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


Reply
 
 
 
Thread Tools Search this Thread
  #1  
Old 11-28-2013, 05:36 AM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default 1975 242 DL Mods and Upgrades

Photobucket is not hosting 3rd party anymore. I am currently redoing the hosting elsewhere. It will take some time to finish.

For the time being, you can view the story here:
https://www.projectmoro.com/1975-242

Images and thread are now on Turbobricks now: http://forums.turbobricks.com/showthread.php?t=317056

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:


Name:  DSC_7802.jpg
Views: 1277
Size:  90.7 KB


Name:  DSC_7816.jpg
Views: 409
Size:  77.7 KB

Name:  DSC_7830.jpg
Views: 408
Size:  81.6 KB







Name:  DSC_8394.jpg
Views: 403
Size:  49.7 KB

Name:  DSC_7895.jpg
Views: 404
Size:  57.3 KB

Cleaning the car for the first Time:

Name:  DSC_7900.jpg
Views: 420
Size:  75.9 KB

Name:  DSC_7921.jpg
Views: 406
Size:  55.0 KB

Testing Kjet system

Name:  DSC_7967.jpg
Views: 410
Size:  76.3 KB

Starting to remove things to fix it:


Gas tank was rusted.


Name:  DSC_7953.jpg
Views: 403
Size:  45.7 KB

Removing the engine since nothing worked right:

Name:  DSC_7985.jpg
Views: 404
Size:  78.9 KB

Name:  DSC_8009.jpg
Views: 405
Size:  66.1 KB

Gross:

Name:  DSC_8012.jpg
Views: 402
Size:  61.7 KB

Fresh paint on the engine:

Name:  DSC_8152.jpg
Views: 405
Size:  71.3 KB




Working on the Engine:


Name:  DSC_8413.jpg
Views: 400
Size:  76.3 KB



Painted the Hood because it was not presentable:


Name:  DSC_9082.jpg
Views: 402
Size:  73.4 KB

Getting the Engine bay prepped for paint:

Name:  DSC_8275.jpg
Views: 404
Size:  73.9 KB

Fresh paint in the bay:


Name:  DSC_9314.jpg
Views: 405
Size:  68.1 KB


Name:  DSC_9316.jpg
Views: 398
Size:  75.3 KB


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


Name:  DSC_9202.jpg
Views: 399
Size:  75.9 KB


Last edited by TIPSP; 11-14-2017 at 09:59 PM.
Reply With Quote
  #2  
Old 11-28-2013, 05:37 AM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Took the entire Interior apart for Cleaning, fixing some rust, and Re Sealing the car:





Name:  DSC_8385.jpg
Views: 399
Size:  53.3 KB


Name:  DSC_9334.jpg
Views: 397
Size:  77.1 KB


New Carpet going in and reinstalling things:


Name:  DSC_9447.jpg
Views: 398
Size:  47.5 KB


Name:  DSC_9451.jpg
Views: 396
Size:  66.2 KB


Name:  DSC_9454.jpg
Views: 393
Size:  60.8 KB


New Mirrors Installed:


Name:  DSC_9449.jpg
Views: 402
Size:  59.8 KB


Name:  DSC_9490.jpg
Views: 399
Size:  40.3 KB


Name:  DSC_9428.jpg
Views: 403
Size:  74.3 KB


Starting to get it all back together:


Name:  DSC_9368.jpg
Views: 399
Size:  51.9 KB



Hydraulic Clutch Conversion.


Name:  DSC_9339.jpg
Views: 397
Size:  43.3 KB

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


Name:  DSC_8773.jpg
Views: 396
Size:  49.9 KB




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

Last edited by TIPSP; 11-28-2013 at 05:47 AM.
Reply With Quote
  #3  
Old 12-14-2013, 11:01 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

A few things recently done:

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

Name:  DSC_9699.jpg
Views: 397
Size:  70.7 KB

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

Name:  DSC_9715.jpg
Views: 397
Size:  74.6 KB

Name:  DSC_9718.jpg
Views: 400
Size:  65.0 KB


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.


Name:  DSC_9738.jpg
Views: 567
Size:  50.7 KB


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


Name:  DSC_9722.jpg
Views: 399
Size:  80.1 KB

Last edited by TIPSP; 12-14-2013 at 11:04 PM.
Reply With Quote
  #4  
Old 12-15-2013, 06:40 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

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.

