The 245 GT, or: another BMWolvo

Arn02 · 07-31-2015, 04:23 PM

As it sits today:

It's about time I start a blog on an international forum. A few years back I started the first iteration of this project, but that got stranded and was scrapped. The car that is.... the stroked engine I kept.

Specs:
M50B25 non-vanos
M54B30 crankshaft, pistons and rods
M52B28 injectors
Decked 0,9mm
Stock camshafts (for now)
Non-turbo

Rotating assembly, making it unofficially an M50B30.

Head rebuild.

In december 2014 I bought another 245. It rolled of the line in July 1975 and it spent most of its life in the north of Sweden, until it was sold to a Dutchman some 8 years ago who brought it to the Netherlands. It had some bad spots but was still in original paint which I think makes the car honest.

Razor blades.

Solid.

Not so solid.

Out with the old.

I'd never seen this type of firewall before...

I “stole” a straight set of Rial Imola 17" 8J ET38 wheels for 75,- euro and tested them on 20mm spacers. I've been experimenting with Brembo calipers from an Alfa Romeo.

The front cross beam was pretty rotten underneat and badly repaired in the past. In stead of spending silly money on a replacement part I decided to fabricate my own out of some 40x60x2 mm tube.

Jig.

Testing.

Mounting point.

New part.

The car had some rusty spots which needed my attention.

More later....

Arn02 · 07-31-2015, 04:33 PM

Prepping for paint. Color 118.

Arn02 · 07-31-2015, 04:47 PM

I decided to use the M20 flywheel/clutch/starter since it's single mass. I mated the engine with a Getrag 240 because it's an OD gear box, which suits my 3.73 final drive better than a prise-direct.

Since the 240 is normally mated to M40/M42/M44 4-cyl. engines it has a small diameter guibo. The box should be plenty strong to hold the torque of the 3 liter engine, but I may be ripping through guibo's every other week. By coincidence I found that the output flange of a Volvo M47 box has the same splines as the 240. I just had to get 18 mm of using my neighbour's lathe.

Then it was time to put the engine in.

And I had to make a new mount for the gear box.

bwiley240sedan · 07-31-2015, 04:58 PM

Looking good! I wish I had had the balls to take it down as far as you did when I did paint. That's quite the job! That green is nice; glad you stuck with the original color. You don't see that shade too often anymore!

peterwgpa · 07-31-2015, 05:33 PM

Great work and love that you kept original colour. Will be watching with interest

Chilm · 07-31-2015, 06:28 PM

Very nice build and great welding man.
I envy you for the workshop, must be very convenient to drop your tools and find them on exactly the same spot after returning a couple of days later

Arn02 · 08-01-2015, 06:44 PM

Thanks! I'm very happy with this color. I was told it was only used for little over a year on the early 240's. I love the '70-ies and the car is full of it.

More of the process....
I had to take several mm off the steering rack to make it fit under the e36 oil pan. I wanted the engine as low and far back as possible; this is the price.

I put a turn buckle in my panhard.

I decided the green car needed a dark brown interior. So I painted some black leather seats brown using Angelus leather paint. So far I'm really happy with how it sticks. Although it does make me crave for cognac, montecristo's and talk about croquet.

Hydrolic clutch pedal conversion.

In-tank pump from a 940 lpt.

I had to adapt the strut brace that I bought since it was interfering with the brake fluid reservoir and blocking the oil filler. Besides, I needed a bracket for the engine loom and I wanted GT style fire wall struts. One stone, three birds.

I used the shifting linkage from a ZF box. I had to adjust only the 1 part of it. An old head bolt fitted perfectly inside the hollow tube, which made extending it as easy as 1,2,3.

Old Iron · 08-01-2015, 09:17 PM

Evertyhing about this is off the charts! Love the home made cross member!

JW240 · 08-02-2015, 10:02 AM

Looking good, very good. Favorite color for 70's 240s!

The Full Banana · 08-02-2015, 12:21 PM

Love this. I have a soft spot for turbocharged M50 swaps... and that paint!

oldschoolvolvo · 08-02-2015, 02:11 PM

good work!

Hank Scorpio · 08-02-2015, 02:33 PM

Looks great! My favorite Volvo Volvo. My 245 is getting something very similar.

Arn02 · 09-02-2015, 04:58 AM

Update time!

I modified the rear window rubbers by drilling 4 holes in each and cut a U-shape. A friend notified me that new rubbers have these (for draining, obviously).

