DeathCanRacing Justin Mason Mod 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! |
alkun Albert Kun Super Moderator Location: SF Ca. Join Date: 01/07/2008 Age: Possibly Wise Posts: 1,732 Rally Car: volvo 242 |
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Steve-O Steve Janes Professional Moderator Location: Cocoa Beach, Florida Join Date: 06/28/2013 Age: Midlife Crisis Posts: 24 Rally Car: '79 Volvo 242 GT |
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fiasco Andrew Steere Mod 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 |
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Eric Ewert Eric Ewert Super Moderator Location: Calgary, Ab Join Date: 05/13/2013 Age: Settling Down Posts: 366 Rally Car: volvo 240 |
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Morison Banned Ultra 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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DeathCanRacing Justin Mason Mod Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
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DeathCanRacing Justin Mason Mod Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
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BobOfTheFuture Rob Professional Moderator Location: LI, NY Join Date: 09/25/2010 Age: Midlife Crisis Posts: 629 Rally Car: None, anymore. |
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DeathCanRacing Justin Mason Mod 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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JohnLane John Lane Senior Moderator Location: Lynden Washington Join Date: 01/14/2006 Age: Possibly Wise Posts: 725 Rally Car: The Fire Breathing Monster |
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DeathCanRacing Justin Mason Mod 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 John Vanlandingham Ultra Moderator Location: Ford Asylum, Sleezattle, WA Join Date: 12/20/2005 Age: Fossilized Posts: 14,152 Rally Car: Saab 96 V4 |
Quickly: I like 3/4 heim and listen: you oughtta make the slot AFTER you have the rod end or bush or whatever for that end of the upper link...
And i mage my stainless spacers at some common size.. Next, we found in a real live CAD dealio that we could move around a axle and shafts and links that in the FULL UP on the one side, and FULL DROOP on the other, the links will contact the sides of the boxes, so we made the boxes taper somewhat.. NEXT!!!! Somebody else has just UPSed me their axle shafts to carve up and mod.. You might ponder the cost versus the convenience--cause doing 4 isn't that much more bother than 2... but think kind fast.. ALSO! I have to order him some links, and some here to make up for those I robbed, you want to go along with THAT order? Links are around $14-15 each, rod ends around $16-17, stainless spacers we'll see. John Vanlandingham Sleezattle, WA, USA Vive le Prole-le-ralliat www.rallyrace.net/jvab CALL +1 206 431-9696 Remember! Pacific Standard Time is 3 hours behind Eastern Standard Time. |
DeathCanRacing Justin Mason Mod Moderator Location: Gladstone, Missouri Join Date: 08/11/2013 Age: Midlife Crisis Posts: 22 Rally Car: Volvo 240 |
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john vanlandingham John Vanlandingham Ultra Moderator Location: Ford Asylum, Sleezattle, WA Join Date: 12/20/2005 Age: Fossilized Posts: 14,152 Rally Car: Saab 96 V4 |
OK I got the email, less hope that this guy jumps on it cause setting up to do the bolt circles is kinda nicer to do a few at one go.. John Vanlandingham Sleezattle, WA, USA Vive le Prole-le-ralliat www.rallyrace.net/jvab CALL +1 206 431-9696 Remember! Pacific Standard Time is 3 hours behind Eastern Standard Time. |