Name:  DSC_9751.jpg
Views: 401
Size:  59.1 KB

Board installed



It gets fused power and a ground.

Name:  DSC_9757.jpg
Views: 397
Size:  61.4 KB

Board with the Cover in

Name:  DSC_9773.jpg
Views: 395
Size:  61.4 KB


Name:  DSC_9770.jpg
Views: 403
Size:  80.8 KB

R-sport Wheel:

Name:  DSC_9764.jpg
Views: 396
Size:  64.7 KB


It's getting there...

Name:  DSC_9778.jpg
Views: 400
Size:  73.8 KB

Last edited by TIPSP; 12-24-2013 at 08:35 AM.
Reply With Quote
  #5  
Old 12-26-2013, 08:46 PM
dnarby's Avatar
Senior Member
 
Join Date: Jun 2010
Posts: 180
Default

That is looking really nice!
Reply With Quote
  #6  
Old 12-27-2013, 02:16 AM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Thank you!

I can't wait to finish it.

More updates will come in a week or so.
Reply With Quote
  #7  
Old 01-04-2014, 02:27 PM
tox_slaughter's Avatar
Member
 
Join Date: Nov 2013
Location: Portland, OR
Posts: 85
Default

Impressive. Man you have motivation and its all looking great Nice work.
Reply With Quote
  #8  
Old 01-04-2014, 10:18 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Thanks!
Reply With Quote
  #9  
Old 01-04-2014, 10:32 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

So, I got the entire interior "finished"

Testing the r-sport gauges...



Name:  DSC_0167.jpg
Views: 395
Size:  63.2 KB

Finishing the interior.

Name:  DSC_0223.jpg
Views: 399
Size:  75.5 KB

Name:  DSC_0205.jpg
Views: 399
Size:  75.6 KB

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

Name:  DSC_0207.jpg
Views: 400
Size:  61.5 KB

Finishing up the firewall wiring for interior.



Should have more tomorrow.

Last edited by TIPSP; 01-04-2014 at 10:35 PM.
Reply With Quote
  #10  
Old 01-05-2014, 09:56 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Painted the upper rad support/ front clip finally and some other misc engine stuff.



Name:  DSC_0224.jpg
Views: 402
Size:  85.8 KB

Name:  DSC_0252.jpg
Views: 397
Size:  85.8 KB

Painted the Mustang Drive shaft for the car:

Name:  DSC_0248.jpg
Views: 396
Size:  85.6 KB

Painted the t-5 cross member also.

Name:  DSC_0240.jpg
Views: 398
Size:  94.2 KB

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

More tomorrow
Reply With Quote
  #11  
Old 01-07-2014, 10:39 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

More Updates...

Here is the front suspension from the 75:

Name:  DSC_0273.jpg
Views: 402
Size:  73.2 KB

Here is an old image comparing the front setups:

Name:  P8130463.jpg
Views: 398
Size:  85.4 KB

Here is the coilover setup:

Name:  PA090995.jpg
Views: 408
Size:  110.6 KB

Name:  DSC_0371.jpg
Views: 402
Size:  54.2 KB

Stock rotor size with the "R" brakes

Name:  DSC_0360.jpg
Views: 396
Size:  77.2 KB

Name:  DSC_0364.jpg
Views: 397
Size:  79.0 KB

Steering rack is in

Name:  DSC_0378.jpg
Views: 398
Size:  49.5 KB

Drive Side

Name:  DSC_0384.jpg
Views: 399
Size:  34.3 KB

passenger side

Name:  DSC_0394.jpg
Views: 396
Size:  55.0 KB

Name:  DSC_0388.jpg
Views: 401
Size:  49.6 KB


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.
Reply With Quote
  #12  
Old 01-08-2014, 08:37 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Here are a few more images of the front.

Name:  DSC_0452.jpg
Views: 395
Size:  59.4 KB

Name:  DSC_0442.jpg
Views: 392
Size:  46.9 KB

Here is the adapter from RSI:

Name:  DSC_0426.jpg
Views: 394
Size:  54.1 KB

Front is done:

Name:  DSC_0459.jpg
Views: 396
Size:  53.0 KB

Name:  DSC_0464.jpg
Views: 399
Size:  48.3 KB

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".

