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Old 06-01-2021, 11:26 PM   #1
76RA24
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Default 1990 245 (millennial falcon)

I have been polluting the VanCity volvos thread with my updates... figured i should just do a thread.


brief history.
bought wagon in 2015 for 600$ approx. 390,000kms
day1 with dads 740


some issues.. bad alternator, no valve cover gasket, exhaust leaks, no guibo joint

leaky fuel pump


Guibo whats that




good points were it was manual rwd wagon.


swapped alternator at farm proceeded to drive 30kms home with no guibo and virtually no valve cover gasket... smokey.

ordered parts from ipd some were bought local.

got the car on the road proper in a couple weeks..

lots of road trips for work ... lots of miles put on had to install some Moog overoad springs


installed Mazda 3 seats at some point



popped a head gasket on my bday one year downtown Van that was fun towed back to mission for dirty replacemnet

re-did headgasket couple months later proper.

at some point I put in a G80, met a Levion at the auto recyclers..



many suspension bushings... some failed new ones. dont buy cheap.

did bilsteins HD, new brakes
need new strut casings mine were 90 with the welded spacer

new ones were still crusty

My old springs were done... the other struts came with better springs.


but got it all cleaned up.


pretty much brings me to now when i had a week off to look for a water leak and ended up cutting rust.

that was 4 months ago...

still finding more.

here is rust repair gallery.

https://imgur.com/a/Zqiu9gK

Last edited by 76RA24; 06-02-2021 at 10:49 AM..
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Old 06-02-2021, 09:29 AM   #2
Scaramanga
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Impressive work with the rust repairs! Well done!
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Old 06-02-2021, 10:11 AM   #3
kyote
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IMGUR blocked at work but props on the name
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Old 06-02-2021, 10:22 AM   #4
76RA24
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How the hell does Rust start here....


seems to never stop... photo dates accroding to phone say i started this about 4months ago.
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Old 08-20-2021, 11:49 AM   #5
76RA24
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progress has been slow.

I dont like working in the heat. give me the single digits temps again.

rear inner using the weldthru copper stuff... I dont like it as much as the weld thru zinc. but the zinc was sold out at local shop.




dressed down and sealed.


working on the replacement buttcheek


might be the last hole on the inside of the car.



still not sure how I want to address that hole in rear upper crossmember.

I feel like dropping the tank and lowering the axle will be my best method to reach... but getting really tired of not having the volvo on the road.
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Old 08-22-2021, 12:04 PM   #6
RedlineDave
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What year Mazda seats? Easy swap or wielding required?
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Old 08-22-2021, 01:31 PM   #7
76RA24
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2004-2005-ish seats.

will take some pics of the base since the seats are out.... dont recall any welding.

I did have to drill out some big rivets to remove the mazda sliders and removed the side airbags...
filled the void with some EVA foam

I am using the original Volvo sliders.
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Old 08-23-2021, 01:20 PM   #8
76RA24
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Mazda seats...

made flat steel plate adapters..




weld one rust hole...

two more appear.


fun times....
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Old 08-23-2021, 01:56 PM   #9
MCHN8
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Great work, and "millennial falcon" is just an awesome name.
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Old 08-24-2021, 11:22 AM   #10
76RA24
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tackled the cross member rust hole...





also where the hell does the water get to this part to rust it out?
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Old 09-03-2021, 01:02 AM   #11
76RA24
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Well interior floors done.







Rear butt cheek replacement.



Fun is coming to an end.
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Old 09-09-2021, 11:33 PM   #12
76RA24
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Went slow

Ran out of welding gas again.





Now to deal with some other crusty bits.

All “seems” like surface rust.

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