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Old 10-04-2019, 04:04 PM   #1
vSleeper
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Join Date: Oct 2019
Location: Raleigh, NC
Question 240 LS1 Swap - vSleeper (I like the name...)

The vSleeper Build:
I am starting this new project and want to solicit comments, advice and observations from the community here. Feel free to say whatever you think may help me along the way. I have a good deal of mechanical experience but also know when to let a pro do something too. I put together my thoughts below if you have the time and interest. This will likely take me 6 months given work (bleh) getting in the way. I will post as I go in return for solid advice! I am in the Raleigh NC area.

History:
“Back in the day” I had a 240 Turbo model with manual trans in white. I miss that old car; it was fun and simple to work on too. With that in mind, I want to build a more modern example with some similarities and some differences. Here is what the old one looked like:
Click to see image

My Build Car:
Recently purchased 240 DL, 4 doors automatic with 250k miles. Nice wheels! Still runs but not well although that does not matter. Bought it for the body which is rust free, straight and solid. Hood is up a bit but that just needs an adjustment. Engine compartment welds/seams are nice still. Here is the first pick of that:
Click to see image

Engine is B230FS1.

Project Goal:
Reliable daily driver that is mostly plain on the outside except for the turbo wheels and maybe a turbo badge in the grille.
Engine will be LS1 with 3rd party engine mounts. Wiring harness will be from donor car (I have help on this item) or will purchase a 3rd party pre-made.
Not decided on manual or automatic as I have driven both long enough to know the pros and cons. Weigh in here if you have an opinion.
Must have AC and decent sound system + USB charging port.
Want to replace the 90s grill with 80’s style 4 headlamp setup:
Click to see image

I will send the seats out to get redone and replace the carpet (black) and headliner myself. Door panels may be good enough for now.
Exterior Color: White
Interior Color: Black dash/panels with cloth dark blue seats
Click to see image

Will replace all rubber components and update the suspension, brakes and exhaust myself.
Power windows and locks work but need to be cleaned and lubed.
Window seals need all new rubber parts as they are there but cracked and hard.
Dash needs attention but not critical at first.
Not sure about rear differential yet, but on my mind.

Budget: 10k
- Spend so far:
o Car: $900
o Trailer rental $115

General Steps:
• Strip car down (bag and tag everything)
• Remove drive train (have engine lift)
• Locate donor car (need to figure this one out to keep purchase cost low as possible but not end up with something unreliable)
• Acquire engine mounts and harness (harness tbd)
• Body needs very little work but is red so I will need to get that done. I used to paint myself but those days are over.
• Upholstery, Carpet and headliner
- EVERYTHING ELSE I DID NOT LIST!

Last edited by vSleeper; 10-04-2019 at 04:10 PM..
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Old 10-04-2019, 04:07 PM   #2
white855T
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First thing to do on a old 240. Lubricate your hood hinges and also your door hinges. People never do this. If you don't lubricate hood hinges, you can damage hinges and damage hood. If your hood is sticking up on the rear corners, it's very likely the hinges are already damage which require replacement(second hand, best option).
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Last edited by white855T; 10-04-2019 at 04:15 PM..
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Old 10-04-2019, 04:30 PM   #3
DrHutch
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I can agree with the hinges. I went through two sets. One set snapped on my when I was driving.

If you’re looking for good condition black interior, back seat, there is a 86 in the Greenville pick n pull. It has pretty decent clean interior. Odometer said 49k.
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Old 10-04-2019, 07:24 PM   #4
vSleeper
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Hey white855T and DrHutch. You are indeed correct. The door hinges are crazy stiff and squeaky. I will definitely lube them up before bad things happen. I do agree the hood hinges are likely a problem but I need to look at them closely to see. Appreciate the tips guys.

The Greenville pick n pull is a good tip. I will look into it. Could be a fun weekend trip. Junk Yard, BarBQ and Beer. Like a perfect weekend.
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Old 10-04-2019, 07:29 PM   #5
DrHutch
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Quote:
Originally Posted by vSleeper View Post
Hey white855T and DrHutch. You are indeed correct. The door hinges are crazy stiff and squeaky. I will definitely lube them up before bad things happen. I do agree the hood hinges are likely a problem but I need to look at them closely to see. Appreciate the tips guys.

The Greenville pick n pull is a good tip. I will look into it. Could be a fun weekend trip. Junk Yard, BarBQ and Beer. Like a perfect weekend.
I literally just did the same thing yesterday haha. Junkyard, BBQ and beer haha.
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Old 10-04-2019, 07:31 PM   #6
vSleeper
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Dang, you should have called!
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Old 10-06-2019, 10:39 AM   #7
Redwood Chair
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Folks on here don't know a good deal when they see it.
how psi stock cna support?

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Old 10-10-2019, 06:44 PM   #8
vSleeper
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Default Teardown Progress

Engine is out. Interestingly there were no problems like subborn nuts or stripped anything in getting the engine compartment 95% cleared out. I am in no rush for this project and since this will be a color change, I may take the car down most of the way. There are lots of rubber parts, gaskets, weatherstripping that needs replacing anyway. 2" rust hole under the battery box but that is it. Easy enough to correct. This needs a serious power washing before I dig into the suspension.

I figure the motor and trans may be of some small value to someone on Craigslist ($250?). Can't hurt to post and see if there are any takers.

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