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Old 10-16-2019, 03:05 PM   #1
rms
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Default 1977 Volvo 242 project-b6304/T5

I just picked this up, and it'll be my first Volvo...and quite a project. Overall a very solid Southern 1 owner car. It doesn't run, but I'm planning on pulling the b21f anyway. It's been sitting outside for the last 8 years after the original owner passed away. Came with a boatload of paperwork, from the original invoice to the last service at over 200k miles.












Just this one rust spot, which will require some attention soon.



I did manage to clean out the inside and overall not too bad for 42 years old. Seats and carpet are faded and dash has cracks. I'm planning new seat covers and if I can find a nice dash pad, then that too.










The original paint is very faded, but I was able to revive it a little. Only cleaned and buffed the hood, but it made a huge difference. I'll get to to the rest soon, but the paint should clean up nicely.










Just a few days after buying my first Volvo, I bought my second. A 1997 960 with only 128k. I figured for $800 this would provide the engine for the 242, and I can part out the rest. So the plan is just that...the b6304 will make it's way into the 242. I just can't bring myself to use the auto from the 960, so I'll be using a Mustang T5, even though the cost of that will be substantial.

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Old 10-16-2019, 03:44 PM   #2
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Your pics aren't working for me, which is sad, because I am also doing a B6304 swap into a 240 and would love to see what you're doing.
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Old 10-16-2019, 03:54 PM   #3
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Quote:
Originally Posted by thatcher.hubbard View Post
Your pics aren't working for me, which is sad, because I am also doing a B6304 swap into a 240 and would love to see what you're doing.
Weird, sorry about that. They don't show up on my iPhone either, but work just fine on my chromebook. Let me look into a fix. BTW, you haven't missed anything, I'm just getting started!

Edit: Pictures should work now.

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Old 10-16-2019, 04:13 PM   #4
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There's nothing wrong with the auto...but if your car os already manual, go for it.
*has 244 with B6304S+T on the auto*
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Old 10-16-2019, 04:41 PM   #5
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Originally Posted by Broke4speed View Post
There's nothing wrong with the auto...but if your car os already manual, go for it.
*has 244 with B6304S+T on the auto*
Correct, it's a fine auto...just not my thing.
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Old 10-16-2019, 08:17 PM   #6
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My car was auto already, so I kinda defaulted to the easy route, lol.

Pics are working for me now. I dig that beige, it cleaned up NICE!
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Old 10-16-2019, 08:38 PM   #7
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Quote:
Originally Posted by Broke4speed View Post
My car was auto already, so I kinda defaulted to the easy route, lol.

Pics are working for me now. I dig that beige, it cleaned up NICE!
Thanks! If I were going +T like you, the auto might stay. Since it'll be N/A, I'm going to need the gearing of the T5.
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Old 11-03-2019, 09:18 AM   #8
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Made my rounds at the local Pull-a-Parts this week, and picked up a few things. Found a 1990 240 that donated itís 1031 rearend and back seat, which is in surprisingly good shape. Then found a 1994 940, which gave up itís g80 locker and diff cover. Still on the junkyard wish list is a power rack & pinion.






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Old 11-03-2019, 10:37 AM   #9
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Great scores! I’m currently looking for the same color rear seat. You’re off to a very nice start!
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Old 11-04-2019, 06:19 PM   #10
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It's beautiful... !!
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Old 11-15-2019, 11:37 PM   #11
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Thanks guys!

Parts are starting to show up. Can't wait to starting bolting stuff on.
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Old 11-15-2019, 11:47 PM   #12
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Looking good!
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1978 242, getting prepped for LS
1979 242, MS, R brakes
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Old 11-24-2019, 08:26 PM   #13
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Because the tan seats turn purple in the sun , I'm converting the seats and carpet to black. I bought some later model 240 used seat skins, but found out they were too big for my early model seats. With nothing really to lose, I bought a few yards of 1/2" high density foam and added to the seats until the covers fit better. Not great, but much better. Also, pulled out the rear seat, as I bought a later model black rear seat as well. That may take some tweaking too. I think the black and tan interior will look pretty good. Rear door cards are almost perfect too.
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File Type: jpg IMG_9524.JPG (73.9 KB, 270 views)
File Type: jpg IMG_9525.JPG (66.7 KB, 269 views)
File Type: jpg IMG_9526.JPG (74.9 KB, 272 views)
File Type: jpg IMG_9529.JPG (109.3 KB, 271 views)
File Type: jpg IMG_9533.JPG (91.3 KB, 271 views)

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Old 11-24-2019, 10:03 PM   #14
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Looks good. That foam looks awfully dark compared to the typical yellowish orange color. Also appears to be deteriorating, I think I’d be looking for replacements from a later 240.
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Old 11-24-2019, 10:55 PM   #15
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Quote:
Originally Posted by Vol242vo View Post
Looks good. That foam looks awfully dark compared to the typical yellowish orange color. Also appears to be deteriorating, I think Iíd be looking for replacements from a later 240.
Yeah, these early seats donít even have foam in the middle, itís like a bunch of straw glued together in the shape of a seat cushion. If I come across some later decent foams, Iíll swap them out.
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Old 11-27-2019, 12:10 AM   #16
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Pulled all the front suspension off today, and got the car up on jack stands. Really happy how easy it all came apart. Noticed it had the offset ball joints with manual steering, wondering if that was an oversight by someone. Stock front sway bar is like 19mm, that's definitely going to be replaced. Really enjoying this project so far.
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File Type: jpg IMG_9552.JPG (102.0 KB, 228 views)
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Old 11-27-2019, 12:37 PM   #17
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Great project! I want one of these in this color!
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Old 11-27-2019, 01:04 PM   #18
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Great project! I want one of these in this color!
Thanks! The color is growing on me.
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Old 11-27-2019, 06:52 PM   #19
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Pulled the rearend out today. I have a '90 model going in with a g80 donated from a 940.
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Old 11-28-2019, 11:53 PM   #20
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Pre-Thanksgiving dinner activities. Anybody need a B21f/M45?
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Old 12-03-2019, 05:42 PM   #21
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Pull-a-Part got a '91 wagon in, so I went to check it out. Pulled the front seats, power steering rack and pinion, brake booster, carpet and foam mats. Lucky for me there are some left over cheetos mashed into the carpet.
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Old 12-03-2019, 11:14 PM   #22
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Nice score! All black too, how’s the condition of the seat cloth?
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Old 12-03-2019, 11:27 PM   #23
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Nice score! All black too, howís the condition of the seat cloth?
Thanks. The seat cloth is pretty good, just a bit faded. The other set of black covers I bought earlier are better. I may swap out some foam from these, I just couldn't walk away for $25 per seat.

I was planning to dye my original carpet black, but as long as this wagon carpet will fit with minor adjustments, I'll just use it instead. We will see.
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Old 12-06-2019, 08:11 PM   #24
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Made some lower control arm boxing plates from 1/16" plate. Still need some clean up and a ball joint bolt access hole. I plan to do the trailing arms as well.
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Old 12-07-2019, 12:37 PM   #25
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Nice project!

I wish you werenít on the other corner of the country, Iíd gladly take that drivetrain off your hands.
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