1982 Volvo 245 The DL Disaster

so welcome to my new project! bought on a kind of blind knowing off john hughes. this being a early 240 (at least early scuttle) that was cheap. and maybe make a good project, the car got delivered early satday morning on the back of a old mitsubishi looking rather sorry for itself knowing prior the engine had "issues" we starter motored it up the yard and parked it in the naughty corner.

initial inspection was good verry minimal rust in the usual areas. some odd areas mainly caused by the prior owners stupidity. the fake cladding caused some rust. vinyl roof didnt help the rain gutters. but we got the engine to fire. and oh god it sounded like someone was smacking the block with a hammer. a real nasty *CLUNK CLUNK CLUNK* so what do you do? pull the engine. and start faffing. ill update each day as its been a few week since i owned this car but been too busy to start a thread!

out comes the old 2.1

https://farm2.staticflickr.com/1475/...62f4c602_b.jpg1 by ramawson, on Flickr

got the wheel trims off to at least make it look semi respectable

https://farm2.staticflickr.com/1678/...c303ed2e_b.jpg2 by ramawson, on Flickr

obligitory "no engine here" shot

https://farm2.staticflickr.com/1676/...fde039a9_b.jpg3 by ramawson, on Flickr

ohhhh deary dear
https://farm2.staticflickr.com/1496/...e3f8eb7b_z.jpg4 by ramawson, on Flickr

yummy. thats some lovely gunk and brass in there

https://farm2.staticflickr.com/1545/...aba9a6eb_z.jpg5 by ramawson, on Flickr

dont think this poor engine's seen a oil change in a LONG time

https://farm2.staticflickr.com/1485/...2b116cb5_b.jpg6 by ramawson, on Flickr

somehow the A cam has survived!

https://farm2.staticflickr.com/1465/...e055db57_b.jpg7 by ramawson, on Flickr

fitted GLT leathers i got off chesh. then turned it into a parts dump

https://farm2.staticflickr.com/1542/...29732e12_b.jpg8 by ramawson, on Flickr

sorta a shot of the rear leathers

https://farm2.staticflickr.com/1659/...14217253_b.jpg9 by ramawson, on Flickr

riding high with no engine

https://farm2.staticflickr.com/1530/...1a56e002_b.jpg10 by ramawson, on Flickr

engine on the floor ready to strip down

https://farm2.staticflickr.com/1628/...0f0bfa40_b.jpg11 by ramawson, on Flickr

how it looked when it arrived. with me faffing with the oil pressure switch

https://farm2.staticflickr.com/1529/...11e30647_b.jpg12 by ramawson, on Flickr

so as promiced another update. this one is more of a "general bodywork search" showing off why we decided this 240 needed saving. and a bit more of the pulling of the engine pictures. also some of the amazing bodge work that has happened on this car before. some how do we say.....interesting fix's going on

bulkhead seam not rusty

https://farm2.staticflickr.com/1617/...7474c2d8_b.jpg13 by ramawson, on Flickr

floor by chassis rail not rusty

https://farm2.staticflickr.com/1526/...de4112b8_b.jpg14 by ramawson, on Flickr

joining seam between rear quater and sil not rusty

https://farm2.staticflickr.com/1699/...ce4daf24_b.jpg15 by ramawson, on Flickr

A pillars not rusty

https://farm2.staticflickr.com/1444/...f28cd624_b.jpg16 by ramawson, on Flickr

rear seam has some slight rust on the inside but not bubbled to the outer edge yet. verry savable

https://farm2.staticflickr.com/1568/...518c0761_b.jpg17 by ramawson, on Flickr

original sils in good condition showing the original weird volvo spray pattern

https://farm2.staticflickr.com/1691/...d12b3b78_b.jpg18 by ramawson, on Flickr

sil ends ok

https://farm2.staticflickr.com/1498/...5ac20a13_b.jpg19 by ramawson, on Flickr

tailgate wiring bodge. supprising the wiring works!

https://farm2.staticflickr.com/1541/...8c5976b0_b.jpg20 by ramawson, on Flickr

3rd brake light bodge. this bodge is hiding a bodge! bodge ception

https://farm2.staticflickr.com/1580/...85d455e3_b.jpg22 by ramawson, on Flickr

by the end of the first day

https://farm2.staticflickr.com/1528/...05402f13_b.jpg24 by ramawson, on Flickr

amazing 3rd brake light bondo job and it still didnt hold

https://farm2.staticflickr.com/1596/...c4b42aef_b.jpg25 by ramawson, on Flickr

fake cladding and torslanda stripes need to come off!

https://farm2.staticflickr.com/1448/...5196765d_b.jpg26 by ramawson, on Flickr

lets see the horrors within. wish i hadnt

https://farm2.staticflickr.com/1666/...7e810d1b_b.jpg27 by ramawson, on Flickr

powerplant sat on the floor. tiny gearbox

https://farm2.staticflickr.com/1460/...21fdedbe_b.jpg28 by ramawson, on Flickr

other side showing the carb

https://farm2.staticflickr.com/1658/...084658d4_b.jpg29 by ramawson, on Flickr

You aint scared of a bit of Toil Husky, good on you !

more updates. so after the engine was chainsawed out of the old 240 the strip down started in the background really mainly cause its not that exciting. rather grimy but ya know. not much special.

i bought a set of early hazzard and rear demist switches off matthew widdop as i much prefer the early switches and the nice clunk they give, meanwhile i had the head skimmed by drakes in bradford and started to build the engine.

its a rather mashup franken engine this as its a 2.1 head on a 2.3 B230E bottom end (luckily still has the hole for the carb fuel pump so swapped aux shafts over) meaning the CR is somewhere between a B21 and B23. but should still be ok to run. gave the block a nice coat of paint n all the parts a good clean up too.

all was going well untill we found number 4 spark plug thread completely gone. nice of drakes to mention that *grumble grumble* so used the head to lift it into the car. sat it on its new engine mounts i bought for it (and gearbox mount) and took the head back off. again.

