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Old 12-20-2014, 11:57 AM   #1
Harlard
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Default Pig: '79 242 DL or How To Reinvent The Wheel by Harlard

Background

After flipping one Volvo and crushing two others, having made mistakes and achieved all the performance metrics I have set for them with various degrees of success I have come to find what I really want out of an older model: comfort, the oddball brick styling and design combined with a nice suspension drop and attractive wheel fitment, handling, good sound, and adequate acceleration. All of these dimensions have to work together with relative reliability and ease of service.

In short, I want my cake and to eat it too.

The car

Quick note, big thank you for all of your generosity with parts and help in getting this car where it is now. I would not have been able to get it so nicely sorted without your help:


Crandandall
RvolvoR
ARD Lucky
Duder
pyrosanltd
Lord_Athlon
T8fanning

After disposing of my last 940 I went on a 10-month Volvo hiatus, which was quite a good thing (except for selling my Siemens injectors. They made for a decent joke and would have worked well for my plans, dammit!) as a kid and new job came about. I took the time to focus on what I wanted (see above). Thankfully I made a very good case to my wife (bless her and her saintly patience and grace) for getting yet another old Volvo. This would need to be reliable and cheap to maintain. As luck would have it, Asher (rvolvor) had recently put up his gorgeous 242 on Sawblades for sale. Didn't care much for the Sawblades, but I had been in love with the car for a long while. Soon money was exchanged for the keys and title. The car has solid bones and a lot of the stuff I wanted done to it already, so it made for an excellent starting point.

So now the list if stuff I want to do to it is fairly short!

Current pics












The wishlist

Some proper front seats
T-5 swap
3.73 LSD rear end (scheduled appointment to get this and new trailing arm bushings installed) Done!
front soundstage (currently no front speakers) Done!
Sound insulation...around the doors, rear bulkhead and firewall would be so nice

The current modlist/resto points

1979 242 DL with sunroof


Engine/EMS

2014:
-Poly accessory bushings
-Nathaninwa fuel rail
-Fuelab adjustable FPR
-New throttle cable
-New radiator with B21FT shroud

Early 2015:
91+ PS conversion
AEM failsafe wideband
Knocksense

5/2015:
John Gates 001 gas flowed 530 head (similar to an RSI Stg 1 head)
RSI econo valve spring and Ti Retainer Kit
NPR intercooler with "custom" hotside charge pipe, all couplings are now reinforced silicone
Mandrel 3" downpipe and Magnaflow metallic substrate spun cat going into a 2.5" IPD/TME over axle exhaust
Ported 90+ exhaust manifold with M10x1.25 studs and welded cracks
740T coolant bottle
Forge 007 CBV

08/2015
Summit Racing oil filter relocation kit mounted behind the grille with Fragola swivel fittings
OEM 240T oil cooler


-Siemens Deka 55 lb-hr injectors, new o-rings, baskets from and cleaned and flowed at ARD Tuning
MS2 v3.0
Wiring harness built by Asher (RvolvoR). Uses EZK117/Chrysler Ignition hall sensor distributor and an MSD box for ignition, fueling/load is handled using a 4 bar MAP with MAT correction,
LH 3.1 TPS, wideband 5v correction
stock LH 2.4 CLT
LH2.4 IAC
PID boost control

9/2016
New fuel filter

10/2016:
RSI Stage 2 cam

3/2017:
Uberhoopt's B230F block and crank: rebuilt at NAPA in SE PDX. polished crank and all bearing clearances checked
Glyco std size rod and crank bearings
Deves piston rings
SPM connecting rods
Melling M181 oil pump
IPD oil pump shaft reinforcement collar
IPD oil pump relief valve spring
ARP head studs
Reinz Seals
Reinz gaskets
Ebay 57 Trim turbo with ATP Ultimate Wastegate
Yoshifab motor mounts
do88 740 coolant hoses
New Hepu water pump
Volvo/VDO 10 bar Oil Pressure Sender
Yoshifab catch can
corrugated pipe intake
Honda S2000 OEM air filter
AEM 320 fuel pump
Braided -6AN fuel return
Braided -6AN feed line
Modified sending untit with -6AN fitting brazed
Fuel pump 12AWG wiring upgrade

7/2017: IPD Turbo Cam (Enem V15)