E-fan.

3mm aluminium.

Atlas Copco 1-axle cnc.

E-fan installed, alu wet sanded with K400.

In.

I had the window installed by a professional.

As the title says, I wanted a sort of 245GT. Or what it could have been if Volvo ever had made one. Or something.

Dave Barton's magic.

Wiring.

BMW connector labeled.

Soldered and ready to go.

I cut of the volvo connector at the bulk head and pulled everthing in.

New location.

Mounted the relay & fuses of the e-fan as well.

The fuse box I will eventually use instead of the stock one.

,

Steering.

I had a neighbour who makes aggricultural vehicles make me a pressure hose.

Made a bracket....

...because I wanted to use the bmw reservoir which I think is much nicer than the black volvo unit.

Prop shaft and exhaust.

I used the rear part of a m47-fitted 240 and the front part and center bearing of an m90-fitted 940. I had the front part 58mm shortened and the whole thing rebalanced.

I adjusted m50 headers, made a connection pipe including an 850T cat and used a 240 Turbo 2.5” exhaust. This is temporary to get it through RDW/MOT/DMW or whatever authority you have in your country of origin. Later on I will probably make a 3” stainless system.

I ordered some hoses and connecting tubes at ASH. Needed to shorten an L-piece which required a new bead. Found a film on youtube on how to make your own bead “roller” so I did that.

Et voila!

Arn02 · 09-02-2015, 05:38 AM

Bead roller diy:

JW240 · 09-02-2015, 07:10 AM

Indeed that ZF reservoir is much nicer. A good idea for when/if I switch PS pumps (now with integral reservoir).
Lots of progress! Ready for VKB?

Arn02 · 09-02-2015, 11:41 AM

Quote:

Originally Posted by JW240

Ready for VKB?

I'd like to say yes..... but I don't think I will. Still so many small but time consuming jobs to do. Plus ever possible gremlins with the engine/gear box/other mechanics. And I have to get it registered as a 6-cilinder vehicle. But Let's hope for the best

12david34 · 09-02-2015, 11:45 AM

Is that gt steering wheel the one i sold you few months ago? Are you satisfied with its condition? Very nice project, indeed.

turbodog · 09-02-2015, 11:46 AM

Wow, amazing work. Looking at the photos makes it look so easy and quick which it is clearly neither. thanks for posting your project.

Dammit · 09-02-2015, 03:53 PM

Fantastic work - do let me know if you decide to sell it at some point in the future, I'd give it a happy home.

JW240 · 09-02-2015, 04:49 PM

Quote:

Originally Posted by Arn02

I'd like to say yes..... but I don't think I will. Still so many small but time consuming jobs to do. Plus ever possible gremlins with the engine/gear box/other mechanics. And I have to get it registered as a 6-cilinder vehicle. But Let's hope for the best

Fingers crossed! I know the feeling

Arn02 · 09-02-2015, 04:57 PM

Quote:

Originally Posted by 12david34

Is that gt steering wheel the one i sold you few months ago? Are you satisfied with its condition? Very nice project, indeed.

It's a beauty ;)

Quote:

Originally Posted by turbodog

Wow, amazing work. Looking at the photos makes it look so easy and quick which it is clearly neither. thanks for posting your project.

Thanks for the kind words. The blog is a bit condensed I admit. There are many, many hours in this car.

Quote:

Originally Posted by Dammit

Fantastic work - do let me know if you decide to sell it at some point in the future, I'd give it a happy home.

So far I have an excellent track record of selling the cars I built. Who knows? But not very likely I must admit. I build this car to be my DD.

Quote:

Originally Posted by JW240

Fingers crossed! I know the feeling

I just keep ploughing on ;)

schaff70 · 09-02-2015, 04:58 PM

Subscribed as this is something I have wanted to do for a long time now.

Harlard · 09-02-2015, 06:00 PM

This is wonderful.

Old Iron · 09-03-2015, 09:32 PM

You make me feel so bad about myself, sh*t, I am inside writing this post! I need to get out and work in the garage!

Arn02 · 09-03-2015, 11:39 PM

Quote:

Originally Posted by Old Iron

You make me feel so bad about myself, sh*t, I am inside writing this post! I need to get out and work in the garage!

