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  1. #1
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    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

    1 by ramawson, on Flickr

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

    2 by ramawson, on Flickr

    obligitory "no engine here" shot

    3 by ramawson, on Flickr

    ohhhh deary dear
    4 by ramawson, on Flickr

    yummy. thats some lovely gunk and brass in there

    5 by ramawson, on Flickr

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

    6 by ramawson, on Flickr

    somehow the A cam has survived!

    7 by ramawson, on Flickr

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

    8 by ramawson, on Flickr

    sorta a shot of the rear leathers

    9 by ramawson, on Flickr

    riding high with no engine

    10 by ramawson, on Flickr

    engine on the floor ready to strip down

    11 by ramawson, on Flickr

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

    12 by ramawson, on Flickr
    The Scrapyard Saved 740


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  3. #2
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    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

    13 by ramawson, on Flickr

    floor by chassis rail not rusty

    14 by ramawson, on Flickr

    joining seam between rear quater and sil not rusty

    15 by ramawson, on Flickr

    A pillars not rusty

    16 by ramawson, on Flickr

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

    17 by ramawson, on Flickr

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

    18 by ramawson, on Flickr

    sil ends ok

    19 by ramawson, on Flickr

    tailgate wiring bodge. supprising the wiring works!

    20 by ramawson, on Flickr

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

    22 by ramawson, on Flickr

    by the end of the first day

    24 by ramawson, on Flickr

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

    25 by ramawson, on Flickr

    fake cladding and torslanda stripes need to come off!

    26 by ramawson, on Flickr

    lets see the horrors within. wish i hadnt

    27 by ramawson, on Flickr

    powerplant sat on the floor. tiny gearbox

    28 by ramawson, on Flickr

    other side showing the carb

    29 by ramawson, on Flickr
    The Scrapyard Saved 740


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  5. #3
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    You aint scared of a bit of Toil Husky, good on you !

  6. #4
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    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

    30 by ramawson, on Flickr

    fairly good condition for their age

    31 by ramawson, on Flickr

    pile o bits to rebuild the engine

    32 by ramawson, on Flickr

    skimmed head

    33 by ramawson, on Flickr

    4x4 ride hight engage!

    34 by ramawson, on Flickr

    bare block start of the build

    35 by ramawson, on Flickr

    head on

    36 by ramawson, on Flickr

    fresh lick of paint and cam in

    37 by ramawson, on Flickr

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

    38 by ramawson, on Flickr

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

    39 by ramawson, on Flickr

    getting closer

    40 by ramawson, on Flickr

    ready for the lift now the sumps on

    41 by ramawson, on Flickr

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

    42 by ramawson, on Flickr
    The Scrapyard Saved 740


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  8. #5
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    You really get cracking on with things - looking good.

  9. #6
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    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 =)
    The Scrapyard Saved 740


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  11. #7
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    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

    43 by ramawson, on Flickr

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

    45 by ramawson, on Flickr

    engine taking shape now

    46 by ramawson, on Flickr

    cleaned the glt leathers

    47 by ramawson, on Flickr

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

    49 by ramawson, on Flickr

    back down on its hubcaps

    50 by ramawson, on Flickr

    cassette holder

    52 by ramawson, on Flickr

    drive belts

    53 by ramawson, on Flickr

    fuel pump

    54 by ramawson, on Flickr
    The Scrapyard Saved 740


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  13. #8
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    Those switches are mental - nearly the full rainbow set!

    Well done on the work so far.

  14. #9
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    Quote Originally Posted by Shinsplintz 101 View Post
    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.
    The Scrapyard Saved 740


  15. #10
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    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.

    56 by ramawson, on Flickr

    new calipers + fitting kits, nice and shiny!

    57 by ramawson, on Flickr

    old front caliper off, pistons were well stuck!

    58 by ramawson, on Flickr

    caliper spider is judging you

    59 by ramawson, on Flickr

    rear calipers on

    60 by ramawson, on Flickr

    enviromentaly friendly my car is =)

    61 by ramawson, on Flickr

    the troublesome 2

    62 by ramawson, on Flickr

    new fuel pump fitted

    63 by ramawson, on Flickr

    new drive belts fitted

    64 by ramawson, on Flickr

    rusty radio

    65 by ramawson, on Flickr

    all back together and working well!

    66 by ramawson, on Flickr

    new cam cover gasket

    67 by ramawson, on Flickr

    A pillar ariel

    68 by ramawson, on Flickr
    The Scrapyard Saved 740


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  17. #11
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    Overall VPCUK car of the year
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    can i request a few pics of the other 240 in some of the pics on polaris

  18. #12
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    Quote Originally Posted by craigoodwood View Post
    can i request a few pics of the other 240 in some of the pics on polaris
    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

    69 by ramawson, on Flickr

    AEM wideband gauge

    70 by ramawson, on Flickr

    pressed plates and sticker

    71 by ramawson, on Flickr

    coffin nose bonnet underside

    72 by ramawson, on Flickr

    slight rust forming

    73 by ramawson, on Flickr

    strapped on the roof. using reflections to judge dents

    74 by ramawson, on Flickr

    new locks for the car

    75 by ramawson, on Flickr

    5 bar oil gauge

    76 by ramawson, on Flickr

    rubber feet for the gauge

    77 by ramawson, on Flickr

    center console

    78 by ramawson, on Flickr

    genuine cam cover gasket

    79 by ramawson, on Flickr

    gt braces and gauges

    80 by ramawson, on Flickr

    close up on the gauges

    81 by ramawson, on Flickr

    how they sit in the car

    82 by ramawson, on Flickr
    The Scrapyard Saved 740


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  20. #13
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    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!