Drivetrain
3/2017: T-5 Swap
Rebuilt 1352-220 Ford T5
Redline ATF
5speeds.com OG cluster gear stabilizer plate
10-spline V8 input shaft
Summit Racing Shifter
Matched speedo drive gearset
Avalanche redblock adapter
Yoshifab speedo cable
Yoshifab steel flywheel
Yoshifab/Clutch Masters FX250 clutch
Yoshifab spaced release bearing
Timken 9103PP pilot bearing
Yoshifab T5 cross member
Polyurethane trans mount
M90 clutch fork
Volvo 260 clutch master cylinder
Volvo 740 clutch slave cylinder
-4AN clutch line in stainless with banjo fittings
New reverse light wiring harness
Shortened/balanced driveshaft with
Jao 940T center support bearing conversion
-3.73 1031 rear end
-Truetrac

Suspension/Steering/Brakes
ESM 002R wheels, 16x8" ET20, running a 5mm spacer up front and 25mm adapters in the back (ET15 and ET-5 respectively) with Achilles ATR Sport 225/50R16 tires
BMW BBS Style 42 wheels, 17x8" ET20 with 215/45R17 Federal 595s
Motorsport Tech 20mm adapters
Ipd front sway bar
240T 21mm rear bar
Homebrew Front short strut coilovers with H&R 2.5x10" 475 lb-in springs
Kaplhenke Rear adjustable spring perches with H&R 5x9.5" 200 lb-in springs
GAZ rebound adjustable inserts
Kaplhenke roll center kit
Kaplhenke strut tower and firewall brace
Kaplhenke split brake line clamps
Kaplhenke brake booster brace
Kaplhenke BNE Select camber plates
Luxesteer
Poly front control arm bushings
Poly torque rod bushings
Poly panhard bar bushings
Poly axle bushings
Heim jointed trailing arms
IPD lower chassis braces
Hawk HPS 5.0 pads front
Hawk HPS pads rear
Mazda FC RX-7 Turbo brake calipers
Volvo 960 11.25" front rotors
Stock rear rotors
Front IPD SS brake lines
Adjustable trailing arms
Adjustable torque rods
Adjustable panhard bar
Suburban billies in back


Electrical/Body
Turbo front spoiler
"TV Screen" rectangular e-codes
Euro side markers
Late battery tray
New style battery and alternator wires
New starter
IPD Skidplate
Denso 100A Alternator
New 91+ windshield
Underhood dynamat (also put the remainder under the trunk)

Interior
Volvo R-Sport Gauge Cluster, with LEDs (restored by Roger, RP80242GT+T on TB)
Felt underdash panels
Mint dash
Rare dash coin tray
Momo mod 8 steering wheel
Audi B5 A5 shift knob and boot
Working moonroof
Stereo (kenwood kdcx592, Alpine V12mrvf357, kenwood 6x9" on back tray, 10" JBL sub, JL 6" components up front)
Late model carpet
New heater valve (adapted new Daimler unit)
New heater core
New blower motor
New heater hoses
Nice map pockets
STS Machining bulkhead coolant hose fittings in stainless
Restored and modified 92 seats with tumblers
New driver's door handle
New driver's door hinge
Freed up window regulators
Custom trunk box for amp and little odds and ends
S60R horns

The stuff that needs my attention

rear butt cheeks have dents
driver door has some missing paint

Old Stuff
-Resealed mystery '77 B21F block
-.027" MLS head gasket. Brought Static compression ratio to 9:1
-Garrett Motorsport GTX2860R with ATP .64 turbine housing (wastegate port has been reshaped) and 3" ultimate wastegate setup under repair...
IPD cam gear


Pics as I have progressed with the car

Picked it up like this from Asher (RvolvoR) in April of 2014. It had a bunch of the basics of what I wanted out of my next car and it was a good deal. Hated the Sawblades so they were the first thing to go (by which I mean, I bought the car with no wheels. Enter the sweet ESM reps!)








Enter new wheels



Yep, they will do nicely. Front end came up and 8" springs were installed afterward
















Rocked it like this all summer. Rear end was clunky, and the wheels weren't filling the fender gaps though...Since then I have been tweaking a bunch of things that I wasn't happy with. Swapped the grille for a prefect one, added H4 headlamps, swapped euro corner lenses, added a Turbo chin spoiler, spaced out the rear wheels 25mm on each side, moved the rear axle forward 15mm, then put in an NPR IC and RSI Stg. 1 camshaft, made the sunroof work again, plus hundreds of other little things. Incremental changes pictured below.
















