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how light can you make a Volvo 240?

Posted by Greg Donovan 
Greg Donovan
Greg Donovan
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how light can you make a Volvo 240?
April 30, 2007 10:43AM
just curiuos how light they can be made.

can they get below 2500?



Edited 1 time(s). Last edit at 04/30/2007 10:44AM by Greg Donovan.
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john vanlandingham
John Vanlandingham
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Re: how light can you make a Volvo 240?
April 30, 2007 10:55AM
Greg Donovan Wrote:
-------------------------------------------------------
> just curiuos how light they can be made.
>
> can they get below 2500?
>
Yes.
>
>
> Edited 1 times. Last edit at Apr 30, 2007 by Greg
> Donovan.






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fridgewagon
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??....81 Volvo 242GLT?...??


Re: how light can you make a Volvo 240?
April 30, 2007 01:40PM
Yes. Everything is listed as what would be saved from what was on my 240GLT. So, like the stock brakes weigh maybe 20lbs for example, rx-7s are a bit under 10, so the weight reduction would be say 10lbs.
Here is a short list of what I've removed and weighed:
-(10-20lbs) Rx-7 brakes.
-(4lbs) Skinny 240 brake booster to save some on the front...dunno what I'll do if it breaks since they are rare as hell. I also like the more linear assist of the single 10" over the dual 8" and that it cleans up the engine bay a bit.
-(5lbs) (3" back, 7lbs full on a alum/plastic as opposed to 15+ for the small brass and 20+ for the large brass radiator) Mounting the radiator on turbo-intercooled mountings to put it 3" farther back in the engine bay for weight placement. Will also decrease response time of the fan clutch and allow the turbo-intercooled shroud to hug the fan a bit tighter too.
-(10lbs for a lighter batt, 20-30lbs off the front and on the back) Junkyard battery in a box in the back unless I score an optima/oddessy in time. -(15-35lbs coming off the front left corner to the rear right)
-(7lbs) Small starter from a 90 and later 200.
-(65lbs) Skinny bumpers (duh) (60lbs from the commandoz)
-(100lbs) A/C complete removal down to the evap.
-(32lbs) Carbon hood sourced.
-(18 lbs) Gut PS rack and all power steering brackets. Debatable...I like power steering on a nice tight new rack. Either way, I can save about 20lbs if I gut it off all the way, or about 8 by using the late pump and alloy brackets.
1(1-2lbs) Grind down intake manifold to save some weight. (about a pound or two can come off I'd guess)
-(15-25lbs)Delete K-jets at some point for much lighter MS&S (20-25lbs)
-(1-2lbs maybe?) Carve out some under the dash.
-(45lbs) Delete of sound deadening tar.
-(40lbs)Remove nasty old sound deadening mats.
-(5-10lbs) Make thinwall N/A header to replace the cast iron primaries
-(15lbs) Late thin manual window regulators from an 88+ 244DL...maybe...242 windows are heavy and I wouldn't mind power regulators...whatever there are only two windows.
Door pockets..gone.
(40-60lbs) Stock seats stay for now due to money. They are 40lbs each (without all bracketry) in a 242T.
(5-10lbs) Light weight/no stereo.
(18-35lbs) T5 aluminum gearbox over iron M46 or auto.

Maybe:
(19lbs) Weld up offending sunroof...maybe...I like the paint.
(7lbs) convert from e-codes to plastic 86+ lights...gross....yeah...no.
(20lbs) Carpet, door cards etc. This is surprizingly light, and I like carpet and door cards. Makes my car feel like less of a rattly piece hehe.

Sorry about the terrible format. I just cut and pasted this from another forum. Some weight would go back in with a cage and based on what I've welded so far (basically the front half of the shell), 5-10lbs will be added in welding wire or so. I have about a 5lb spool in it.




Edited 9 time(s). Last edit at 04/30/2007 02:09PM by fridgewagon.
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Topi
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Re: how light can you make a Volvo 240?
May 01, 2007 11:08AM
- Mine was 2200 lbs with 2.4 liter B20, M45 and rear radiator.
- Except aluminium hood, fibreclass truck lid and lexan rear window rest was lightened OEM Swedish steel.
- The nose was shortened and the floor was cut off past front seats. The Volvo floor is heavy!
- Weight was 40% front, 60% rear. Quite handful at hi speed but had great grip! Felt like Porsche 911.
http://pic80.picturetrail.com/VOL827/4337302/9228656/249681463.jpg





- RWD rocks -



Edited 1 time(s). Last edit at 05/01/2007 11:11AM by Topi.
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fridgewagon
James Kramer
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??....81 Volvo 242GLT?...??


Re: how light can you make a Volvo 240?
May 01, 2007 12:42PM
Cool stuff. I'm aiming for about 2500 or a touch lighter, but retaining most of what was there and without really compromising safety of what would be there without a cage.

Was it a 75 242 that already had the B20, or did you actually select that engine for the car?

Putting the rad in the back when turboed is something I've pondered a bit. What with the space for a rear muffler, radiator and a couple of triumph spitfires in the back...

The floor is fairly heavy. If you cage it, early 140 doors are quite a nice bit lighter than 240 doors all around, but no side-impact beams. Also, functionally I hate 140 wing windows. Miserable flimsy leaky things.

The rear side glass isn't very heavy at all. I doubt there'd be a lot of savings going to plastic. It is quite thin.

Most volvo rear floor boards rust out anyway. Nature's weight reduction lol.



Edited 1 time(s). Last edit at 05/01/2007 12:53PM by fridgewagon.
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