old style switches

https://farm2.staticflickr.com/1556/...7848f690_b.jpg30 by ramawson, on Flickr

fairly good condition for their age

https://farm2.staticflickr.com/1597/...26d3b812_b.jpg31 by ramawson, on Flickr

pile o bits to rebuild the engine

https://farm2.staticflickr.com/1662/...863cc912_b.jpg32 by ramawson, on Flickr

skimmed head

https://farm2.staticflickr.com/1693/...6d69b522_b.jpg33 by ramawson, on Flickr

4x4 ride hight engage!

https://farm2.staticflickr.com/1603/...d64e0ebe_b.jpg34 by ramawson, on Flickr

bare block start of the build

https://farm2.staticflickr.com/1466/...983d02b4_b.jpg35 by ramawson, on Flickr

head on

https://farm2.staticflickr.com/1565/...b9769023_b.jpg36 by ramawson, on Flickr

fresh lick of paint and cam in

https://farm2.staticflickr.com/1593/...6d2608c8_b.jpg37 by ramawson, on Flickr

hand polished the cam. not the greatest job in the world but its better than what it was

https://farm2.staticflickr.com/1523/...73a61523_b.jpg38 by ramawson, on Flickr

turbo lid on loan by john hughes as mine is proper gammy

https://farm2.staticflickr.com/1711/...5f2b62b0_b.jpg39 by ramawson, on Flickr

getting closer

https://farm2.staticflickr.com/1451/...5353446c_b.jpg40 by ramawson, on Flickr

ready for the lift now the sumps on

https://farm2.staticflickr.com/1606/...934f9198_b.jpg41 by ramawson, on Flickr

in the car but head off. one step back =(

https://farm2.staticflickr.com/1697/...05bd0d95_b.jpg42 by ramawson, on Flickr

You really get cracking on with things - looking good.

the updates are old updates. owned the car for about 3 week now so this is collective. updates will slow down when we catch up to where i am =)

were now caught back up to where the car is currently so updates will slow as its now as i do the work and a HUGE thanks to ste and john to help me get the car to this stage. its now sorta moving and showing life but were not done yet.

so after all that debarkle with the head after i got it back it was back into full swing. i bought some more early switches off ebay as im going for the early switch look. including a rear fog light switch fasten seatbelts and a purple aux switch that will be used for my efan.

put the head on the car and torqued up. we had a issue with our torque wrench out of calibration so first it leaked water like a sive but after a 2nd re-torque all was well and runs really well. block has some slight piston slap on cold. but they all do specialy after 202,000 miles, put some thicker oil in n a pressure gauge to keep a eye on stuff n itll be right. my 740 does it on cold at a certain rpm. never caused a issue.

cleaned up my glt leathers a bit and started a brake service that turned out to be bad news as 3 outta 4 calipers are shot. so dropped it back onto its wheels for now as we cant do much currently till the calipers arrive. but some nice things did arrive, a original casssette tape holder, some drive belts and a replacement fuel pump as mine is leaking air and fuel so its not doing many favors and ruining my paintwork!

more early switches

https://farm2.staticflickr.com/1682/...997ebb8f_b.jpg43 by ramawson, on Flickr

all installed. the 2 blank ones will be used for power windows. if i can find some of them switches

https://farm2.staticflickr.com/1652/...4bb40628_b.jpg45 by ramawson, on Flickr

engine taking shape now

https://farm2.staticflickr.com/1715/...446cf531_b.jpg46 by ramawson, on Flickr

cleaned the glt leathers

https://farm2.staticflickr.com/1602/...ac1db85b_b.jpg47 by ramawson, on Flickr

up in the air. its had one recon caliper. passenger side all the rest are rodgered

https://farm2.staticflickr.com/1586/...333e2181_b.jpg49 by ramawson, on Flickr

back down on its hubcaps

https://farm2.staticflickr.com/1638/...3bb7025e_b.jpg50 by ramawson, on Flickr

cassette holder

https://farm2.staticflickr.com/1702/...a77f9931_b.jpg52 by ramawson, on Flickr

drive belts

https://farm2.staticflickr.com/1509/...ee219e66_b.jpg53 by ramawson, on Flickr

fuel pump

https://farm2.staticflickr.com/1613/...56471986_b.jpg54 by ramawson, on Flickr

Those switches are mental - nearly the full rainbow set!

Well done on the work so far.

Quote:

---

Originally Posted by Shinsplintz 101

Those switches are mental - nearly the full rainbow set!

Well done on the work so far.

---

thanks. each one has a small bulb holder in it so the whole switch lights up when you turn it on. meaning the hazzard switch flashes red. the yellow fog switch glows a weird purple. rear demist is green and the purple switch turns a sorta blue. but the *CLUNK* they give switching them is so much better than the late switches that feel like their gonna snap if you breathe on them.

so some more stuff happened to the 245 over this long easter weekend i got some nice shiny recon calipers thanks to brakes int including fitting kits at not a bad price. got what we thought would be a temporary exhaust holding system turns out none of it fitted at all as it was all the wrong type. so that sadly went back. i have a jetex system on order but we wanted to MOT the car with this exhaust. deciding to wait now as other things are also on backorder so its not moving as fast now.

so fitting the calipers was a utter bitch the rears after taking the spring out to get a proper grip did come undone and the rear set of brake pipes were savable. the front did NOT want to play so got chopped off and a new one will be made. rear calipers on. i have black diamond pads and Mtec disks on order. once again back ordered so waiting on them sadly.

fitted my new fuel pump that cant be properly tested currently as the engine has no exhaust but it dosent appear to leak so. that much is good, fitted some new drive belts and then started to faf with the old volvo sound radio. gave it a clean up and WD40'd the hell out of everything to get it free again and it works! supprising with all the rust on the inside even the tape works.

new exhaust on the floor.

https://farm2.staticflickr.com/1676/...35604e53_b.jpg56 by ramawson, on Flickr

new calipers + fitting kits, nice and shiny!

https://farm2.staticflickr.com/1480/...91c1b596_b.jpg57 by ramawson, on Flickr

old front caliper off, pistons were well stuck!