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Herr Harlard am Erstens

1979 242 DL

Quote:
Originally Posted by t8fanning View Post
My knob has a big chunk of steel on it

Last edited by Harlard; 08-21-2017 at 01:48 AM..
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Old 12-20-2014, 01:15 PM   #2
cosbySweater
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Fix the fuccking grill
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1979 Volvo 244DL 6.0/4l80e,8.8,Ms3x goldbox ecu and Mircrosquirt tcu, s366 clone.
2005 Honda Civic Hybrid, 5 Speed
1991 Volvo 245, so stock it hurts, and I like it that way
1982 Ford Fairmont Futura, 4.8/th400, 8.8, mircrosquirt, 7665 turbo, Project Cheap Thrills

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Old 12-20-2014, 01:18 PM   #3
Harlard
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Find me one and I will.
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Old 12-20-2014, 01:22 PM   #4
Redwood Chair
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http://forums.turbobricks.com/showthread.php?t=303844

http://forums.turbobricks.com/showthread.php?t=290701
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Folks on here don't know a good deal when they see it.
how psi a stock can support?

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Old 12-20-2014, 01:43 PM   #5
Harlard
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As much as I would love some e-codes they are too rich for my blood right now and will have to wait.

That other grille on the other hand though...
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Old 12-20-2014, 01:46 PM   #6
cosbySweater
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They pretty much throw away tv screen ecodes in sweden
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Old 12-20-2014, 02:42 PM   #7
Harlard
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Opportunity cost is high in the Sverige.

One star thread. Nice.
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Old 12-20-2014, 03:06 PM   #8
adomz
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Lovely modlist! Love this car! Shame UK never got these 242's sold here...

Will be keeping an eye on this!

Good job man ;)

Adam
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Old 12-20-2014, 03:11 PM   #9
Harlard
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Thanks Figured that I'd be spending the same money on a newer car so I may as well build up on one of my favorite platforms of all time!
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Old 12-20-2014, 03:18 PM   #10
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Alll that money spent....imagine what pleasure the car would be with good suspension.
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Old 12-20-2014, 03:24 PM   #11
Harlard
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The car is as comfortable as any stock 240. Very compliant suspension with good geometry. Even you would approve if you bothered to make your way down here and drive it.
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Old 12-20-2014, 07:57 PM   #12
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sick pics bro
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Old 12-20-2014, 08:20 PM   #13
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Quote:
Originally Posted by harribert View Post
The car is as comfortable as any stock 240. Very compliant suspension with good geometry. Even you would approve if you bothered to make your way down here and drive it.
My visa is expired for trips to Oregon.
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Old 12-20-2014, 08:33 PM   #14
Harlard
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Quote:
Originally Posted by Josh View Post
sick pics bro
Bro, wash my car and take sweet pics of it with your DSLR bro.
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Old 12-21-2014, 12:02 AM   #15
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Great looking 242! You mention that you replaced the heater valve...what does "M-B" mean in your mod list?
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Old 12-21-2014, 12:14 AM   #16
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Quote:
Originally Posted by harribert View Post
Bro, wash my car and take sweet pics of it with your DSLR bro.
Bro I can wash and buff it, but I don't have a dslr

Edit: bro
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Old 12-21-2014, 12:19 AM   #17
Harlard
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Quote:
Originally Posted by oldschoolvolvo View Post
Great looking 242! You mention that you replaced the heater valve...what does "M-B" mean in your mod list?
Mercedes-Benz! A shop out in Independence, OR has put together a kit using an OE Benz valve made of bronze plated steel. Works a charm!


Quote:
Originally Posted by Josh View Post
Bro I can wash and buff it, but I don't have a dslr

Edit: bro
Bro, do you even photog?

Last edited by Harlard; 12-21-2014 at 12:34 AM..
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Old 12-21-2014, 12:50 AM   #18
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Nah bro
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Old 12-21-2014, 03:30 AM   #19
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Beautiful color, and I love it even more because of the gold bbs-style wheels. More pics pls.
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Old 01-02-2015, 08:24 PM   #20
Harlard
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Ordered a few bits and bobs:

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Old 01-02-2015, 09:52 PM   #21
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Tru trac. Do want.
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Old 01-02-2015, 10:07 PM   #22
Harlard
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Also got myself a near-perfect grille and some veeery clean headlight trim. Plastidipped them. Grille came out great, surrounds not so much. Will be posting that too later
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Old 01-02-2015, 11:04 PM   #23
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Why did you get those cheesy headlights? And pay that much for them.
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Old 01-02-2015, 11:09 PM   #24
Harlard
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I wanted e-codes with clear lenses and steel bowls
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Old 01-02-2015, 11:17 PM   #25
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All these words and no word about what block it has. Sheesh.
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