Justin Mason Elite Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
Hi, my name is Justin. I just bought a 1990 Volvo 240 5spd last week and I'm in the process of gutting it to seam weld and build the roll cage. I'm new to this and looking for any tips and tricks anyone wants to share. I work on cars for a living and have a background in welding and fabrication, but I've never built a rally car. I have no background in racing at all, but I've always wanted to try it.
I'd like to have the car ready for testing by the first of the year and start with 100 acre wood in 2014. I work on the car before and after work. The guys I work for at KCAutosport are kind enough to let me use the shop and work on the car when we aren't busy. Besides gutting the car and starting on the roll cage, John Vanlandingham is fabricating the coilovers. He's been really helpful and is patient in answering all of my noob questions. Here a couple of pictures of the build so far. If anyone has any suggestions for me, I'd appreciate them! Nice to meet you all! |
Albert Kun Mega Moderator Location: SF Ca. Join Date: 01/07/2008 Age: Possibly Wise Posts: 1,732 Rally Car: volvo 242 |
Steve Janes Senior Moderator Location: Cocoa Beach, Florida Join Date: 06/28/2013 Age: Midlife Crisis Posts: 24 Rally Car: '79 Volvo 242 GT |
Welcome aboard car looks good so far, this is what I initially was looking for when I ended up with my 242 that I too am in the process of building just not for stage rally
 can't wait to watch the progress of this.
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Andrew Steere Senior Moderator Location: South Central Nude Hamster Join Date: 12/29/2005 Age: Possibly Wise Posts: 2,008 Rally Car: too rich for my blood, share a LeMons car |
Shit the fuck yeah!
 Andrew Steere Lyndeborough, NH KB1PJY |
Eric Ewert Mod Moderator Location: Calgary, Ab Join Date: 05/13/2013 Age: Settling Down Posts: 366 Rally Car: volvo 240 |
No way!!! I've got a 89 240 sedan 5 speed in the exact same colour haha. Im envious of your lack of speed divots though! Looking forward to progress! This makes me think I should really update my build
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Banned Elite Moderator Location: Calgary, AB Join Date: 03/27/2009 Age: Ancient Posts: 1,798 Rally Car: (ex)86 RX-7(built), (ex)2.5RS (bought) |
I've always had a thing for 240s.
I've owned two and sold Volvos new in the mid/late 80s. Had one just like this as a damagestrator. Best looking front end of all the 240s I think!  First Rally: 2001 Driver (7), Co-Driver (44) Drivers (16) Clerk (10), Official (7), Volunteer (4) Cars Built (1), Engines Built (0) Cages Built (0) Last Updated, January 4, 2015 
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Justin Mason Elite Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
Justin Mason Elite Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
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Rob Infallible Moderator Location: LI, NY Join Date: 09/25/2010 Age: Midlife Crisis Posts: 629 Rally Car: None, anymore. |
Justin Mason Elite Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
Update on Progress: I removed the sunroof cassette, which was a bigger pain in the ass than I thought it would be. It was welded and glued around the perimeter and it was welded around the opening so it had to be cut out. Reinforcement was removed from the skin and tack welded in. I also removed the front bumper supports and cut out the radiator supports and now I'm ready to remove the engine.
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John Lane Ultra Moderator Location: Lynden Washington Join Date: 01/14/2006 Age: Possibly Wise Posts: 725 Rally Car: The Fire Breathing Monster |
Justin Mason Elite Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
Found a toyota 4runner axle at the junkyard. It came with 4.56 gear and open diff. I will use the 4.56 gears but not sure if i should weld the spider gears or try to find a good clutch type diff.
Cut slots in the floor pan for the 4-link setup. I'm thinking about using 1/2 inch heim joints 3/4 inch .120 wall tube for the 4-link and 3/4 inch heim joints 1 inch .120 wall tube for the panhard rod. Does that sound sufficient? |
John Vanlandingham Infallible Moderator Location: Ford Asylum, Sleezattle, WA Join Date: 12/20/2005 Age: Fossilized Posts: 14,152 Rally Car: Saab 96 V4 |
Justin Mason Elite Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
John Vanlandingham Infallible Moderator Location: Ford Asylum, Sleezattle, WA Join Date: 12/20/2005 Age: Fossilized Posts: 14,152 Rally Car: Saab 96 V4 |
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