1975 242 DL Mods and Upgrades - Volvo Forums - Volvo Enthusiasts Forum


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Old 11-28-2013, 04:36 AM
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Default 1975 242 DL Mods and Upgrades

Volvo 242 DL

Well, I had some downtime and thought I would at least start the project thread for the new 240.

When the Beige car was totaled, I was able to finally search for a smog exempt car. Being how I love the classic styling of the 240, I decide that a 1975 240 was the way to go, since I had all these parts to reuse. Finding one is a little more difficult than I thought, and I got pretty lucky getting this one. On with the thread.

So this car is a 1975 Volvo 240 DL with 49,000 original miles on it. It is Volvo Sapphire Blue, turns out it did get resprayed at some point a long time ago, and it has a pretty awesome interior. It is from the east coast, where it was sort of taken care of. I bought the car from whom I think is the forth owner. I am now the Fifth owner of this 242DL and hopefully, will be its last. The car is powered through a B20 engine, and is fueled by Kjet. It has an 3speed automatic transmission and 4.10 rear gear.

Long story short, I had the car shipped here, and once I got it, noticed it need a lot more attention than I originally thought. This thread will show my attempt to recreate my daily driver and improve on what I originally did within this 75 242 DL. Hope you guys enjoy this mild restore, and modification of a really iconic Volvo.

Here is when I first Got:



















Cleaning the car for the first Time:





Testing Kjet system



Starting to remove things to fix it:


Gas tank was rusted.




Removing the engine since nothing worked right:





Gross:



Fresh paint on the engine:






Working on the Engine:






Painted the Hood because it was not presentable:




Getting the Engine bay prepped for paint:



Fresh paint in the bay:








Boxes of Cleaned, sand blasted and painted parts ready to go back on the car:





Last edited by TIPSP; 11-29-2013 at 02:45 AM.
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Old 11-28-2013, 04:37 AM
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Took the entire Interior apart for Cleaning, fixing some rust, and Re Sealing the car:











New Carpet going in and reinstalling things:











New Mirrors Installed:











Starting to get it all back together:






Hydraulic Clutch Conversion.




Fixed, cleaned and New undercoating and paint for the car:







That's all for now.
More to Come!!!

Last edited by TIPSP; 11-28-2013 at 04:47 AM.
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Old 12-14-2013, 10:01 PM
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A few things recently done:

Put a new moister barrier and put the door panels back.



Panels and seats are still a little dirty, but I haven't cleaned them yet.






Also Finally got one of these. A factory GT cluster, also known as the R-Sport cluster. Brand New, original packaging also. Never Installed. Just a little dusty.





Recent outside. The hood is just resting on the towers.



Last edited by TIPSP; 12-14-2013 at 10:04 PM.
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Old 12-15-2013, 05:40 PM
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More Progress... yeah!

This is a sweet product from a member on turbobricks.com

It is a Triple "komfortblinker" board kit.

It allows the Volvo turn signal to react like the newer cars when you tap the turn signal you get three flashes instead of one.



This is the kit with the three pigtails I made to adapt the board and move it.



Board installed



It gets fused power and a ground.



Board with the Cover in






R-sport Wheel:




It's getting there...


Last edited by TIPSP; 12-24-2013 at 07:35 AM.
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Old 12-26-2013, 07:46 PM
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That is looking really nice!
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Old 12-27-2013, 01:16 AM
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Thank you!

I can't wait to finish it.

More updates will come in a week or so.
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Old 01-04-2014, 01:27 PM
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Impressive. Man you have motivation and its all looking great Nice work.
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Old 01-04-2014, 09:18 PM
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Thanks!
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Old 01-04-2014, 09:32 PM
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So, I got the entire interior "finished"

Testing the r-sport gauges...





Finishing the interior.





Top of the rear seat showing it's years...



Finishing up the firewall wiring for interior.



Should have more tomorrow.

Last edited by TIPSP; 01-04-2014 at 09:35 PM.
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Old 01-05-2014, 08:56 PM
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Painted the upper rad support/ front clip finally and some other misc engine stuff.







