the last harness was melted by the turbo - really odd location !

20200523_232014 by V G, Flickr에서

it took an age !

Old Vs new!
20200523_232319 by V G, Flickr에서

oh and picked up a ridiculously huge roof box for the truck !

20200520_214656 by V G, Flickr에서

20200521_180939 by V G, Flickr에서

New bits and bobs - had to use the hair dryer to make the rubber grommet soft enough to push through the bulkhead!
20200521_185604 by V G, Flickr에서

These shrink wrap connectors are a great idea !

20200521_191605 by V G, Flickr에서

20200524_150915 by V G, Flickr에서

In the cabin went with regular connectors.

20200524_150943 by V G, Flickr에서

20200524_162120 by V G, Flickr에서

Wrapped in conduit - I've yet to figure out how to mount it up and away from the turbo but that's the plan!

Rooting around in the passenger footwellI found this connector

20200524_152319 by V G, Flickr에서

Really clean and had a galvanised bracket on the bulkhead - obviously missing a module for something - I'm hoping it's cruise control??

The ecu is still there at least !

20200524_152335 by V G, Flickr에서

So that's where it stands for a while, I'm not hearing any clicking or fuel pump engaging when I turn the key, so have yet to dig out the relay and test that. It's sat for a while and broke down where it was left so maybe a fuel pump / pair of them is in order.


The new house is saking up a lot of time so it may be a while before I can get anything else done on it !
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Old 05-25-2020, 12:05 PM   #29
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yes, the white connector is for cruise control (a black ~6"x6"x1" box, from Dana Corp.), and the crusty can is a vacuum reservoir for the cruise control.

If you don't have one already, get a copy of the Bentley Volvo 240 Service Manual - it does a nice job going through all the k-jet systems and diagnostics.
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Old 05-25-2020, 10:01 PM   #30
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I think I have a digital copy knocking around alright, must charge up the Kindle !

Thanks for the info !

Quote:
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yes, the white connector is for cruise control (a black ~6"x6"x1" box, from Dana Corp.), and the crusty can is a vacuum reservoir for the cruise control.

If you don't have one already, get a copy of the Bentley Volvo 240 Service Manual - it does a nice job going through all the k-jet systems and diagnostics.
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Old 05-28-2020, 04:54 PM   #31
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So, trying to keep the costs down on this as the new house has stolen my wallet - focusing on repairs replacement of as much as possible!

The grille was falling apart so had a go at plastic welding - first time, so focused mostly on rebuilding the broken parts - I'll tidy it up when I get paint to rejuvenate it properly.

20200527_192421 by V G, Flickr에서

20200527_201636 by V G, Flickr에서

Carefully removed some material from this later grille behind the emblem

20200527_201642 by V G, Flickr에서

20200527_201639 by V G, Flickr에서

20200527_202153 by V G, Flickr에서

20200527_201636 by V G, Flickr에서

Let in the bits, step by step

20200527_210654 by V G, Flickr에서

Started thinking on an emblem and wanted to test out the prancing moose before committing to a proper version 20200527_231033 by V G, Flickr에서

20200528_000900 by V G, Flickr에서

20200528_001334 by V G, Flickr에서

2020-05-28_12-22-28 by V G, Flickr에서

Not sure how I feel about it but I don't know I need some filler and more sanding work on the grill lats to make it look decent :D[/QUOTE]
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Old 05-29-2020, 10:39 AM   #32
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I do a lot of plastic welding for volvo parts. What I use as filler is the base material. I save a lot of plastic pieces that normally people trash for this reason. The plastics are all some sort of abs composites(each vary). Go back and keep filling in the area where it needs it. You can go back and smooth everything out with a die grinder or a dremel tool(I've been using a die grinder with a coarse sanding roll). Once everything is smooth out. You can use a primer-filler to smooth out imperfections. I use SEM trim black for the finishing coat.