https://farm2.staticflickr.com/1677/...a844db33_b.jpg58 by ramawson, on Flickr

caliper spider is judging you

https://farm2.staticflickr.com/1537/...f8acb1e6_b.jpg59 by ramawson, on Flickr

rear calipers on

https://farm2.staticflickr.com/1668/...202f4782_b.jpg60 by ramawson, on Flickr

enviromentaly friendly my car is =)

https://farm2.staticflickr.com/1710/...17b9e954_b.jpg61 by ramawson, on Flickr

the troublesome 2

https://farm2.staticflickr.com/1479/...aa9e1a5f_b.jpg62 by ramawson, on Flickr

new fuel pump fitted

https://farm2.staticflickr.com/1558/...e124a4d0_b.jpg63 by ramawson, on Flickr

new drive belts fitted

https://farm2.staticflickr.com/1528/...bd41636b_b.jpg64 by ramawson, on Flickr

rusty radio

https://farm2.staticflickr.com/1478/...9c51088c_b.jpg65 by ramawson, on Flickr

all back together and working well!

https://farm2.staticflickr.com/1704/...8034b365_b.jpg66 by ramawson, on Flickr

new cam cover gasket

https://farm2.staticflickr.com/1582/...919667ed_b.jpg67 by ramawson, on Flickr

A pillar ariel

https://farm2.staticflickr.com/1551/...fd165ed9_b.jpg68 by ramawson, on Flickr

can i request a few pics of the other 240 in some of the pics on polaris :B_thumb:

Quote:

---

Originally Posted by craigoodwood

can i request a few pics of the other 240 in some of the pics on polaris :B_thumb:

---

will get some when his cars out the garage its hidden away sulking currently.

right another update. been slightly quiet mainly due to work etc but im back

so, whats been happening on the 245. not a great deal. bought some nice Mtec drilled and grooved disks + black diamond pads to go with my recon calipers as a brakes overhaul, got my AEM wideband to setup the carb/check for fueling issues on the motorway and then will be used after the car is turbo'd too so not a total waste.

some nice pressed plates and a sticker that if people can work out is rather true, then i dordled off to banrsley with the roof bars on the 740 to secure this really good condition cofin nose bonnet. it has slight rust where the frame used to sit as its come away from the inner frame as most do it seems but its major dent free and rust free so will be a good addition as i prefer the coffin nose style.

bought a set of complete locks as currently i got a differant key for each thing. drivers door is diff to passengers door thats diff to the ignition and the boot key i aint even got!, got a 5 bar oil pressure gauge and the rubber feet to mount it. a rare 265 early uncracked center console with the rare rear power window bucket bit for cheap as it was advertised as "volvo center console" on ebay america. score!

got a genuine cam cover gasket as mine will invevitbly leak sometime and my amazing 3 gauge pod and GT braces from aus, in real good condition for the price and age i bought them at, 1 broken tab but find me one that isnt broken or cracked or something nowerdays, and dropped them into the car to give me a motivation boost n cheer me up, so thats all for now. more to come soon on the brakes mission.

brakes and pads

https://farm2.staticflickr.com/1595/...2b5db665_b.jpg69 by ramawson, on Flickr

AEM wideband gauge

https://farm2.staticflickr.com/1443/...81b39340_b.jpg70 by ramawson, on Flickr

pressed plates and sticker

https://farm2.staticflickr.com/1452/...de8e0132_b.jpg71 by ramawson, on Flickr

coffin nose bonnet underside

https://farm2.staticflickr.com/1499/...c51058bc_b.jpg72 by ramawson, on Flickr

slight rust forming

https://farm2.staticflickr.com/1720/...88f08b7a_b.jpg73 by ramawson, on Flickr

strapped on the roof. using reflections to judge dents

https://farm2.staticflickr.com/1582/...85004f7a_b.jpg74 by ramawson, on Flickr

new locks for the car

https://farm2.staticflickr.com/1573/...f6b9aaf0_b.jpg75 by ramawson, on Flickr

5 bar oil gauge

https://farm2.staticflickr.com/1664/...5cb3551d_b.jpg76 by ramawson, on Flickr

rubber feet for the gauge

https://farm2.staticflickr.com/1516/...5a6f85e0_b.jpg77 by ramawson, on Flickr

center console

https://farm2.staticflickr.com/1673/...fc36dbaf_b.jpg78 by ramawson, on Flickr

genuine cam cover gasket

https://farm2.staticflickr.com/1519/...76114a73_b.jpg79 by ramawson, on Flickr

gt braces and gauges

https://farm2.staticflickr.com/1686/...643f2681_b.jpg80 by ramawson, on Flickr

close up on the gauges

https://farm2.staticflickr.com/1506/...db632abe_b.jpg81 by ramawson, on Flickr

how they sit in the car

https://farm2.staticflickr.com/1668/...c76e11fd_b.jpg82 by ramawson, on Flickr

another small update that i couldnt fit into the last!

after resting the gauges in the car i went about sorting the brakes out with new Mtec disks, recon calipers black diamond pads and new hardware all round, even the rain wasnt stopping me as 740 to the rescue to make a make shift tent untill the hail past, managed to put them on the wrong way around first time whoops! also "adjusted" volvos stupid strut design and slotted the brake line bracket so i can remove them later on.

then did some wiring to take my fog light switch from on the dashboard to the center console on the old style switch, love how they light up the whole switch, and then warming the car up it just died, no fuel being delivered at all n heres your issue, pump arm had snapped almost clean off, crappy pro parts sweden part couldve easily been a lot worse aka dead engine!

other than that gave it a clean sorted out the front and then made the volt gauge work to cheer me up a bit more after the fuel pump fiasco!