Painted the Mustang Drive shaft for the car:



Painted the t-5 cross member also.



I have also cleaned and routed the wiring harness in the engine bay.

More tomorrow
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Old 01-07-2014, 09:39 PM
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More Updates...

Here is the front suspension from the 75:



Here is an old image comparing the front setups:



Here is the coilover setup:





Stock rotor size with the "R" brakes





Steering rack is in



Drive Side



passenger side






This car should be pretty fun with that brake setup. I have a rear setup to compliment the fronts.

The calipers are factory Volvo R parts, and the Adapter plates are from RSI. Nice setup, and should stop this car fairly well.

The pads and rotors are just an OEM set. I will upgrade the rotors to stop tech slotted and throw on some Ferodo racing pads when it is time to replace.
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Old 01-08-2014, 07:37 PM
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Here are a few more images of the front.





Here is the adapter from RSI:



Front is done:





Wheel bearings are greased up, and feel good.
Everything is torqued, and waiting to be driven.

Here it is on the ground. Remember, there is no engine or extra weight in the car, so it will drop at least ~1.5".



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Old 01-10-2014, 10:37 AM
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Nice.

Have you considered a 'mild' chin spoiler? Always liked the look of that myself.
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Old 01-10-2014, 01:43 PM
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Quote:
Originally Posted by dnarby View Post
Nice.

Have you considered a 'mild' chin spoiler? Always liked the look of that myself.
Thanks. and yes. I do have one from the turbo car. seen here



I will add it after the car is driving.
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Old 01-10-2014, 01:49 PM
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Small update:

Fixing some rust spots and undercoating the under side moving forward to the front of the car.



still have a little more to do for undercoating.

Did the wheel arches:



The car is not perfect, but still looks pretty good.



There is still some rust on the car, but I am not dealing with that right now. Those areas will require cutting and welding the body, which then means repainting the car. That might happen at a much later time.

Axle and rear suspension are next on the list.

Edit:

Here is the clutch, flywheel and pressure plate for the T-5 setup:




Last edited by TIPSP; 01-10-2014 at 03:17 PM.
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Old 01-12-2014, 01:21 AM
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Got a new oil pan for the car.

it is a B20 pan that has been upgraded to help the oil stay near the pump.





It has a oil trap baffle and an upper oil trap baffle. Pretty cool, and should allow for high G turns without risking low oil pressure.

Nice thing is this part can also be used on a Vertical mounted B21/B230 motor, which I am gathering pieces to finish the other car. For now, it will be used on the B20.

Got the pan from Ian at http://hiperformanceautoservice.com/

Nice products and Awesome guy to work with.

Last edited by TIPSP; 01-12-2014 at 01:26 AM.
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Old 01-18-2014, 10:45 PM
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Small Update...

Got the pan painted:



Front of the engine is getting back together:

Put on some steel gears instead of the stupid fiber gears.


Working on the Head

Took the valves out and started cleaning the head:



I ordered new plastic fuel line for the car. So, once the last piece comes in, I can start changing the fittings over. That is going to be fun.
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Old 01-20-2014, 03:21 AM
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Was not able to do much today...

But we did get the head back together. Its all clean, plus new valve seals.

Before:



After:



Made a simple head stand to help install the valves easier.





Engine is almost done. Few more little things.
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Old 01-31-2014, 05:23 PM
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Got the front and rear seals done:





Finally got the gauges installed:



Put them in the glove box.



There was no where to put them that would look good, so that is why the glove box was used.



You can see them from the passenger and driver seat. These are used for testing and monitoring the AFs.



The AF gauge is done. I just need to finish wiring up the vacuum gauge and put the vacuum line to the intake manifold.
I'm thinking the vacuum gauge light will be triggered from the glove box switch.

Last edited by TIPSP; 01-31-2014 at 05:25 PM.
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Old 02-01-2014, 03:08 PM
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You putting a turbo on it? If so, what size?
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