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Volvo Build?

Posted by Paul Buck 
Paul Buck
Paul Buck
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Location: Portland, OR
Join Date: 03/23/2015
Age: Settling Down
Posts: 155

Rally Car:
Volvo 242 in progress


Re: Volvo Build?
April 25, 2015 07:53PM
still working on ironing out the kinks of general workability before i can get to the fun stuff.

needs new fuelpump, vaccum diaphragm replaced, rear right taillight circuitboard and i'm sure i'll find seven more things when i dig into those.

more patience...
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napearson
Nick Pearson
Junior Moderator
Location: Ukiah, CA
Join Date: 09/09/2010
Age: Settling Down
Posts: 23

Rally Car:
Volvo 244


Re: Volvo Build?
May 12, 2015 11:17PM
Watching this one! Great score with the 2door, visibility is way better when sideways!
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Paul Buck
Paul Buck
Super Moderator
Location: Portland, OR
Join Date: 03/23/2015
Age: Settling Down
Posts: 155

Rally Car:
Volvo 242 in progress


Re: Volvo Build?
May 24, 2015 10:38PM
So as some of you know the big bad money wolf (the IRS) is in my beeswax and I haven't had the bankroll to get a lot done on the volvo. But that's not to say that, момчад волво!!!! hasn't been busy.

So while soo many of you guys worry about things like suspension, steering, brakes, and tough engines, we have been focused on the truly important things. Like:

Fixing and replacing broken mudflap! (they're mandatory they tell me.)

Removing useless radio antena and welding plug in hole! (improved aerodynamics and structural stability.)

Grinding welds! (shedding weight.)

Priming metal! (paint smells good.)

Car runs great now that most of the regular bugs have been worked out, just gotta get the man paid off and I can start buying all the real fun stuff.

Oh, and please take note of the 'Slavic Squat' being employed while setting up welder, it's like yoga for slavs.
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alkun
Albert Kun
Junior Moderator
Location: SF Ca.
Join Date: 01/07/2008
Age: Midlife Crisis
Posts: 1,732

Rally Car:
volvo 242


Re: Volvo Build?
May 25, 2015 12:44AM
Minty fresh!
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Paul Buck
Paul Buck
Super Moderator
Location: Portland, OR
Join Date: 03/23/2015
Age: Settling Down
Posts: 155

Rally Car:
Volvo 242 in progress


Re: Volvo Build?
October 11, 2015 08:14PM
Status report:

4.88 gears installed in Dana 30. New oil seals and it's done.

Clearances checked on axle.

Towers roughly assembled. Just need good welding and grinding off of excess.

ABS front brake calipers going in when Dana 31 comes out and 30 goes in.

It's slow, but progress is being made.
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Eric Ewert
Eric Ewert
Ultra Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 355

Rally Car:
volvo 240


Re: Volvo Build?
October 12, 2015 01:01AM
Good stuff! Fyi on the tops of the towers... That bolt hole looks like you may have some clearance issues when you run a weld under it. I didn't account for the space the weld bead takes up but got very lucky. Based on your pic not sure if you will have the same luck.

Just thought I would mention it, easier to double check now than redoing things when its welded in.
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Paul Buck
Paul Buck
Super Moderator
Location: Portland, OR
Join Date: 03/23/2015
Age: Settling Down
Posts: 155

Rally Car:
Volvo 242 in progress


Re: Volvo Build?
October 12, 2015 09:55AM
Thanks Eric, good eye! The crux of that whole mounting hole was that we had some 1 1/2" by 2" box tube and if I put the hole any higher the collar of the shock was going to rub against the box tube. It wasn't until Robert pointed the same thing out that I had that "Doh!" moment. So the plan now is to do some welding on the inside of the tube as well, and grind down the weld by the mounting hole if we have to. Welding the inside should be lots of fun!
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Eric Ewert
Eric Ewert
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Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 355

Rally Car:
volvo 240


Re: Volvo Build?
October 12, 2015 12:24PM
Glad to hear thats on the radar. I just realized I never did post any photos on how I built mine because I figured no one would care. If you want I can throw them up here if you think they will help you. That being said looks like your getting along a-ok! thumbs up
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Paul Buck
Paul Buck
Super Moderator
Location: Portland, OR
Join Date: 03/23/2015
Age: Settling Down
Posts: 155

Rally Car:
Volvo 242 in progress


Re: Volvo Build?
October 12, 2015 12:50PM
Yeah, I would like to see those pictures.