740 to the rescue!

https://farm2.staticflickr.com/1496/...6b3ae348_b.jpg83 by ramawson, on Flickr

disks on! the wrong way around.

https://farm2.staticflickr.com/1617/...268c7afd_b.jpg84 by ramawson, on Flickr

"adjusting" the strut

https://farm2.staticflickr.com/1514/...9637b321_b.jpg85 by ramawson, on Flickr

disks and calipers all finished

https://farm2.staticflickr.com/1569/...95835b7e_b.jpg86 by ramawson, on Flickr

rear foglight switch light up

https://farm2.staticflickr.com/1534/...3cbf3a31_b.jpg87 by ramawson, on Flickr

broken fuel pump

https://farm2.staticflickr.com/1647/...488d27e1_b.jpg88 by ramawson, on Flickr

dropped the car back onto the ground

https://farm2.staticflickr.com/1623/...bbbe3e6a_b.jpg89 by ramawson, on Flickr

volt meter working

https://farm2.staticflickr.com/1668/...d31bcb5b_b.jpg90 by ramawson, on Flickr

cleaned up the front

https://farm2.staticflickr.com/1502/...73a9f73f_b.jpg91 by ramawson, on Flickr

fear my performance brakes behined DL steelies! looks so stupid

https://farm2.staticflickr.com/1475/...577f3314_b.jpg92 by ramawson, on Flickr

so heres a small update things have been happening just mainly off camera and slowly as the 740's been a priority for its MOT. more on that in the other thread, anyway the 240 has had a bit done.

dragged the cover off it and got it in the sun with johns 245 turbo, went to a 80 244 breaker and got some good big bumpers + rubbers, early center console (i was toying with the idea but not gonna work sadly with a late dash) and some other odds n sods for the car. then it got rolled into johns workshop for some roof work. sanding all the horid vinyl glue off the roof and filling dents. going well so far i think!

i also got a coffin nose grill. that came off the same car my bonnet came from! but that will be a inbetween grille untill i find a good condition turbo one.

the 2 together

https://farm2.staticflickr.com/1691/...930cbe4a_b.jpg93 by ramawson, on Flickr

the DL disaster

https://farm2.staticflickr.com/1551/...878a9527_b.jpg94 by ramawson, on Flickr

sanding of roof almost complete

https://farm2.staticflickr.com/1679/...61d375c2_b.jpg95 by ramawson, on Flickr

first time the rust bucket has moved more than a foot. into johns workshop

https://farm2.staticflickr.com/1548/...77a2f005_b.jpg96 by ramawson, on Flickr

new grille

https://farm2.staticflickr.com/1699/...486cf9ba_b.jpg97 by ramawson, on Flickr

Another update on the 245, i have been doing stuff just been neglecting a update untill something with some bulk came along, so i tried the new grille i got on from minty and fits as well as volvo did, aka a pinky finger pannel gap each side! and started the prep on my bonnet removing the tiny parts of surface rust and fading it out found some of the original style VDO external temp senders on skandix for my gauges.

got a oil temp gauge in celcius from the states and fitted a new (used) fuel pump from a breaker car meaning the 245 now runs again! then stripped the interior back apart to give it a good clean and re-fit the gear shift boot.

then after a bit more prep i myself sprayed my bonnet in primer, first time ive ever sprayed anything in my life but it was quite fun and didnt go to badly i think. will update when the proper paint gets applied big thanks to john H as usual for showing me the basics of what to do when spraying, was quite a fun evening

bonnet on the pannel stand

https://farm8.staticflickr.com/7583/...ac74cf24_b.jpg98 by ramawson, on Flickr

testing grille fit

https://farm8.staticflickr.com/7671/...9649fbfd_b.jpg99 by ramawson, on Flickr

underbonnet shot

https://farm8.staticflickr.com/7689/...16daafed_b.jpg100 by ramawson, on Flickr

dealing with rust

https://farm8.staticflickr.com/7274/...eaa76897_b.jpg101 by ramawson, on Flickr

soon my vision will come good

https://farm8.staticflickr.com/7278/...b882a9f3_b.jpg102 by ramawson, on Flickr

a rare coffin flat 2460 with a roof mounted bonnet

https://farm8.staticflickr.com/7481/...a99a6a2f_b.jpg103 by ramawson, on Flickr

senders and a NOS air condo switch for me

https://farm8.staticflickr.com/7766/...69266b5f_b.jpg104 by ramawson, on Flickr

oil temp gauge

https://farm8.staticflickr.com/7323/...11910cdd_b.jpg105 by ramawson, on Flickr

fuel pump on n running

https://farm8.staticflickr.com/7240/...d402c029_b.jpg106 by ramawson, on Flickr

cleaning the interior

https://farm8.staticflickr.com/7556/...e452d332_b.jpg107 by ramawson, on Flickr

cleaned carpets

https://farm8.staticflickr.com/7357/...c30e6c2b_b.jpg108 by ramawson, on Flickr

bonnet prepped

https://farm8.staticflickr.com/7649/...12bb2303_b.jpg109 by ramawson, on Flickr

finished primer layer

https://farm8.staticflickr.com/7724/...2bacd171_b.jpg110 by ramawson, on Flickr

me spraying the bonnet

https://farm8.staticflickr.com/7099/...46d392bd_b.jpg111 by ramawson, on Flickr

so another update as its been a while, went to birmingham for a week so the 240 halted briefly, whats been going on? well.

got my new 5 bar oil pressure gauge kit from the states this one has a non sun faded needle, factor wiring and the sender included so was a straight fit and got it working, 203,000 mile block donated by Ste right up to 5 bar on the flick of the key so not too bad.

got a blue headrest to paint black as im having early headrests front + back in a sorta 260 style if volvo had done it that way, i do carry passengers in the rear so headrests will be usefull, got some early style indicator trim for it, replaced the broken glovebox with a working one despite the huge gap at the top thats how they seem to fit.

sorted my gauges into a final resting possition untill the turbo swap, cut most of a L.H wiring loom out of a 240 (EZK side anyway) need a cross over part to the ECM as i didnt have time to get that but ah well, did some flatting on the bonnet underside in prep for paint so it will be nice and shiny under the bonnet, cleaned up my early breather style rocker lid bought from Antz's breaker 240 came up well i think possibly gonna polish it up.

finally got pictures of my big bumpers i own i got 3 in total 1 bent one 1 complete rear and 1 body with no rubbers so ill make 1 good one out of the few i got their relitively corrosion free, and got a early style gear knob from antz too. so yeah projects moving just slowly

