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Old 07-24-2012, 03:02 AM   #1
Jack
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how it sits as of 5/1/16




the day I got it the wagon

stock 1985 245 DL
-automatic trans
- blue vinyl interior
- manual windows

(specs area is under construction)



engine
- b21ft long block
- gasket matched intake and exhaust 530ft head
- ipd Turbo cam
- IPD old adjustable cam gear
- 15g rebuild and reclocked turbo
- NPR gen2 intercooler
- b21ft oil cooler with steel braided hoses
- 100 amp denso alternator
- updated wiring harness
- ezk ignition
- 2.25 exhaust
- 90+ turbo manifold
- volvo 850 orange injectors
- 10bar oil pressure sender

drive train
- M46
- 373 rear end


font suspension
- 25mm IPD bar
- B&G lowering springs
- OEM GT upper and lower strut braces
- Wilwood calipers
- 302mm P80 chassis rotors
- steel braided brake line hoses


rear suspension
25mm IPD bar
B&G sedan lowering springs
yoshifab torque rods

interior
- e420 Mercedes-Benz front sport seats - black leather power recliner and head rest
- black headliner
- black roof grab handles from e28 bmw
- black Turbo/GLT power window door cards with backing painted white to keep rot out
- black leather seat back (OEM)
- black 3rd seat with self retracting seatbelts
- two map/rally/butler lights installed
- purple dash switch
- orange rear fog switch
- OEM Volvo Momo "Roma" steering wheel
- Leather shift boot
- lined whole foor with peal-n-seal
- lined DF door and 2/3 of the roof with Dynamat Xtreme


exterior
- 25mm front and 25mm rear IPD bar
- boxed-in and powdercoated black front and rear control arms
- poly bushings installed everywhere but the axle
- 1980 flathood painted black
- 1981 headlight trim
- WADE headlight covers
- HELLA E spec headlamps
- choice of volvo OEM 144/2 roof rack or OEM "MOOSE" rack
- 89+ "flush" tailgate
- 89+ updated rear window seals
- skinny black/chrome trim sprayed with plastidip black
- actual Homogelian 242 grille
- Early power mirrors
- OEM snow scoop
- plugged roof rack holes (for now)




sitting on the shelf
- skid plate
- color matched spray cans for painting hood, roof, tailgate
- Volvo LSD
- Garett T3 Turbo
- 2x 16V head with accessories
- Yoshi fab 16V short dizzy
- Rally light
- 5x B23 and 90+ b230 blocks
- p80 serpentine belt setup with accessories
- Kalpenike "economy" strut plates
- R sport cluster and Jet cockpit gauges
- uncracked black dashboard

Last edited by Jack; 05-12-2016 at 02:42 AM..
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Old 07-24-2012, 03:20 AM   #2
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1985 volvo 240 wagon DELuxe. 225k auto runs strong- salvage title (someone bought it from a wrecking yard 5 years ago). got it for $300
pretty much original everything but comes with 134a ac volvo converted

1983 volvo 240 sedan deluxe. 54k orignal miles - wrecked . super clean brown interior got it for 800.00 but it comes with
less them 5k miles on
- michelins
- ipd exhaust
- bilstein HDs
- ipd sways
- brakes
- ignition
- cooling (waterpump , tstat, radiator)
- keenwood headunit and speakers


the day i got it the wagon



engine was covered with years of oil (cant tell from the pic)

other side




got this about 30 days later.





















Wagon will be my wife's dd and I will take her 850 as mine.
plan is to transfer everything possible to the wagon, add a turbo, flat hood, low etc
sell of everything else from the donor including the brown interior

some "progress"

got a super steam cleaner at work
did this to the wagon




next came the suspension and looks
I installed front and rear: ipd sways, bilstines yellows, B&G lowering springs. Flat hood, grille and single rounds. (went from double monitors - double rounds with turbo grille - single round and flat grille) I also became part of the Black Hoods Club.