Example(this repair is not too pretty but it doesn't need to be): Door pocket tab broken


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Old 05-29-2020, 10:56 AM   #33
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Your headlights would benefit from these black out trim pieces. You can make a wanted post and I'm sure someone will have a pair to sell you.

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Old 06-03-2020, 06:08 PM   #34
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Quote:
Originally Posted by white855T View Post
I do a lot of plastic welding for volvo parts. What I use as filler is the base material. I save a lot of plastic pieces that normally people trash for this reason. The plastics are all some sort of abs composites(each vary). Go back and keep filling in the area where it needs it. You can go back and smooth everything out with a die grinder or a dremel tool(I've been using a die grinder with a coarse sanding roll). Once everything is smooth out. You can use a primer-filler to smooth out imperfections. I use SEM trim black for the finishing coat.

Example(this repair is not too pretty but it doesn't need to be): Door pocket tab broken


Awesome 👍 thanks for the tip. I've heard good things about baking soda and super glue of all things !
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Old 06-03-2020, 06:09 PM   #35
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Quote:
Originally Posted by white855T View Post
Your headlights would benefit from these black out trim pieces. You can make a wanted post and I'm sure someone will have a pair to sell you.


Sweet ! Didn't even know they existed!
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Old 06-03-2020, 06:11 PM   #36
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So I finally did more testing of the fuel system. I thought I'd heard the pumps running but it's only the tank one whining away. I tested them both. My only issue now is waiting to get the cash in to replace the main pump and that the tank is three quarters full which I'm sure will be allover my garage floor soon ;)
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Old 06-03-2020, 06:14 PM   #37
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Hopefully your gas tank is in good shape.
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Old 06-27-2020, 06:15 PM   #38
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So sorry for the later update, had a bunch of landscaping land in my lap at the house. We now have a small orchard and vegetable patch in the making as well as a rainwater harvesting system!

I had ordered the pumps about a month ago and got a delivery notification for them, never saw the package arrive despite me having signed for it, still waiting on the replacements.

20200619_200139 by V G, on Flickr

Of course I had drained 99% of the gas out of the tank in preparation- all clean and no rust so may have lucked out, the sender appears to be working and on testing the pumps my in tank one seems to have survived, I'll replace it anyways when I've the system drained. Then hopefully I can get it running. I know the external pump is bad - even without the relay, jumping the connection gives nothing. To be expected after 2+ years off the road I guess.


So mechanicals on pause until parts arrive I turned to the niggly bits I knew I'd live with once the car was driving so tried to get them fixed - the passenger door handle was broken. Drilled it out, tapped it and added an ikea screw and end with some loctite to keep the scandinavian theme.

20200623_155707 by V G, on Flickr

20200623_161321 by V G, on Flickr

20200623_161458 by V G, on Flickr

20200623_161505 by V G, on Flickr

I then moved on to the keys scenario, the trunk, glovebox and doors/ ignition - got the trunk re-keyed and got some copies made and YES! I had to use every, single extension I could find in the garage to undo the trunk lock receiver from the ski-hole in the back seat. I was welcomed with various intake parts, a can of easy start and a rust free trunk pan/wells so very happy there!

20200623_154459 by V G, on Flickr

I finally got the title paperwork sorted last week - my county insists waiting 40 days for any previous owners to lodge an appeal for storage lien title transfers. Given the last time it was in their possession was over 2 years ago and the only hope of them getting ownership again was paying the $16,000 bill for the towing and storage fees I was pretty sure there'd be no contest.

Still waiting on the fuel parts I decided to do something I had the materials/ tools for and give it a bit of a detail.

20200624_200149 by V G, on Flickr

20200624_201951 by V G, on Flickr

Half the reason I wanted this car was it's turbo intercooler setup, the other half was the body. Incredibly straight and rust free. I can't stand paint/body work!

20200624_213524 by V G, on Flickr

Just one layer of finnish kare sealant, buffed. I didn't even polish/ claybar it yet !