5 bar oil pressure gauge kit

https://c3.staticflickr.com/8/7353/2...6a123860_b.jpg113 by ramawson, on Flickr

early headrest

https://c4.staticflickr.com/8/7092/2...cb693b4e_b.jpg114 by ramawson, on Flickr

fixed glovebox

https://c4.staticflickr.com/8/7493/2...be13d6f9_b.jpg116 by ramawson, on Flickr

gauge position sorted

https://c7.staticflickr.com/8/7257/2...0cbec565_b.jpg117 by ramawson, on Flickr

L.H loom

https://c1.staticflickr.com/8/7239/2...d2bebb8d_b.jpg118 by ramawson, on Flickr

oil pressure gauge working

https://c3.staticflickr.com/8/7536/2...1a629033_b.jpg119 by ramawson, on Flickr

hosing the flatting water off

https://c5.staticflickr.com/8/7538/2...5a26897a_b.jpg120 by ramawson, on Flickr

wet flatting

https://c3.staticflickr.com/8/7315/2...6d651108_b.jpg121 by ramawson, on Flickr

early rocker lid cleaned

https://c1.staticflickr.com/8/7762/2...14ac5be7_b.jpg122 by ramawson, on Flickr

insides cleaned

https://c7.staticflickr.com/8/7450/2...0cfcc835_b.jpg123 by ramawson, on Flickr

early big bumpers in storage

https://c5.staticflickr.com/8/7675/2...541e64ef_b.jpg124 by ramawson, on Flickr

bumper body waiting

https://c4.staticflickr.com/8/7636/2...af1632c1_b.jpg125 by ramawson, on Flickr

rubbers and mounts

https://c3.staticflickr.com/8/7328/2...803c68fe_b.jpg126 by ramawson, on Flickr

early gear knob

https://c4.staticflickr.com/8/7443/2...26e0d734_b.jpg127 by ramawson, on Flickr

so i suppose i should update this thread too its been a while but just not much happening on the old flat nose with the germany trip the 740 needs the attention.

so, whats been going on, well i managed to source most of a early front end for my car, early lower pannel, headlight pannels, slam pannel, all in good condition minor surface rust to be expected, some good condition indicator units, good condition TV screens one has had a smashed lense and has rusted sadly so will need re-chromeing.

grille and surrounds for them are knackered and sadly no headlight wipers (boooo) so on the search for those + RHD lenses as these are from the continent, tore my interior back apart to re-fit the stupid gear shifter boot + GLT leather cover and early shift knob, looks ok i think and with a bit of leather conditioner it will come back i think.

got a set of early wing badges that i will have dave barton make me up some stickers for them, got a set of early rear side markers in good condition off ebay, chrome is pitting on one of them but perfectly usable for now.

got a 260 style bonnet chrome strip its slightly bent but i hope it will be salvagable if not then back searching i go, then put the interior back together again with the new radio i got from bkv, but sadly my car being a 82 no amplifier here, this radio needs a amp so some wiring to be done!

early front end parts

https://c8.staticflickr.com/8/7379/2...c98f7622_b.jpg128 by ramawson, on Flickr

interior back apart

https://c8.staticflickr.com/8/7451/2...e47263e0_b.jpg129 by ramawson, on Flickr

gear lever installed

https://c8.staticflickr.com/8/7315/2...578293e7_b.jpg130 by ramawson, on Flickr

wing badges

https://c1.staticflickr.com/8/7415/2...2da4f692_b.jpg131 by ramawson, on Flickr

side markers

https://c2.staticflickr.com/8/7407/2...eccc341c_b.jpg132 by ramawson, on Flickr

chrome bonnet strip

https://c1.staticflickr.com/8/7307/2...20c875a2_b.jpg133 by ramawson, on Flickr

showing the slight bend

https://c6.staticflickr.com/8/7733/2...eb6ebc3c_b.jpg134 by ramawson, on Flickr

interior mostly back together

https://c8.staticflickr.com/8/7319/2...f9c48a3e_b.jpg135 by ramawson, on Flickr

right sorry its been a while since i did one of these everyone. life got in the way of my precedings and well. the project sorta has been in a limbo stage for a while but now were moving forward. at a good pace so heres a update.

after the car got unearthed from its hiding space i gave it a quick wash off to get all the tree sap and crap off it ready for the bodywork by john but also to give me some inspiration. changed 2 of the door cards over to my better condition ones to give one side of the interior a small lift. used later style non power window handles so they arent all crumbley.

did some fancy shots with my gauges and badges and then my nice genuine volvo R sport turbo gauge arrived in the post from norway. its got a small crack on it and the bezel needs refurbishing but it works and its all complete so cant complain.

obiously as soon as i could i put it in the dash to realise it looks epicly awesome. and what would the gauge be without a turbo engine right? well here it is i bought this B21AT from a excelently kind old gent who has a 242 rally car. this engine was bought brand new as a crate engine. used for a few runs then taken out as the power band was limited. insides are like new bar a tiny bit of surface rust on the crank. the dizzy and fuel pump are missing (dizzy being a issue but will sort it)

the intake was modified to take a single SU already pre set for forced induction engines. this deal also came with a 740 intercooler and a uncracked turbo manifold as it has a late model head on (original head was porious) and included 2 A cams.

so back in the workshop the cars had the tailgate stripped by me. some awfuly doggy grease was found and cleand off anything before re-fitting (re-greased obiously) and i had a tidy up in the rear to do spare wheel wells. thats it for now more to follow soon =)

cleaned up

https://c8.staticflickr.com/9/8072/2...eb89f1fb_o.jpg136 by ramawson, on Flickr

door card fitted in the dark!

https://c5.staticflickr.com/9/8432/2...677e3d85_o.jpg137 by ramawson, on Flickr

gauges n badges

https://c4.staticflickr.com/9/8412/2...2898d266_o.jpg138 by ramawson, on Flickr

gauge face

https://c7.staticflickr.com/9/8647/2...f2bf2934_o.jpg139 by ramawson, on Flickr

small crack

https://c1.staticflickr.com/9/8183/2...4664ca94_o.jpg140 by ramawson, on Flickr

fitted in the cluster for now. remote mount like a saab 99 turbo is considered so i still have a wideband space

https://c1.staticflickr.com/9/8020/2...910f60ce_o.jpg141 by ramawson, on Flickr

looks cool as!

