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#1 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() I had a small thread elsewhere on here, but Photobucket tanked it. Rather than try to fix that one, I'll start over here.
I'm 12 years deep into a build that is taking a 1949 Willys Jeep ![]() and a 1987 Volvo 740 ![]() to end with a very street and dirt friendly rig. ![]() Almost every part of this has been hand built. The following will be a story through pictures, since I don't have enough patience to sit and type the whole story. If you have any questions, please feel free to ask. |
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#2 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() Body work
![]() Joining the M45 to a Dana 300 transfer case ![]() ![]() ![]() ![]() ![]() ![]() ![]() Fitting the shifter ![]() |
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#3 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() ![]() ![]() I toyed with the idea of adding turbo. Ultimately decided against it, but left room for it if I go that route in the future. ![]() New engine mounts ![]() Engine cradle ![]() Crossmember. Round hole for exhaust, other hole for wiring. Front driveshaft utilizes the support bearing from Volvo ![]() ![]() Transfer case mount will allow the exhaust to pass through ![]() Radius arm links for the front coil suspension are from the rear of an 850 ![]() ![]() Front axle is from a Toyota truck ![]() Last edited by itlksez; 10-02-2019 at 03:47 PM.. |
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#4 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() Rear axle is from an Isuzu Rodeo. I had to buy the whole truck for $100 just for the rear axle.
![]() That was a lot of mounts to remove. ![]() I sent the shaft off to Moser to shorten it by 7 1/2" ![]() ![]() Cage work up in the engine bay included a sway bar up over the engine because I had nowhere else to fit it. The links go down through the coil springs. ![]() Radiator mount. Rad is an aftermarket 3-core unit for a Honda Civic. ![]() ![]() ![]() Working on the alternator/air compressor mount ![]() ![]() |
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#5 |
Board Member
Join Date: Oct 2005
Location: Norfolk, VA
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![]() Sweet! Reminds me of the B230FT I saw in a Samurai twenty years ago.
__________________
Got boost? Yes! Got manual? Yes! Got gear? Yes! Got V-8 power? No ![]() 1995 940t |
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#6 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() Power steering pump mount on the other side
![]() Gas tank fabrication incorporating the 740 in-tank pump and sender ![]() ![]() ![]() ![]() Rear shock mounts ![]() Pedal assembly using Volvo booster and pedal pads. ![]() ![]() Cage work between the firewall and dash ![]() Building the cage ![]() ![]() ![]() |
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#7 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() Upgraded fuel pump mount
![]() And I just got finished with the exhaust. I had to build the muffler from scratch due to space restraints. It is surprisingly quiet. ![]() And that catches me up to today. Next up is thinning the wiring harness down to a manageable clump. |
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#8 |
Board Member
Join Date: Mar 2004
Location: Lancaster, PA
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![]() cool project and nice fab work!
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#9 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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#10 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() After 15 hours of tracing wires, this...
![]() ...turned to this. ![]() ![]() It needs one relay and three fuses to run. I’ll go back and add the wiring for the lighting later. The original firewall grommets are getting re-used. I threw the body back on to start to figure out placement. ![]() ![]() I’m re-proposing the original location of the jeep’s hand brake for the Volvo ignition switch. ![]() |
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#11 |
Chubfest 2009 Survivor
![]() Join Date: Nov 2002
Location: The neighborhood with the ******* guitar player.
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![]() I absolutely love this!
__________________
Hank Scorpio is from the Simpsons. You can call me Doug ;) Will trade guitars/guitar parts for go fast goodies or stuff I need. Just PM. www.kauerguitars.com the second best way to upset neighbors and alienate people. History: Car 1 (242) | Car 2 (t5r) | Car 3 (255) |
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#12 |
Salaminizer
Join Date: Nov 2007
Location: Reading pa
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![]() ![]() Very cool! Way to gloss over an incredible amount of hard work haha, dam.
__________________
Feedback thread https://forums.tbforums.com/showthread.php?t=144924 1978 242, getting prepped for LS 1979 242, MS, R brakes 2006 V50 T5 AWD @ 17 PSI |
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#13 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() Thanks guys.
Hey @2turbotoys, I’m from your neck of the woods! Boyertown HS, class of ‘93 |
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#14 |
Salaminizer
Join Date: Nov 2007
Location: Reading pa
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![]() No sh$$, I am currently working at a Jeep specialist there...stop by and say hi at MPG if your in the area, Manifest Performance Group might help Google. '93...we know some of the same people, bet
Love your ideas and build. |
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#15 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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#16 |
80/20 speed parts club
Join Date: May 2007
Location: PDX
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![]() I read through a thread about this some years ago in some forum that I can't remember. Glad it's still moving along.
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#17 |
Salaminizer
Join Date: Nov 2007
Location: Reading pa
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![]() Hahaha
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#18 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() I’ve been working on figuring out where to route the air intake. The engine bay is getting so crowded, I have no choice but to go inside the cab with it. I was able to turn the stock air horn 180° and run the bellows through the firewall between the cage and the brake booster.
![]() ![]() This moves the air mass sensor inside the cab. I’ll need to cut the wires, add a connector and about 2’ of length to get it to reach. I dug through my supply of junkyard parts and was able to piece together the elbows and tubes I need from stock replacement parts for a turbo 940. These get me up and over the steering column and behind the gauges. I’ll build an air box behind the dash on the passenger’s side with the air intake possibly dumping into the wheel well, à la Project Binky, if anyone here is following that built. ![]() |
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#19 |
Board Member
Join Date: Feb 2015
Location: Walla Walla, Washington
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![]() You're in Post Falls? My old neck of the woods. I'd love to check this out some time when I'm home
__________________
![]() ______________________________________ 1983 Volvo 242 - 4.8/AR5 1986 Volvo 744Tic @beige242 on instagram |
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#20 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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#21 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() Picked up a filter and made the template for the air box.
More to come. ![]() ![]() |
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#22 |
F*ck Edgar
Join Date: Jan 2010
Location: Franklin, NC
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![]() This is hilarious and amazing.
__________________
My Project (It's a 1979 244DL...sort of.) K-Jet to Megasquirt Article The Departed: 1981 245, 1983 245 Turbo, 1983 244 Turbo, 1983 242 Turbo, 1984 244, 1985 245 Turbo, 1989 244, 1989 244, 1989 765, 1990 245 Turbo, 1991 244, 1992 245, 1997 855 |
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#23 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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#24 |
Board Member
Join Date: Oct 2009
Location: Post Falls, ID
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![]() My daily two hour allowance towards this just flies by.
![]() I got the pieces for this air box cut out. After I traced the pattern, I re-assembled the cardboard templates and measured the angles so I could write the numbers on the corresponding bend marks. ![]() ![]() With the air cleaner in place: ![]() Now that the corners are tacked and the inner frame is in place, I can massage the bends a little to fine-tune the joints before welding it up. |
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#25 |
Board Member
Join Date: Nov 2017
Location: Tempe, AZ
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![]() this is awesome, looks like quality fabrication work!
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