20200624_213518 by V G, on Flickr

20200624_213540 by V G, on Flickr

Next up was fitting my momo I've had 15 odd years with my new hub from Estonia - cheap on ebay and seems to fit very nicely !

20200627_155809 by V G, on Flickr

It was last seen in my mk2 golf :D

20200627_162002 by V G, on Flickr

I've a generic horn push ordered, the volvo ones are stupid money and this is a beer change build !
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Old 06-27-2020, 11:23 PM   #39
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Found a set of seat covers local for $20 and they'll do until I go over the interior properly/ until the kids are past incontinence/dropping icecream :D

20200627_173847 by V G, on Flickr

Out came the seats - not too bad a job despite my 6ft2' big arse in there - I think someone had loosedned them up for me. Again astounded to find no rust hiding and I had a peek under the carpets too - nothing thankfully !

20200627_173914 by V G, on Flickr

Found more cable than a radioshack would've had on hand back in the day !

20200627_203612 by V G, on Flickr
20200627_173944 by V G, on Flickr
Then the Baja modifications started...

It's basically a rally car now. Used space- tape, NASA and dollar store approved along with some skinny cable ties to contour fit the quality walmart offerings to the formerly supple leatherette which now has the texture of a 90 year old Floridian's hide.

20200627_205152 by V G, on Flickr

20200627_203654 by V G, on Flickr

20200627_205145 by V G, on Flickr

These skinny ties from dollar store were gold - slipped through the fabric - didn't have to cut any holes !

Then I went to work on removing the cables

20200627_210555 by V G, on Flickr


20200627_210608 by V G, on Flickr

20200627_210618 by V G, on Flickr

20200627_210625 by V G, on Flickr

20200627_211719 by V G, on Flickr

Basically has the grandma look for when I get pulled over.

20200627_211729 by V G, on Flickr

20200627_211807 by V G, on Flickr

20200627_212044 by V G, on Flickr
and for my next act...
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Old 06-28-2020, 11:39 PM   #40
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Heck yeah man, I love what you’re doing. Looks like a great weekend project with rapid results!

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Old 06-29-2020, 08:29 AM   #41
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Quote:
Originally Posted by Vol242vo View Post
Heck yeah man, I love what you’re doing. Looks like a great weekend project with rapid results!

I thought I was taking forever 😂

Just put in a rock auto order, $260 worth of belts, tensioners, ignition,cooling hoses, seals, everything serviceable in the engine bay. Now the real hardship starts. I'm praying it's just the pumps that are bad !
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Old 06-29-2020, 12:47 PM   #42
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20200628_225628 by V G, on Flickr

Had a bit of brown weavy material knocking around - more a test of concept than anything, I'll find something more durable/fitting down the line. The vent plastics crumbles away in my hands and I've no speakers to replace the old ones with just yet so a plain wrap was in order.

20200628_225642 by V G, on Flickr

It's a bit thin but nice material and would look nice for a re-trim of back seat to tie in with the beige - the black and white seat covers not so much !

20200629_113727 by V G, on Flickr

Just sitting there until I can find those vents and some speakers - I'm a bit meh about the color now - might go for something plain black.

or use more of that seat cover material

20200627_235343 by V G, on Flickr

Center console armrest got two headrest covers :D

20200628_194617 by V G, on Flickr

Then I started making a list !

Then I bought the list!

Screenshot_20200628-221755_Chrome by V G, on Flickr

Hopefully that will get her running - the heat here in Texas is killer, so it may take me a while !
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Old 06-30-2020, 09:11 PM   #43
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Well got the plugs out after a good overnight soak in penetrating oil - two different types of bosch an 1 ngk in there. Replaced the plugs with the ngk's - sold tops rather than screw on type - hoping the leads I ordered fit them. Listed as oe replacement on rockauto.