https://c2.staticflickr.com/9/8231/2...2e33e898_o.jpg142 by ramawson, on Flickr

B21AT R sport turbo kit

https://c4.staticflickr.com/9/8029/2...59b5f5c3_o.jpg143 by ramawson, on Flickr

insides of the B21

https://c7.staticflickr.com/9/8435/2...b724aa5d_o.jpg144 by ramawson, on Flickr

turbo plenum with SU carb

https://c4.staticflickr.com/9/8344/2...f0333f1e_o.jpg145 by ramawson, on Flickr

uncracked turbo manifold

https://c8.staticflickr.com/9/8076/2...fe13d639_o.jpg146 by ramawson, on Flickr

in the workshop

https://c3.staticflickr.com/9/8079/2...845a8d3c_o.jpg147 by ramawson, on Flickr

https://c3.staticflickr.com/9/8119/2...eb72aa10_o.jpg148 by ramawson, on Flickr

all cleaned

https://c6.staticflickr.com/9/8510/2...b62949b6_o.jpg149 by ramawson, on Flickr

sorting all my parts out

https://c1.staticflickr.com/9/8150/2...707d1c32_o.jpg150 by ramawson, on Flickr

Continuing to do a great job, love the bank of guages!

been slacking updating these things so heres 2 large updates from what the hells been going on!

the car got prepped and primered expertly by john hughes as he is kindly helping with the bodywork on this project. i tested out the AEM gauge in the volvo gauge holder and it will work with minor trimming to make it work. tested my mounting location for my R sport boost gauge. it will be mounted like a saab 99 turbo style on the dashboard as i prefer it in view.

the tailgate also got a coat of primer by john and i started to strip my B21AT down sadly when the head was taken off water has got in and wrecked the bores and watermarked the crank fillet radius meaning its practically a paperweight sadly. so that needs approaching from another angle. the bearings show quite some wear too. we tried to save a crank from the scrap pile but that was also junk. and then started to poke at the verry rusty wing bottoms to assess further the damage.

first layer primer going on

https://c3.staticflickr.com/6/5515/3...6e364cc8_o.jpg152 by ramawson, on Flickr

more primer applied

https://c3.staticflickr.com/6/5490/3...4a39aa45_o.jpg153 by ramawson, on Flickr

aem gauge fitment test

https://c5.staticflickr.com/9/8670/3...d415b7f1_o.jpg154 by ramawson, on Flickr

turbo gauge location test

https://c1.staticflickr.com/6/5533/3...1dcfcb6d_o.jpg155 by ramawson, on Flickr

all prepped for primer

https://c7.staticflickr.com/6/5532/3...73305215_o.jpg156 by ramawson, on Flickr

during the spraying

https://c5.staticflickr.com/6/5491/3...cc15539d_o.jpg157 by ramawson, on Flickr

tailgate primered

https://c5.staticflickr.com/9/8635/3...c6aa7928_o.jpg158 by ramawson, on Flickr

exchange sticker on my old B21AT

https://c1.staticflickr.com/6/5565/2...f91ff540_o.jpg159 by ramawson, on Flickr

watermarked bores

https://c5.staticflickr.com/6/5489/2...e578cd3e_o.jpg160 by ramawson, on Flickr

bearing wear

https://c1.staticflickr.com/6/5653/3...c206f8b6_o.jpg161 by ramawson, on Flickr

bottom end condition

https://c1.staticflickr.com/9/8676/3...19b2fc69_o.jpg162 by ramawson, on Flickr

pistons removed

https://c3.staticflickr.com/9/8623/3...9e7c61f0_o.jpg163 by ramawson, on Flickr

trying to save a crankshaft

https://c5.staticflickr.com/6/5495/2...565daaed_o.jpg164 by ramawson, on Flickr

said harness damage

https://c3.staticflickr.com/6/5646/2...e75f734b_o.jpg165 by ramawson, on Flickr

crusty wing bottoms

https://c6.staticflickr.com/6/5475/2...0de000a9_o.jpg166 by ramawson, on Flickr

gave the interior another quick clean up before i start to take it apart for the main part of the bodywork stage. got a rare late model GT badge for some badging ideas in the post, we also fitted its new face. the bonnet underside already painted by john hughes again was fitted turning it into a coffin nose. one step closer to the 260 look i want.

got a early M46 OD knob for the correct period style and stripped the interior out. usual rust in places. floors slightly crusty but overall really good inside for a 82 240 got my early rear corners to weld in to create a early rear end too from max who i thank hugely for selling them.

got my roof rack from ebay that was a nice find as they were never sold in england weirdly but this 240 did have one. its good condition bar some minor pitting to the rack feet but will be sorted out, pushed the car out into the sun to show off the new red paint and started to pull the front apart for the early front end conversion.

