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Volvo 240 Rally build

Posted by Eric Ewert 
Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
November 22, 2014 05:10PM
Well might actually have something worth posting as far as progress goes. Closed up the rear towers. Interior back together, driver seat and harness in. Interior is very half ass put together simply because it will be apart in the near future for paint.
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Asphyxious
Nickilas Kramer
Mega Moderator
Location: Calgary AB
Join Date: 11/23/2014
Age: Party Animal
Posts: 1

Rally Car:
Volvo 244


Re: Volvo 240 Rally build
November 23, 2014 09:41PM
Hey, nick here. Really like what you've done with the car. I'm also located in Calgary.
Would love to see this in person some time.
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Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
November 23, 2014 10:34PM
Feel free to swing by whenever! Just give me a bit of a heads up. Im in the northwest corner towards bears paw.
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Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
December 02, 2014 02:42AM
Well not much this week but its something so i'm moving forward which is never a bad thing. And for the first time I actually got everything done that I wrote down to do for the week. smileys with beer The space next to me felt very empty so I filled it up with some co driver, seat, harness and associated mounts. Hopefully they give me a log book. confused smiley
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MattP
Matt Pullen
Elite Moderator
Location: Calgary
Join Date: 10/22/2013
Age: Midlife Crisis
Posts: 257

Rally Car:
2002 Ford StRanger


Re: Volvo 240 Rally build
December 02, 2014 10:00PM
Mike will give you a Log book. Are you going to be ready for Cochrane?



Yes, it's a Ranger.
Xr4Ti, it is rwd and was made in Germany.
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Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
February 23, 2015 12:54AM
Matt sadly the car would be but my wallet wont due to school. If the rally were in a few months I would be golden. In other words see you in may at radium!

So I've been working on this thing... Toyota axle is almost complete in terms of fab. Just need to strengthen the panhard mount and add some points for brake lines to be bolted to. The 4 link also got completed. Butt cheeks also got hacked out.

T5 is kinda in. I need to fab up a cross member for it but all parts are ready to go including driveshaft. Might modify the stock crossmember for now in the interests of saving some time.

Probably a days work to do before painting the interior and underside! "Knock on wood"

I got a few questions on how I did the turrets so if anyone is interested I can show in more detail how I did the 4 link boxes. Just ask.
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Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
February 23, 2015 01:13AM
And some more of my antics... btw the elastics on the axle are not for keeping the bolts in place they are there as a centerline point. Oh and the t5 was rebuilt early january with all new bearings, seals, shift fork pads, v8 2.95 first gear ratio, etc. On a side note the underside was sandblasted and I sorted out some hidden rust spots. Nothing too scary though.
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MattP
Matt Pullen
Elite Moderator
Location: Calgary
Join Date: 10/22/2013
Age: Midlife Crisis
Posts: 257

Rally Car:
2002 Ford StRanger


Re: Volvo 240 Rally build
February 25, 2015 12:48PM
Looking good Eric, soooo if you can't rally how about coming out to volunteer?



Yes, it's a Ranger.
Xr4Ti, it is rwd and was made in Germany.
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tdrrally
edward mucklow
Infallible Moderator
Location: charleston,wv
Join Date: 05/31/2011
Age: Midlife Crisis
Posts: 736

Rally Car:
ford mustang LX 5.0, 1973 VW Beetle



Re: Volvo 240 Rally build
February 25, 2015 12:57PM
looking good !!!



I would rather drive a slow car fast as a fast car slow!
first rule of cars: get what makes you happy, your the one paying for it!
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Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
March 16, 2015 01:20AM
Sorry Matt i'd normally be out there volunteering ( I have for the last 2 or 3 years) but this time round I just had too much going on with school + loosing a weekend due to some unexpected events. In the end its a good thing I couldn't race. Hope it went well for you and everyone out there!

I have made some progress on the car... 4 link complete, panhard mount done and axle painted. Modified transmission tunnel to cram 1 piece shaft in there (probably can't see from photos). It just barely interfered and had I noticed it earlier I probably could have gotten away with altering the pinion angle sightly. However the driveshaft sits nice and straight this way.

Interior painted. Forgot to throw a photo up on the last post. The car got a logbook at the very end of 2014.

Need to make some caliper adapters. I painted the axle before doing this to force myself to make a bolt on solution for a number of reasons. Truth is it should be fairly easy compared to all the other fab i've done to this thing. After that just rear brake lines and some assembly!

Im now slightly scared to smack it up... maybe Ill leave the exterior in a state of silver+ primer+ hail damage+ white overspray to help with this fear. Then again... i've gone this far.eye rolling smiley
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alkun
Albert Kun
Professional Moderator
Location: SF Ca.
Join Date: 01/07/2008
Age: Midlife Crisis
Posts: 1,732

Rally Car:
volvo 242


Re: Volvo 240 Rally build
March 16, 2015 02:02AM
awesome sause
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MattWatson
Matt Watson
Ultra Moderator
Location: Calgary
Join Date: 04/17/2013
Age: Settling Down
Posts: 151

Rally Car:
Merkur



Re: Volvo 240 Rally build
March 18, 2015 05:13PM
Man those axles look nice... especially since they aren't in my garage anymore.

I like your interior paint. Nice and glossy. I say nicer than the 'pure' epoxy I used.
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aj_johnson
A.J. Johnson
Professional Moderator
Location: Pendleton OR
Join Date: 01/07/2011
Age: Settling Down
Posts: 1,349

Rally Car:
88 Audi 80


Re: Volvo 240 Rally build
March 18, 2015 09:49PM
You're gonna whack the snot outta that interior. Did mine in a chevy white so I could keep a rattle can of the stuff handy for all the grinding and cutting of stuff I din't think of and for all the whacks of the door bars.

Looks real purty



Edited 1 time(s). Last edit at 03/18/2015 09:50PM by aj_johnson.
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napearson
Nick Pearson
Mega Moderator
Location: Ukiah, CA
Join Date: 09/09/2010
Age: Settling Down
Posts: 23

Rally Car:
Volvo 244


Re: Volvo 240 Rally build
May 12, 2015 10:52PM
Great build! Just read through the entire thing, have you driven it? Raced it?
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Eric Ewert
Eric Ewert
Mod Moderator
Location: Calgary, Ab
Join Date: 05/13/2013
Age: Party Animal
Posts: 354

Rally Car:
volvo 240


Re: Volvo 240 Rally build
May 19, 2015 07:02PM
Quote
napearson
Great build! Just read through the entire thing, have you driven it? Raced it?


Opps I dont know how I didn't see this till now.

I drove the car as something of a dry build, when it only had the rear shock towers in place and a cage. It was fun. Have not raced it yet or driven it since the t5 + 4 link install as I have been too busy as of late to put it back together. Currently it is sitting mostly bolted back together with a half finished diff/ r&p install and some funky electrics. Really not much more to do just need to find time to do it.
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