Yes, a man needs a man-cave where he can be focused and isolated from all the bullsh!t going on everywhere else. Works far better than a psychiatrist

07-31-2015, 04:23 PM	#1
Arn02 Board Member Join Date: Jul 2012 Location: Amsterdam, NL	The 245 GT, or: another BMWolvo As it sits today: It's about time I start a blog on an international forum. A few years back I started the first iteration of this project, but that got stranded and was scrapped. The car that is.... the stroked engine I kept. Specs: M50B25 non-vanos M54B30 crankshaft, pistons and rods M52B28 injectors Decked 0,9mm Stock camshafts (for now) Non-turbo Rotating assembly, making it unofficially an M50B30. Head rebuild. In december 2014 I bought another 245. It rolled of the line in July 1975 and it spent most of its life in the north of Sweden, until it was sold to a Dutchman some 8 years ago who brought it to the Netherlands. It had some bad spots but was still in original paint which I think makes the car honest. Razor blades. Solid. Not so solid. Out with the old. I'd never seen this type of firewall before... I “stole” a straight set of Rial Imola 17" 8J ET38 wheels for 75,- euro and tested them on 20mm spacers. I've been experimenting with Brembo calipers from an Alfa Romeo. The front cross beam was pretty rotten underneat and badly repaired in the past. In stead of spending silly money on a replacement part I decided to fabricate my own out of some 40x60x2 mm tube. Jig. Testing. Mounting point. New part. The car had some rusty spots which needed my attention. More later.... __________________ Ambitious but rubbish. The 245 GT The Euromurican Last edited by Arn02; 08-03-2015 at 12:11 AM..

07-31-2015, 04:58 PM	#4
bwiley240sedan Professor Dickweed Join Date: Jul 2010 Location: Boise, Idaho	Looking good! I wish I had had the balls to take it down as far as you did when I did paint. That's quite the job! That green is nice; glad you stuck with the original color. You don't see that shade too often anymore! __________________ My feedback thread here

07-31-2015, 06:28 PM	#6
Chilm Double Dutch Join Date: Apr 2009 Location: The Netherlands	Very nice build and great welding man. I envy you for the workshop, must be very convenient to drop your tools and find them on exactly the same spot after returning a couple of days later __________________ Flying Dutchman - Build and goodies thread ;P ======================================= Volvo 945 - Blue Pearl - LPT Polar 2.3 Limited Edition B230-FK Turbo - 90+ ported - 15G Ported - Airintake Erland Cox Regrind - Blabla Chips - 3 inch exhaust MBC on 0.95 - Wasted Spark - Sponsored by my wife =======================================

08-01-2015, 06:44 PM	#7
Arn02 Board Member Join Date: Jul 2012 Location: Amsterdam, NL	Thanks! I'm very happy with this color. I was told it was only used for little over a year on the early 240's. I love the '70-ies and the car is full of it. More of the process.... I had to take several mm off the steering rack to make it fit under the e36 oil pan. I wanted the engine as low and far back as possible; this is the price. I put a turn buckle in my panhard. I decided the green car needed a dark brown interior. So I painted some black leather seats brown using Angelus leather paint. So far I'm really happy with how it sticks. Although it does make me crave for cognac, montecristo's and talk about croquet. Hydrolic clutch pedal conversion. In-tank pump from a 940 lpt. I had to adapt the strut brace that I bought since it was interfering with the brake fluid reservoir and blocking the oil filler. Besides, I needed a bracket for the engine loom and I wanted GT style fire wall struts. One stone, three birds. I used the shifting linkage from a ZF box. I had to adjust only the 1 part of it. An old head bolt fitted perfectly inside the hollow tube, which made extending it as easy as 1,2,3. Last edited by Arn02; 08-01-2015 at 07:01 PM..

08-02-2015, 12:21 PM	#10
The Full Banana not yet good enough Join Date: Apr 2007 Location: Lake Mills, WI	Love this. I have a soft spot for turbocharged M50 swaps... and that paint! __________________ -Tom 1980 242 T5

07-31-2015, 04:33 PM	#2
Arn02 Board Member Join Date: Jul 2012 Location: Amsterdam, NL	Prepping for paint. Color 118.