interior clean

https://c2.staticflickr.com/9/8574/2...5491b7f3_o.jpg167 by ramawson, on Flickr

late model gt badge

https://c8.staticflickr.com/9/8410/2...aeb353e6_o.jpg168 by ramawson, on Flickr

last time it will be flathood

https://c4.staticflickr.com/6/5798/2...2933788f_o.jpg169 by ramawson, on Flickr

new bonnet fitted

https://c7.staticflickr.com/6/5550/3...5ea4111e_o.jpg170 by ramawson, on Flickr

underside finish

https://c7.staticflickr.com/6/5498/3...2aaf3ca7_o.jpg171 by ramawson, on Flickr

new face

https://c7.staticflickr.com/6/5747/3...9fa6785a_o.jpg172 by ramawson, on Flickr

early M46 knob

https://c8.staticflickr.com/6/5743/2...cbac0e7a_o.jpg173 by ramawson, on Flickr

crusty floor

https://c8.staticflickr.com/6/5774/2...69ae867b_o.jpg174 by ramawson, on Flickr

stripping the car out

https://c6.staticflickr.com/6/5333/3...99fc0638_o.jpg175 by ramawson, on Flickr

rear floor condition

https://c8.staticflickr.com/6/5747/3...2869aa4d_o.jpg176 by ramawson, on Flickr

gutted inteiror to assess bodywork

https://c6.staticflickr.com/9/8571/3...190df2f6_o.jpg177 by ramawson, on Flickr

early rear corners collected by john

https://c2.staticflickr.com/6/5626/3...538afe8f_o.jpg178 by ramawson, on Flickr

roof rack disassembled

https://c2.staticflickr.com/6/5576/2...d27a9fcf_o.jpg179 by ramawson, on Flickr

pushed the car outside

https://c2.staticflickr.com/9/8138/3...4f71de3e_o.jpg180 by ramawson, on Flickr

started to take the front end apart

https://c2.staticflickr.com/6/5614/3...3da6c39a_o.jpg181 by ramawson, on Flickr

another small update just to keep on top of these things! after the respray i started to strip the front end of the car down. to assess the condition of inner wings etc and to start the early front end conversion so all the front pannels i wont be using. after getting everything off and drilling spot welds off it turns out its real good condition underneath.

a tiny ammount of surface rust on one inner arch nothing on the other. chassis legs ends are good. radiator crossmember has a tiny scab but otherwise good. gave the whole car a good clean and the engine bay a vector bath to make it look better i also got a early style wing from tom butterworth off ebay with minimal surface rust on the inner section. laid it on the car for some motivation as its started!

wings off

https://c7.staticflickr.com/6/5501/3...c874cd8d_b.jpg182 by ramawson, on Flickr

front pannel + headlight pannels removed

https://c3.staticflickr.com/6/5346/3...660cda94_b.jpg183 by ramawson, on Flickr

passengers arch

https://c7.staticflickr.com/6/5451/3...a178ff9b_b.jpg184 by ramawson, on Flickr

drivers arch

https://c1.staticflickr.com/6/5681/3...afa676e0_b.jpg185 by ramawson, on Flickr

chassis leg ends

https://c8.staticflickr.com/6/5762/3...ce3f6612_b.jpg186 by ramawson, on Flickr

everything cleaned up

https://c6.staticflickr.com/6/5834/3...f36abff6_b.jpg187 by ramawson, on Flickr

washed the car

https://c7.staticflickr.com/6/5495/3...f00c66bc_b.jpg188 by ramawson, on Flickr

front end washed

https://c1.staticflickr.com/6/5477/3...063e863b_b.jpg189 by ramawson, on Flickr

old stlye wing test fitted

https://c3.staticflickr.com/6/5615/3...7b04c7f6_o.jpg190 by ramawson, on Flickr

another small update just to keep up with things happeneing. i got a lovely coffin nose turbo grille from mr martin leaf for finding him a set of early round headlight buckets and bezels, it needs restoration but it will work. even if i have to replace the surround the middle is good.

gave the 240 a wash then went on a epic roadtrip in my 740 to collect some 240 parts. from huddersfield to southampton to collect another B21 that will be built into my turbo project, then up to norwich to collect a absolute huge haul of R-sport parts from a memeber on here. amazin.

lovely chap and the parts haul is just amazing. many NOS parts, literature that makes this swap a lOT easier. and some general knowlage and interesting parts. so as this update ends the 240 is sat in the sun trying to get the UV to harden the paint a bit more so we can flat and buff it. problem with painting cars in winter!

Turbo grille

https://c1.staticflickr.com/6/5786/3...40bdfe70_o.jpg191 by ramawson, on Flickr

washed the 240

https://c2.staticflickr.com/6/5706/3...dcc95623_o.jpg192 by ramawson, on Flickr

B21 in the back

https://c5.staticflickr.com/6/5688/3...70193dfb_o.jpg193 by ramawson, on Flickr

huge R-sport parts haul

https://c5.staticflickr.com/6/5459/3...c34f9f06_o.jpg194 by ramawson, on Flickr

240 parked in the sun

https://c1.staticflickr.com/6/5694/3...f0e17df1_o.jpg195 by ramawson, on Flickr

paint hardening hopefully

https://c5.staticflickr.com/6/5701/3...d8e1771b_o.jpg196 by ramawson, on Flickr

so a fairly small update but progress is being made none the less. with help from john we fitted the tailgate back onto my 240, involved flatting and polishing the paint around the hinges first before and went rather well i think. i need new rubber gaskets as mine are ruined but both hinges are nice condition now. one replaced with one i found in my r sport parts haul and one from matthew widdop.

in the meantime i just been sorting my parts into a more organised spiders nest. also making me slightly laugh how im stacking up carb turbo kits.

warming the car up on a briskly cold morning

https://c3.staticflickr.com/1/451/31...778c0a99_b.jpg197 by ramawson, on Flickr

tailgate fitted

https://c1.staticflickr.com/1/684/31...3b424852_b.jpg198 by ramawson, on Flickr

parts storage sorted

https://c1.staticflickr.com/1/106/31...0b167c27_b.jpg199 by ramawson, on Flickr

stacking them kits up

https://c3.staticflickr.com/1/94/315...684e9ae3_b.jpg200 by ramawson, on Flickr

another shot of the tailgated car

https://c1.staticflickr.com/6/5607/3...79be8737_b.jpg201 by ramawson, on Flickr

update time =) so whats been doing on not a great deal hugely. but over the festive period its had some more done. was dragged into johns workshop for another stage of bodywork. this included chopping arches, spare wheel wells, lower wings and start of the conversion to early lights.

chopped away the first arch to find the inner arch in good condition, the lip has rotted but im going narrow lip to stop the rust issue so it was simply chopped off, took the early style wing out of the cellar for marking up purposes.

we had matthew widdop re-wire my tailgate and add wiring for a 3rd brakelight as thats one safety addon i do want to do even if its not "period" people are too stupid nowerdays to look for the normal brake lights.