some comparison between stock and B&G springs


stock sway vs ipd


final result in rear



final result in front


side shots next morning



front setup #2 - also installed front spoiler


"VS" classic mod on a 240 - moved the horns

moved the under front bumper
Posted Image

front set up #2.5 - in between hoods
Posted Image

final product


next came the interior
this is what 26 years worth of usage looks likes. found about $5 worth of change and most of it came from the parking brake lever
I also found some small rust spots... more on that later







driver rear






small rust spots i thought turned out to be rather big (for California that is)

removed all the old sound detoning stuff and applied roofing insulation (don't want to argue this with anyone stuff works and does not smell)





had to cut out a part of driver seat frame support to get to all the rust






and driver rear rust cut out


I forgot to take pictures of some of the floor repair but here is the final product before i painted it. got the rust free part from parts car


as you can see Swedish production isn't always 100% parts car was starting to have the same issue. note the lack of sealant under the seat support


painted result and then insulated




thenI stopped taking pictures

friends at work call it 'The Chariot'

- got aligned
- rebuild valve body assembly with new seals and check balls from Toyota.
- shimmed shift solenoids
- replaced driver seat frame (original was broken and leaning to one side)
- have about 6 set of wheels for it
- rear seat got upgraded to one with headrests
- installed 3rd seat (seat belts will go in this week)
- retrofired late-model trunk floor board to fit (no more metal garbage)
- tune up - spark plugs, wires, dizz cap, rotor, msds coil, BG fuel cleaner, etc
- ipd sport exhaust
- wife did not like the flat hood so back went the coffin lid

around march it was back on the road and registered. took a first road trip through a local canyon with wife and kids.

took this while double square headlight bucked were getting powder coated
I kind of like it with the single lights and coffin hood


one from the back


on that trip we found a Montgomery ward bike from the 70s in the bushes next to a rest stop. all original made in Germany. even had the original tires made in Czechoslovakia. Someone must have unloaded it and forgot about it. (will post some pictures of this)

thanks for looking. will post some more pictures this week and as I get more done with it.
Jack

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Old 07-24-2012, 05:21 AM   #3
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i like this. very nice rust repair, looks like a very thorough repair!

The engine cleaned up very nicely too, looks good.
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Old 07-24-2012, 01:28 PM   #4
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If you still have that yellow car I might be interested in the engine if you're not
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Old 07-25-2012, 02:03 AM   #5
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Quote:
Originally Posted by JW240 View Post
i like this. very nice rust repair, looks like a very thorough repair!

The engine cleaned up very nicely too, looks good.
thank you i really enjoy welding

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If you still have that yellow car I might be interested in the engine if you're not
keeping the engine. I pulled it out a while ago. next week or so im going to fill it full of oil and store it away.
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Old 07-26-2012, 02:18 AM   #6
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last night I installed new alternator bushings and powder coated bracket for oil cooler off a turbo 240

old vs new. make sure you use some lubricant to get these on


installed - I found out I need to replace alternator ground wire

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Old 07-26-2012, 03:21 AM   #7
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very nice
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1984 242ti Hi-Comp b23 N/A, m46. Work in progress

93's Build Threadhttp://forums.turbobricks.com/showthread.php?t=264885
84 242 Hi-Comp N/A Build Thread
http://forums.turbobricks.com/showthread.php?t=290023
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Old 01-26-2013, 11:44 PM   #8
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It has been way too long since I updated this.
since last time I
- switched to a large glass tail gate
- h1 and h4 headlights
- fixed the heater fan - thankfully it was just a corroded fuse holder
- got rid of the donor car shell - It made me sad when I was cutting up, all I could think of is people fixing up rusted out shells
- installed center arm rest

This is what I did today
- installed poly bushings in accessory bracket - the AC belt adjuster on this style is just stupid (rarely am I disappointed in Volvo Engineering)


- pressure washed the bay while i was in there


- Replaced/repaired ac wireing



Soon to come
- manual trans - thanks to RWC aka Ken

- rear evacuation fan - big thanks to "Prof" for his helping me find this part


- set of JY Ronals


inspired by this

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Old 01-27-2013, 12:33 AM   #9
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I really dig the single rounds and coffin hood. I saw a 262c in england that had the E-codes that would have been for the flat hood and wide grille, with trims around them to fill in the gap created by the car's narrower coffin hood and matching grille. It was a really neat set up, seeing your car like that reminded me.
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Old 01-27-2013, 12:52 AM   #10
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I liked that look the best. Maybe when more stuff is done Ill attempt to make something like that

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Old 01-31-2013, 08:50 PM   #11
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Today I installed oil temp gauge sensor. I found one at a junk yard on a 780 v6 that fits the redblock oil pan. I also relocated my ecu behind the glove box because I installed the passenger side air vent from a diesel.I mounted the ecu to an existing cruise control computer bracket.
The new kick panel is much thinner than the old one and I didn't think about garbing the dash underside sound cover thingamaho until today.