07-31-2015, 04:47 PM	#3
Arn02 Board Member Join Date: Jul 2012 Location: Amsterdam, NL	I decided to use the M20 flywheel/clutch/starter since it's single mass. I mated the engine with a Getrag 240 because it's an OD gear box, which suits my 3.73 final drive better than a prise-direct. Since the 240 is normally mated to M40/M42/M44 4-cyl. engines it has a small diameter guibo. The box should be plenty strong to hold the torque of the 3 liter engine, but I may be ripping through guibo's every other week. By coincidence I found that the output flange of a Volvo M47 box has the same splines as the 240. I just had to get 18 mm of using my neighbour's lathe. Then it was time to put the engine in. And I had to make a new mount for the gear box.

07-31-2015, 05:33 PM	#5
peterwgpa Board Member Join Date: Dec 2011 Location: Australia	Great work and love that you kept original colour. Will be watching with interest

08-02-2015, 02:11 PM	#11
oldschoolvolvo Board Member Join Date: Mar 2004 Location: Lancaster, PA	good work! __________________ -Mike ~~1998 V70 T5~~ 1979 242 DL 16v \|Feedback\|

08-02-2015, 02:33 PM	#12
Hank Scorpio Chubfest 2009 Survivor Join Date: Nov 2002 Location: The neighborhood with the ******* guitar player.	Looks great! My favorite Volvo Volvo. My 245 is getting something very similar. __________________ 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)

09-02-2015, 04:58 AM	#13
Arn02 Board Member Join Date: Jul 2012 Location: Amsterdam, NL	Update time! I modified the rear window rubbers by drilling 4 holes in each and cut a U-shape. A friend notified me that new rubbers have these (for draining, obviously). E-fan. 3mm aluminium. Atlas Copco 1-axle cnc. E-fan installed, alu wet sanded with K400. In. I had the window installed by a professional. As the title says, I wanted a sort of 245GT. Or what it could have been if Volvo ever had made one. Or something. Dave Barton's magic. Wiring. BMW connector labeled. Soldered and ready to go. I cut of the volvo connector at the bulk head and pulled everthing in. New location. Mounted the relay & fuses of the e-fan as well. The fuse box I will eventually use instead of the stock one. , Steering. I had a neighbour who makes aggricultural vehicles make me a pressure hose. Made a bracket.... ...because I wanted to use the bmw reservoir which I think is much nicer than the black volvo unit. Prop shaft and exhaust. I used the rear part of a m47-fitted 240 and the front part and center bearing of an m90-fitted 940. I had the front part 58mm shortened and the whole thing rebalanced. I adjusted m50 headers, made a connection pipe including an 850T cat and used a 240 Turbo 2.5” exhaust. This is temporary to get it through RDW/MOT/DMW or whatever authority you have in your country of origin. Later on I will probably make a 3” stainless system. I ordered some hoses and connecting tubes at ASH. Needed to shorten an L-piece which required a new bead. Found a film on youtube on how to make your own bead “roller” so I did that. Et voila!

09-02-2015, 05:38 AM	#14
Arn02 Board Member Join Date: Jul 2012 Location: Amsterdam, NL	Bead roller diy:

09-02-2015, 07:10 AM	#15
JW240 All idiot, no savant Join Date: Aug 2004 Location: The Netherlands, Europe	Indeed that ZF reservoir is much nicer. A good idea for when/if I switch PS pumps (now with integral reservoir). Lots of progress! Ready for VKB?

09-02-2015, 11:45 AM	#17
12david34 Board Member Join Date: Sep 2012 Location: Slovak Rep.	Is that gt steering wheel the one i sold you few months ago? Are you satisfied with its condition? Very nice project, indeed.

09-02-2015, 11:46 AM	#18
turbodog from out of nowhere... Join Date: Oct 2002 Location: South LA (the state)	Wow, amazing work. Looking at the photos makes it look so easy and quick which it is clearly neither. thanks for posting your project. __________________ current fleet: '88 745T, '89 780T x 2, '91 745SE, '98 S70T5, '95 855 T-5R (yellow), '97 855 T5 past volvos: '87 244DL, '93 944T

09-02-2015, 03:53 PM	#19
Dammit +8cm Join Date: Nov 2009 Location: London	Fantastic work - do let me know if you decide to sell it at some point in the future, I'd give it a happy home.

09-02-2015, 04:58 PM	#22
schaff70 Board Member Join Date: Jun 2003 Location: Cypress, TX	Subscribed as this is something I have wanted to do for a long time now.

09-03-2015, 09:32 PM	#24
Old Iron I Roll Join Date: Jun 2009 Location: Dela-Where?	You make me feel so bad about myself, sh*t, I am inside writing this post! I need to get out and work in the garage!

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