got a lovely set of early mudflaps from Ste as a christmas present so thanks to him for these they will look lovely on the car when its all done

we also then found out the prior bodyshop had put about 1" of filler on my rear wing. god knows what shape they were going for but its nowhere near right! so more of the green early pannel will be used to make it the right shape once again.

arch cut off

https://c3.staticflickr.com/1/580/31...78e00655_b.jpg202 by ramawson, on Flickr

early rear pannel

https://c1.staticflickr.com/1/521/31...7a2ee566_b.jpg203 by ramawson, on Flickr

amazing wiring found.....

https://c3.staticflickr.com/1/678/31...0a74f5b4_b.jpg204 by ramawson, on Flickr

my new mudflaps

https://c1.staticflickr.com/1/566/31...f881173b_b.jpg205 by ramawson, on Flickr

thickness of filler

https://c6.staticflickr.com/1/336/31...f66e4aa6_b.jpg206 by ramawson, on Flickr

early pannel mocking up

https://c8.staticflickr.com/1/618/31...4fbf4964_b.jpg207 by ramawson, on Flickr

end of the day progress

https://c2.staticflickr.com/1/408/31...70aff54f_b.jpg208 by ramawson, on Flickr

thickness of filler again

https://c8.staticflickr.com/1/661/31...04f42aa9_b.jpg209 by ramawson, on Flickr

another update. some more bodywork advances and general tat going on, me and john started the cutting out of the rear quater removing rust and accident damage that looked like the hms titanic crashed into the bloody thing!

welded on the new arch and once cold filled in with more stitches to limit filler sinkage, we inspected the window ledges and glad i got large repairs as the pictures tell the story, lots of grot, got a top executive radio for restoration for a nice cheap price nice touch for that 260 look.

and after a absolute weldathon and a few late nights the rear quater is looking a lot better, new window ledge, early rear quater installed, fixed lower wings n spare wheel wells, primered and put back outside briefly as we have other cars that need the workshop space.

and then bought a gauge pod cheap for my r sport turbo gauge cause why not.

rear quater chopped

https://c5.staticflickr.com/1/633/31...4f9b3f24_b.jpg210 by ramawson, on Flickr

lovely rust

https://c6.staticflickr.com/1/453/32...f6d8975a_b.jpg211 by ramawson, on Flickr

rust

https://c3.staticflickr.com/1/480/32...5cd05b56_b.jpg212 by ramawson, on Flickr

more rust n bad attempted repair job

https://c4.staticflickr.com/1/493/32...15450f98_b.jpg213 by ramawson, on Flickr

not much left of the seatbelt pole mount

https://c1.staticflickr.com/1/508/32...c66e8edd_b.jpg214 by ramawson, on Flickr

arch taced on

https://c6.staticflickr.com/1/319/32...1002f5ac_b.jpg215 by ramawson, on Flickr

down the door shut

https://c7.staticflickr.com/1/623/31...9e31b1b4_b.jpg216 by ramawson, on Flickr

volvo top exec ratio

https://c4.staticflickr.com/1/352/32...364c2499_b.jpg217 by ramawson, on Flickr

wiring i need to figure out

https://c5.staticflickr.com/1/528/32...4a761f01_b.jpg218 by ramawson, on Flickr

rear quater primered

https://c4.staticflickr.com/1/732/32...37da78dd_b.jpg219 by ramawson, on Flickr

first glimpse at its new look

https://c3.staticflickr.com/1/429/32...e42b3e90_b.jpg220 by ramawson, on Flickr

parked back outside

https://c3.staticflickr.com/1/438/32...fe0eaf65_b.jpg221 by ramawson, on Flickr

cheapy gauge pod

https://c1.staticflickr.com/1/256/32...0e6141fa_b.jpg222 by ramawson, on Flickr

right ive been meaning to update this for a while! life got in the way n progress has been slow but figured id show what i got

so i bought some parts from that irish breaker 262C yeah the parts arent of 100% quality as i wouldve liked but i can work with them, including the early electric mirrors, headlight wipers for tv screens n chrome door handles, then with them not being up to scratch i also bought some mirrors off USA ebay that were mint and rather cheap for the price, and im gonna work on making them RHD angle somehow with the 2 sets i got.

got a nice "intercooler" grille badge from my freind in sweden and test fitted it on the car and collected my doors from simon ward, so this lead to taking my old doors off the 245 and stripping them down for parts. and starting to prep my new doors for paint including thinnersing all the black paint off to reveal the shiny stainless underneath for my early look. and thats it! so far anyway

early wiper linkage

https://c1.staticflickr.com/4/3925/3...b6aca41b_o.jpg223 by ramawson, on Flickr

chrome door handles

https://c1.staticflickr.com/1/581/33...f9774cd9_o.jpg224 by ramawson, on Flickr

early electric wing mirrors

https://c1.staticflickr.com/1/699/32...4828d9ea_o.jpg225 by ramawson, on Flickr

intercooler badge featuring the cat

https://c1.staticflickr.com/1/775/32...bc894780_o.jpg226 by ramawson, on Flickr

another set of early mirrors

https://c1.staticflickr.com/4/3708/3...8b1d56db_o.jpg227 by ramawson, on Flickr

grille all badged up

https://c1.staticflickr.com/1/638/32...d5cfe483_o.jpg228 by ramawson, on Flickr

doors removed

https://c1.staticflickr.com/4/3671/3...5c5b8dd7_o.jpg229 by ramawson, on Flickr

door-less 240

https://c1.staticflickr.com/4/3743/3...a9ffa514_o.jpg230 by ramawson, on Flickr

a side shot, slowly comming together

https://c1.staticflickr.com/4/3904/3...97fa759e_o.jpg231 by ramawson, on Flickr

new door prep

https://c1.staticflickr.com/1/735/33...cd448355_o.jpg232 by ramawson, on Flickr

slowly getting there

https://c1.staticflickr.com/4/3666/3...40ba759e_o.jpg233 by ramawson, on Flickr

cleaned door shuts

https://c1.staticflickr.com/1/734/32...59dde0e7_o.jpg234 by ramawson, on Flickr