Thanks
Jack






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Old 01-31-2013, 09:06 PM   #12
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I have an 86 245 that has rear floorpan rust issues almost the same as yours. I am curious what kind of welder did you use and if you had any tips or advice for the operation?
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Old 01-31-2013, 09:11 PM   #13
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Awesome work man,

Whos LT T100! haha
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Old 01-31-2013, 09:18 PM   #14
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Too bad about the sedan with 58K, wagons are better though, let it live on for ever now!
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Old 01-31-2013, 09:23 PM   #15
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^thank you

t100 is my answer to speeding on highways

supercharged 3.4 with urd 7th injector and fuel/timing ecu
front is Total Chaos gen2 with TC heim steering, upper and lover heims, TC idler arm. TC extended front axles matched to FOX shocks and coilovers 550lbs
rear is f67 devers with 3 inch tripple bypass 16 inch shocks

bunch of other stuff....





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Old 01-31-2013, 09:25 PM   #16
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Quote:
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Too bad about the sedan with 58K, wagons are better though, let it live on for ever now!

244 saved me a ton of money on fixing up the 245 ..... and now i have a ton of spare parts
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Old 01-31-2013, 09:35 PM   #17
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True, having a parts car seems to be a growing necessity for me, around here the 240's are dried up. Have not seen one for well over a year in the yards. Checked every yard on Delmarva to no avail. It'll be nice for you to have low mileage part to swap too! Still a sin that the insurance companies get a way with totaling such nice low mileage cars. That interior looks darn nice too, will service a high mileage beat down 244 really nice!
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Old 02-17-2013, 09:32 PM   #18
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Today I got around to refreshing my front turn signal light.
-I washed it with dish soap first.
-sprayed it with SEM bumper paint to renew the black
-lastly I sprayed it with "chrome" paint.







final result (the little bit of overspray will not show up with lens on)

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Old 02-21-2013, 04:35 AM   #19
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I forgot to post this update. Wife finally got the license plates she wanted... first 2-3 got denied.
I also gave the 245 a bath



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Old 02-21-2013, 02:18 PM   #20
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Looks good!
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Old 02-21-2013, 02:30 PM   #21
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Those Ronals are awesome!
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Old 04-17-2013, 01:59 PM   #22
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I haven't had the time to work on the car much. I got way too many projects going on at once and keep starting new ones without finishing the others

I installed IPDs braided SS lines this weekend. I didn't notice much difference (unlike my other cars that have SS lines) but some of the old rubber was cracking.




I also acquired two map reading lights. One is missing the switch (it was gift via "prof" ) and the other is missing the light shade. I got an original switch coming new from UK. I got 3 coming in case anyone needs one. Does anyone know where to get another shade?
I will install both lamps. One will go on the passenger front side and the other will go either to the 3rd seat or the "middle" row

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Old 04-17-2013, 03:42 PM   #23
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I want a ride in the T!!
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Old 04-17-2013, 04:17 PM   #24
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I want a ride in your 245
let me know when you are in these parts I'm usually always home
I cant take it off road for another 200 miles since i recently replaced spider gears (500 easy miles is what is recommended)
also at some point I'm taking the front end off apart for some maintenance.
- take stuff to powder coating
- replace heims
- repack front hubs.
- put zerk fittings to lube the poly bushings without taking the control arms off (it sounds like a used mattress going down the road)
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Old 04-17-2013, 04:55 PM   #25
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Good stuff so far, I have two of those Bentley lights as well, both with the switch on different sides. I am missing the spacer and some of the hardware, do you have any of the hardware or mounting brakets?
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