1975 Volvo 242 Dl

The Beginning

When the Beige car was totaled, I was able to finally search for a smog exempt car. Being how I love the classic styling of the 240, I decide that a 1975 240 was the way to go, since I had all these parts to reuse. Finding one is a little more difficult than I thought, and I got pretty lucky getting this one. On with the thread.

So this car is a 1975 Volvo 240 DL with 49,000 original miles on it. It is Volvo Sapphire Blue, turns out it did get resprayed at some point a long time ago, and it has a pretty awesome interior. It is from the east coast, where it was sort of taken care of. I bought the car from whom I think is the forth owner. I am now the Fifth owner of this 242DL and hopefully, will be its last. The car is powered through a B20 engine, and is fueled by Kjet. It has an 3speed automatic transmission and 4.10 rear gear.

Long story short, I had the car shipped here, and once I got it, noticed it need a lot more attention than I originally thought. This thread will show my attempt to recreate my daily driver and improve on what I originally did within this 75 242 DL.

 

My father and I tackled this project over the course of two and a half years. This page is a condensed version of the story, so with out any further delay... enjoy the pictures! Click the Load more! There are a lot of Images.

Here is when I first Got:

The Tear Down

The car was in pretty decent shape overall considering the age. Unfortunately, as we dug into the car, it became apparent this would not be as simple as swapping parts from from the old beige 240 turbo.  The rear brakes were frozen. The engine would not run very well. It struggled to get up the driveway when it was first delivered. The engine would not idle. The interior smelled of mold. There was rust in the gas tank. Our plan of attack was now clear... Gut the whole car and fix everything.

Production 

Warning: This section will be scattered slightly. Some items will be shown out of order in terms of completion. Not that this is really important haha. I will let the pictures do most of talking in this section also.

Once we gutted the whole care and cleaned everything, we tackled the small surface rusted areas as shown above, we proceeded to catalog all the parts, form those that only needed some freshening up, to the parts that needed repair, and finally, the parts that had to be replaced.

 

We started with the body repair. The interior was leaking water from the front cowl area, firewall plates, and side body seams. The caulking failed on the body in those areas, so all we had to do was remove the old stuff, and re-caulk the front of the interior. The carpet was moldy at this point, so I bought a set of black carpet from a buddy on turbobricks.com. The door panels showed evidence of water staining on the back side of the panels. The vapor barrier was missing so we just used some of the heavy duty painters paper from home depot. That stuff works very well, and has a nice coloring to it! As we finished the repairs and sealing the car, During reassembly, I added some light weight sound damping to help with the vibrations from the future installments. 

The next step was the suspension work. Fortunately, most of the rusted suspension parts where all being replaced with the custom setup from the beige 240 turbo. I did upgrade the front brakes with the "R" units. I have the rear "R" setup in a box still.  All in all, the swap was pretty painless. Everything bolts right up. the only really issue we ran into was the panhard bar bolt that was apart of the rear end snapped off. It was rusted. We simply drilled and tapped the shaft and are using a bolt for the time being. I can make a bracket to lower the bolt to keep the panhard bar flat, but that isn't really needed anymore. This car sits higher than the beige 240 by 1.5 inches. Everything is perfect right now.

Most of the suspension is from https://www.kaplhenke.com/ 

Anyways... on to the images!

Here is where the images start to get scrambled. Most of these events happened simultaneously. 

The Rest of the engine, and custom work will be shown now. We tore the stock engine apart. and cleaned everything we could on/ in it. The engine was in horrible shape (and still is) for only having 50,000 miles on it. The Fuel system was trash because of the rust, so we replaced the k-jet parts with rebuilt/ cleaned units, and we redid the fuel lines with new lines.

Once the engine was back in the car, we aligned the drivetrain, I went to work on the new exhaust. The budget aspect guided this part. I was learning to tig weld on this car, so I went with cheap and stuff that was easy to work with. The Header was a cheap aftermarket. The muffler was a very cheap baffled single in and out. The whole system is 2.5 inches and the tip is 2.75" piece of stainless steel. It was a little loud with just the muffler, so I added the 18" resonator in the middle section. It is still kind of loud. hahaha. 

The Next few Image sets will discuss the interior modifications, left over suspension goodies, like the rims and extend wheel studs! The rims are HRE 525s 17x8. The tires are Continental Extreme Contact DW 245 /40 17. I bought the rims off a guy i meet from another forum. They needed some work done, so I sent them off to HRE to have them refinished. The results are pretty amazing! 

The interior was in pretty nice shape. The rear bench seat back was a little faded on the top from the sun, but overall, the seats are in great condition! As much as I enjoy the stock seat styling, they offer no support for the way this car can perform. Plus I did not want to ruin the stock front seat from daily use, So I swapped them out for a set of Sparco Revs, the same seats that where in the beige 240.  The other interior feature I enjoy in a car is the stereo. Some people will argue, trying to have a car that is fun to drive on a track and still supplying everyday comforts is contradiction...  It does add weight, but its only 100lbs of extra weight! nothing a little extra power from the engine can't handle.

Anyways, Its a custom 2.1 setup. Very small and compact system, but it still can supply a big bang! The only issue.... The exhaust is a little to loud to enjoy the system sometimes. hahaha. 

After All of that was completed, we did an alignment. Once that was done, it was off for the first test drive since I got the car. Almost three years in the making to this point. Boy did it feel great to get this car on the road!

Once the car was registered, and driven for a few months, I decide this little under powered B20 needed some attention. The next item to tackle is the power. I felt that leaving the B20 in the car was the most appropriate thing to do, but then i asked myself... how to make some power? The answer was simple! supercharger! I bought a used supercharger from an old Mercedes, and went to work with planning out the rest of the setup.

First I designed the crank pulley, and started to make the bracket to hold the charger. I ordered all the plumbing parts for the intake and charge pipes, as well as, the electronics to control the boost. I am having a turbobrick forum member do the machining for the pulley and its looking nice!

Fueling with be handle via k-jet. I still need to go through my options, but I think I found which distributor and injectors I will be using. Ignition will also be stock. I might mess with the distributor a little... 

More of this project to follow!

The Sad, Mad, and the Future!

The car was on the road for 9 months since we got it running and register back in January 2016, when some lady turned way to wide on my street and hit the front of the car as I was driving to work!

Luckily the damage was not that bad, but it was a freaking nightmare dealing with insurance and a joke body shop. I was fortunate enough to find a fantastic body shop close by and they did a great job with the metal work and color matching! Unfortunately, due to insurance budget, and the overall condition of the car, the paint was not fully done on the car. But overall, the car came back from the shop and we drive on to another adventure!

The stock engine started to develop a nasty oil leak as the car was being driven during those 9 months. Long story short, The engine we had apart, was in worse shape then we originally thought. I have a new big bore B20 street tuned engine being built by Ian at Hi Performance Auto, and it is close to being done!

 

More of this to come later!

So It Begins!

The engine is now out of the car! We spent the weekend pulling it and getting all the parts ready to drop off at the builder.

Thanks for looking!

So as of July 7th 2017, the car is sitting in my driveway waiting for the new engine to come in. The "R" rear brakes, supercharger, and other missing items not listed in here will be completed once the engine is in the car and derivable. 

This car has been through a lot, and this project is very close to being completed! I have had lots of help over the years from a lot of great people in and outside the volvo community. 

All work and Images © by Jeff Moro. Usage and distribution is strictly prohibitive without my consent.