    83 by ramawson, on Flickr

    disks on! the wrong way around.

    84 by ramawson, on Flickr

    "adjusting" the strut

    85 by ramawson, on Flickr

    disks and calipers all finished

    86 by ramawson, on Flickr

    rear foglight switch light up

    87 by ramawson, on Flickr

    broken fuel pump

    88 by ramawson, on Flickr

    dropped the car back onto the ground

    89 by ramawson, on Flickr

    volt meter working

    90 by ramawson, on Flickr

    cleaned up the front

    91 by ramawson, on Flickr

    fear my performance brakes behined DL steelies! looks so stupid

    92 by ramawson, on Flickr
    The Scrapyard Saved 740


  21. #14
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    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

    93 by ramawson, on Flickr

    the DL disaster

    94 by ramawson, on Flickr

    sanding of roof almost complete

    95 by ramawson, on Flickr

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

    96 by ramawson, on Flickr

    new grille

    97 by ramawson, on Flickr
    The Scrapyard Saved 740


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  23. #15
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    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

    98 by ramawson, on Flickr

    testing grille fit

    99 by ramawson, on Flickr

    underbonnet shot

    100 by ramawson, on Flickr

    dealing with rust

    101 by ramawson, on Flickr

    soon my vision will come good

    102 by ramawson, on Flickr

    a rare coffin flat 2460 with a roof mounted bonnet

    103 by ramawson, on Flickr

    senders and a NOS air condo switch for me

    104 by ramawson, on Flickr

    oil temp gauge

    105 by ramawson, on Flickr

    fuel pump on n running

    106 by ramawson, on Flickr

    cleaning the interior

    107 by ramawson, on Flickr

    cleaned carpets

    108 by ramawson, on Flickr

    bonnet prepped

    109 by ramawson, on Flickr

    finished primer layer

    110 by ramawson, on Flickr

    me spraying the bonnet

    111 by ramawson, on Flickr
    The Scrapyard Saved 740


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  25. #16
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    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

    113 by ramawson, on Flickr

    early headrest

    114 by ramawson, on Flickr

    fixed glovebox

    116 by ramawson, on Flickr

    gauge position sorted

    117 by ramawson, on Flickr

    L.H loom

    118 by ramawson, on Flickr

    oil pressure gauge working

    119 by ramawson, on Flickr

    hosing the flatting water off

    120 by ramawson, on Flickr

    wet flatting

    121 by ramawson, on Flickr

    early rocker lid cleaned

    122 by ramawson, on Flickr

    insides cleaned

    123 by ramawson, on Flickr

    early big bumpers in storage

    124 by ramawson, on Flickr

    bumper body waiting

    125 by ramawson, on Flickr

    rubbers and mounts

    126 by ramawson, on Flickr

    early gear knob

    127 by ramawson, on Flickr
    The Scrapyard Saved 740


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  27. #17
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    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

    128 by ramawson, on Flickr

    interior back apart

    129 by ramawson, on Flickr

    gear lever installed

    130 by ramawson, on Flickr

    wing badges

    131 by ramawson, on Flickr

    side markers

    132 by ramawson, on Flickr

    chrome bonnet strip

    133 by ramawson, on Flickr

    showing the slight bend

    134 by ramawson, on Flickr

    interior mostly back together

    135 by ramawson, on Flickr
    The Scrapyard Saved 740


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  29. #18
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    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

    136 by ramawson, on Flickr

    door card fitted in the dark!

    137 by ramawson, on Flickr

    gauges n badges

    138 by ramawson, on Flickr

    gauge face

    139 by ramawson, on Flickr

    small crack

    140 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

    141 by ramawson, on Flickr

    looks cool as!

    142 by ramawson, on Flickr

    B21AT R sport turbo kit

    143 by ramawson, on Flickr

    insides of the B21

    144 by ramawson, on Flickr

    turbo plenum with SU carb

    145 by ramawson, on Flickr

    uncracked turbo manifold

    146 by ramawson, on Flickr

    in the workshop

    147 by ramawson, on Flickr

    148 by ramawson, on Flickr

    all cleaned

    149 by ramawson, on Flickr

    sorting all my parts out

    150 by ramawson, on Flickr
    The Scrapyard Saved 740


  30. The Following 4 Users Say Thank You to hemihusky For This Useful Post:

    jamesy12345 (Tuesday 20th September 2016),kmb (Wednesday 21st September 2016),petrolh34d (Wednesday 21st September 2016),Shinsplintz 101 (Tuesday 20th September 2016)

  31. #19
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    Continuing to do a great job, love the bank of guages!

  32. #20
    Senior Member
    Swede demon
    hemihusky's Avatar
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    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

    152 by ramawson, on Flickr

    more primer applied

    153 by ramawson, on Flickr

    aem gauge fitment test

    154 by ramawson, on Flickr

    turbo gauge location test

    155 by ramawson, on Flickr

    all prepped for primer

    156 by ramawson, on Flickr

    during the spraying

    157 by ramawson, on Flickr

    tailgate primered

    158 by ramawson, on Flickr

    exchange sticker on my old B21AT

    159 by ramawson, on Flickr

    watermarked bores

    160 by ramawson, on Flickr

    bearing wear

    161 by ramawson, on Flickr

    bottom end condition

    162 by ramawson, on Flickr

    pistons removed

    163 by ramawson, on Flickr

    trying to save a crankshaft

    164 by ramawson, on Flickr

    said harness damage

    165 by ramawson, on Flickr

    crusty wing bottoms

    166 by ramawson, on Flickr
    The Scrapyard Saved 740



 

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