20200630_174634 by V G, on Flickr

20200630_180510 by V G, on Flickr

20200630_170737 by V G, on Flickr

Fresh air filter !
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Old 07-07-2020, 11:44 AM   #44
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20200706_195807 by V G, Flickr에서

Had to do something about the red paint, I know it makes it faster but underhood I just want it a bit more subtle.

Still waiting on my external fuel pump and need to get the bung nut tool to do the in tank pump.
That and a timing belt tool I think I'll save up for next !


20200706_215155 by V G, Flickr에서

Had a bit of por15 lying around so did some painting and rustproofing on the inside lip of the hood - only space I found surface stuff!ldn't get the last elbow of the intake off so it remains red for now !

On the parts list i've fit the distibutor cap, rotor, ht leads, plugs and a new uro relay - my in tank pump is cycling but the in line is dead as disco. So at a standstill till that comes in !

So back to the body:

20200705_201501_002 by V G, Flickr에서

The black trims were quite washed out so a quick dose of vht trim paint and they look about right, wiper arms got a lick of paint and added new wipers too!
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Old 07-12-2020, 06:06 PM   #45
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20200711_211514 by V G, Flickr에서

Only real rust I found in the car other than the aforementioned.

20200711_210951 by V G, Flickr에서

Quick wire brush and a dab of Por15 has her right as rain!

New plastic tray and longer hardware

20200712_155113 by V G, Flickr에서
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Old 07-14-2020, 01:58 AM   #46
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Nice work. Bringing lots of life back into this one. Love the updates.
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Old 07-15-2020, 11:48 AM   #47
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Nice work. Bringing lots of life back into this one. Love the updates.
Hopefully it'll start when all the mechanical work is done. Still waiting on my external pump, have the bungnut tool inbound from a member on here and just got a new distributor from a member too with new wiring - mine wasn't sending out consistent spark.

I really should do the service items too but really ant to hear it running before I go too far !
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Old 07-21-2020, 11:06 AM   #48
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20200720_161244 by V G, on Flickr

Tank pump time, thanks to the member who sent the bung nut tool, at least that bit was easy ! I had a dog of a time getting the nylon line off and then used a barbed splice piece to tap into it with a fresh piece of hose to the pump for the return.

I did try getting underneath with the 14 and 15 mm spanners to release it from the hardline but it wouldn't budge and a bit of pick my battles kicked in. I'm trying to locate the fuel line from pump to the external pump - hard got it seems. Mine is okay a bit wet looking at the external pump end, so I may just end up replacing the whole thing later if I've to order parts.

20200720_171249 by V G, on Flickr

This is what I was greeted with on taking out the sending unit/pump, insulation on wires shagged, pump sock 1/2 eaten alive and the pickup pipe between pump and fuel line completely gone.

20200720_170929 by V G, on Flickr

I've got the proper submersible line to replace it with. New sending unit on the way from autozone, the uro parts one I believe. I'll hunt down the fuel line today - maybe Napa will have it - 11mm I think?

20200720_170927 by V G, on Flickr
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Old 07-22-2020, 11:48 PM   #49
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20200722_193119 by V G, Flickr에서

Well this is an arsepain of a job - I think I've got like 20 small cuts all over my paws :D

Never again hopefully~

20200722_174708 by V G, Flickr에서

I did forget which way the fuel sock went - so I angled it slightly away from the return line pipe.

Oh and I used my old float - figured it's lasted 36 years and god knows what cheap plastic the new one is made with!

20200722_191638 by V G, Flickr에서

Also replaced the fuel line to the external pump (which I've yet to replace), went with regular fuel line to the external pump - the high pressure stuff was 10 dollars a foot, I figured this tiny tank pump is maybe max delivering 2-3 psi?

Checked all the wiring was correct, submersible fuel line fitted between pump and outlet pipe and proper hardware, new bung nut and volvo seal and threw it all back in, at least now one of the pumps is delivering fuel !
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Old 07-23-2020, 03:06 AM   #50
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I'm enjoying seeing the progress. Keep it up. Keep us posted with lots of pics.
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