We're from the "learn as you go" school so that's why I'm always asking so many dang questions. Luckily for us Robert has been around to point out various possibilities and gently tell us our ideas are stupid. He also donated all that 1/8" plate and the box tube section.

So huzzah to everyone who has helped with ideas, pictures, materials, support, etc. It is appreciated.
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Eric Ewert
Eric Ewert
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Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 355

Rally Car:
volvo 240


Re: Volvo Build?
October 12, 2015 10:01PM
"Remember, im pulling for ya, were all in this together!"

Here's some stuff that will hopefully help you out.

Pic 1: Rough cut a 6 inch dia circle and tack it to the tube, you now have the tube as a guide to sand the flat bar to a perfect circle. (well as perfect as we need it) Note: buying a 6 inch chunk of flat bar from the get go makes the cutting easier and quicker.

Pic 2: Mark out where side plates are going to go.

Pic 3: Positioning the plates with the bolt hole/ spacer. The spacer in between them is the same width as the spacers WHEN INSTALLED IN THE COILOVER EYELETS. It when bolted in there keeps the two plates the correct width apart.

Pic 4: After welding you should have nice guides from the welding heat staining to cut the bottoms out and give a final sanding and blending.

Pic 5: Final top mount from the top view



Edited 5 time(s). Last edit at 10/12/2015 10:12PM by Eric Ewert.
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Paul Buck
Paul Buck
Super Moderator
Location: Portland, OR
Join Date: 03/23/2015
Age: Settling Down
Posts: 155

Rally Car:
Volvo 242 in progress


Re: Volvo Build?
October 12, 2015 10:12PM
I would have rather done it the way you did. But we were resigned to using what was on hand or donated. So instead of using a whole circle of 1/8" plate and then welding on some box section and cutting, (which seems the most logical,) we made half circles of plate and welded the halves to the box section. C'est la vie.
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Eric Ewert
Eric Ewert
Ultra Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 355

Rally Car:
volvo 240


Re: Volvo Build?
October 12, 2015 10:21PM
Understandable and I am by no means saying my way is "the way". Obviously what you got going on should work just the same. Your method also uses a piece of rectangular tube which I like... cuts down on welding the top of it shut and possibly saves a bit on grinder use which im always into.

Continue on!!!
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B85
Randy Wefel
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Location: Glendale,AZ
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98 Forester


B85
Re: Volvo Build?
October 13, 2015 09:18AM
Nice welds !



"Oh, RALLY !
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john vanlandingham
John Vanlandingham
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Saab 96 V4



Re: Volvo Build?
October 19, 2015 10:40AM
Quote
Paul Buck
Yeah, I would like to see those pictures.

We're from the "learn as you go" school so that's why I'm always asking so many dang questions. Luckily for us Robert has been around to point out various possibilities and gently tell us our ideas are stupid. He also donated all that 1/8" plate and the box tube section.

So huzzah to everyone who has helped with ideas, pictures, materials, support, etc. It is appreciated.

And how's the fit? In other words, what's the side to side distance inside the box section relative to the nifty spacers that you have for the upper eyelet?
Or isn't that important?



John Vanlandingham
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Robert Culbertson
Robert Culbertson
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Location: Portland , Or
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MK2 VW GTI



Re: Volvo Build?
October 19, 2015 02:28PM
Quote
john vanlandingham

And how's the fit? In other words, what's the side to side distance inside the box section relative to the nifty spacers that you have for the upper eyelet?
Or isn't that important?

The outside measurement for the spacers when stuck into the bearings was 32mm, correct?
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