Name:  DSC_0414.jpg
Views: 395
Size:  64.5 KB

Name:  DSC_0478.jpg
Views: 394
Size:  64.7 KB
Reply With Quote
  #13  
Old 01-10-2014, 11:37 AM
dnarby's Avatar
Senior Member
 
Join Date: Jun 2010
Posts: 180
Default

Nice.

Have you considered a 'mild' chin spoiler? Always liked the look of that myself.
Reply With Quote
  #14  
Old 01-10-2014, 02:43 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

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

Name:  DSC_0172.jpg
Views: 398
Size:  79.7 KB

I will add it after the car is driving.
Reply With Quote
  #15  
Old 01-10-2014, 02:49 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Small update:

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

Name:  DSC_0505.jpg
Views: 404
Size:  59.0 KB

still have a little more to do for undercoating.

Did the wheel arches:

Name:  DSC_0503.jpg
Views: 404
Size:  54.5 KB

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

Name:  DSC_0512.jpg
Views: 396
Size:  79.9 KB

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:

Name:  DSC_0521.jpg
Views: 394
Size:  64.7 KB

Name:  DSC_0536.jpg
Views: 397
Size:  72.6 KB

Last edited by TIPSP; 01-10-2014 at 04:17 PM.
Reply With Quote
  #16  
Old 01-12-2014, 02:21 AM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

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.

Name:  DSC_0553.jpg
Views: 410
Size:  29.3 KB



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 02:26 AM.
Reply With Quote
  #17  
Old 01-18-2014, 11:45 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Small Update...

Got the pan painted:

Name:  DSC_0576.jpg
Views: 418
Size:  55.5 KB

Front of the engine is getting back together:

Put on some steel gears instead of the stupid fiber gears.
Name:  DSC_0585.jpg
Views: 394
Size:  64.0 KB

Working on the Head

Took the valves out and started cleaning the head:

Name:  DSC_0593.jpg
Views: 390
Size:  68.7 KB

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.
Reply With Quote
  #18  
Old 01-20-2014, 04:21 AM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Was not able to do much today...

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

Before:

Name:  DSC_8134.jpg
Views: 393
Size:  77.2 KB

After:

Name:  DSC_0610.jpg
Views: 393
Size:  61.5 KB

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

Name:  DSC_0652.jpg
Views: 392
Size:  56.8 KB

Name:  DSC_0657.jpg
Views: 378
Size:  58.8 KB

Engine is almost done. Few more little things.
Reply With Quote
  #19  
Old 01-31-2014, 06:23 PM
TIPSP's Avatar
Got Boost?
Thread Starter
 
Join Date: May 2008
Location: Moorpark, CA
Posts: 3,547
Default

Got the front and rear seals done:

Name:  DSC_0659.jpg
Views: 379
Size:  69.2 KB



Finally got the gauges installed:

Name:  DSC_0713.jpg
Views: 376
Size:  59.8 KB

Put them in the glove box.

Name:  DSC_0736.jpg
Views: 377
Size:  59.8 KB

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

Name:  DSC_0740.jpg
Views: 379
Size:  63.9 KB

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

Name:  DSC_0742.jpg
Views: 375
Size:  61.6 KB

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 06:25 PM.
Reply With Quote
  #20  
Old 02-01-2014, 04:08 PM
rspi's Avatar
Administrator
 
Join Date: Mar 2009
Location: Albuquerque, NM
Posts: 15,726
Default

You putting a turbo on it? If so, what size?
Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
1982 244T Mods and Upgrades TIPSP Volvo 240, 740 & 940 120 09-07-2013 06:10 PM
1991 745T Mods and Upgrades TIPSP Volvo 240, 740 & 940 222 08-16-2013 03:55 AM
Volvo 242 DL - 1975 JFB Volvo 240, 740 & 940 2 07-03-2010 04:45 AM
1975 Volvo 164E - Thermostat Housing? swederacer All Other Volvo's 9 05-25-2009 11:09 AM
Restoration of a 1975 Volvo 242 DL, US spec alexander_k Volvo 240, 740 & 940 0 02-15-2009 12:14 PM


Tags
1975, 242, 244, coilovers, engine, mods, performance, racing, volvo

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Advertising
Featured Sponsors
Vendor Directory

All times are GMT -5. The time now is 08:08 PM.


We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.