740 / 242 Going Inline 5 and other projects

[juss]

I dont where even to start, but here goes. Thought that it would be interesting for somebody to read and even for me to look back what i have done.

Already almost 4 years ago I bought this Volvo 242 from a friend. It had already been modified to be a track car. But for some things that had been done weren't that good, previous project car things I guess and more the reason to make it my own.
Couple of seasons i used it as it was. Built B230F with 16T turbo, Ecumaster and loads of supporting mods.

Exact spec list how I got it:
B230F 8V, honed and added oil squirters
531 head with slight porting done to it
Maxspeeding rods
Pistons from a turbo engine
KL Racing T2 camshaft
875cc Siemens deka injectors
Electronic boost controller
VAG coilpack
Greddy replica BOV
Ecumaster Emu black
Ebay intercooler
XC70 radiator with 2 stage fans
16T turbo, 3" downpipe and exhaust with one resonator
Setrab oil cooler
Bosch 044 fuel pump, Generic 2 litre fuel surge tank
BMW ZF transmission with an adapter plate
OE Flywheel
AAN Clutch pressure plate, BMW tds clutch disc
Mixmatched driveshaft
Eaton Detroit truetrac differential
BC Racing coilovers
Poly bushings all around
Modified rear axle control arms, adjustable torque rods and panhard bar rod
Stainless steel braided brake lines and otherwise stock brakes
Recaro SPG seats
6p harnesses
Half cage
Autometer gauges (Oil temp, pressure, boost, tach)
Sabelt steering wheel
Group A replica wing
Eggcrate grill

As I got it:

View this content on Instagram

View this content on Instagram

Now almost two seasons ago I discovered that Estonian weather and the salts that are on our roads (I have not driven this car during winter) have done irreversable things to the metal structure of the car. So bodywork was in order. But in my typical fashion things went out of proportion really quickly. Initially I found that the floors weren't that good. The driver seat actually moved from side to side. No bueno. As i started to repair it I found more previously done repairs that are not up to my quality standards and I want to keep this car longer, even forever?
Today the car is a blank slate, a rolling shell with front and back windows but nothing more.

If I find a better solution for picture uploading then I will add more of the repair process.

 

[propav8r]

Good looking car, and everybody loves a 5 cylinder swap. I like imgur.com for image hosting, but there are plenty of options out there.

 

[dl242gt]

If you make your pictures 1mb then they will upload directly to the forum except for off topic.

 

[James M]

Mmmm yes whiteblock all the 242s

 

[adomz]

Nice one!

Car looks really great!

ADam

 

[juss]

This is going to be a glimpse into the work i have done already and surely does not reflect all of it.
In the end of 2022 I started to dismantle the car in the hopes that I don't have to go to far. First up was the nose. Somebody previously had hacked up the front end to get the intercooler piping to fit and from there some rust started to form. So one of the front light fixtures was rotten from the bottom.









Also 240's had the headlight wipers, those holes are starts of rust as well and mine is no different, so those needed repairs.







After those first repairs I decided that is probably a good idea to pull out rest of the interior. It did not have much due to the fact that it's a racecar already but the HVAC, dash, wiring, etc had to go..



Revealing stuff..

 

[juss]

Actually does not seem that bad



After a little bit of cleaning and paint thinner fumes most of the sounddeadening glue was removed



But it already made a pile of garbage on the floor



First repair panel testfit.. Here you can see that the driver side floor is mostly eroded away.





Driver side sill that i cut open, also the previous repairs are seen. Patches on patches.



Then i got carried away. It had to be done. Sill removed, driver side rear floor cut out.





Also started repairing the inner rocket panel. The lower portion was so gone that there was almost nothing to go of.

 

[juss]

Driver front also removed



Outer rocker testfit





Inner sill ready and under primer. Where I welded I used Kent's weldthrough primer. Great stuff, and does not smell horribly when hot.



Outer sill in place and welded.



Driver side rear patch panel in place.



Front patch panel cut to size and almost prepared to be welded in.



But before the driver front can go in the frame rail had to be cleaned, treated and primered. Afterwards when I clean the underside and see that some of the framerail has to be replaced then I will do that. Not the best way to go but what are you gonna do. Did not think that far ahead.

 

[juss]

At some point I got an engine. This one is B5244T3, but I discovered that this has 147mm rods, I bought 139,5mm H-profile rods. So have to think what to do about that.




Continuing with the repairs. The left hand rear arch was also previously replaced, but the inner wing was left alone. So that was complete garbage.



Also the rear buttcheek portion was badly repaired and was rotting.





And the state it is in currently. There is lots more to do. Right side of the car needs the same treatment basically, the rear panel where lights go, the lower lip is rusty, engine bay etc.

 

[poulrais]

I admire your skills and even more your dedication. Bodywork is definitely not my thing!

 

[juss]

Yesterday night after work i did some more work on the 242. The rear section and trunk floor has some rust damage aswell. The lip where the rear lightpanel, inner structure and trunk floor meet are crusty the crab looking. Some spot weld drilling, cutting etc later i got the inner structure and portion of the outer panel removed so I can go forward repairing the trunk floor.
For the outer panel I have a repair panel bought.
Also got one of the bumper outer mounting panel removed as well, it is so rusty that i think i will make both new ones from scratch.









And for the floor I have not taken pictures of the end result. Currently it's possible to compare it to the passenger side, although it is not as bad.

 

[adomz]

Damn this si looking great! Subbed!

ADam

 

[244tiCanuck]

I admire your skills and even more your dedication. Bodywork is definitely not my thing!

Agreed. I will rebuild an entire car, mechanically and interior, but a little spot of rust and I'll scrap it and get another project.

 

[juss]

I admire your skills and even more your dedication. Bodywork is definitely not my thing!

Here in Estonia the 2 doors are quite rare and the ones that are decent, cost way too much or are not for sale. The ones that are for sale (none I have seen in recent years) most likely are like mine. This actually was brought over from Finland and at first it was considered a really good shell. Now I am the one repairing it

Damn this si looking great! Subbed!

ADam

I hope it will look great. I have a color in mind also, will see about that.

Agreed. I will rebuild an entire car, mechanically and interior, but a little spot of rust and I'll scrap it and get another project.

In hindsight I should have done the mechanical side first, the T5 engine etc. Would have drove it a while and then the bodywork after when everything else was sorted. But this gives me way more planning time

This weekend I started on one of the front fenders, as it was a simple thing to do and I did not have much time. It's a spare I got from another car with slight surface rust and couple of dents. I welded the trim holes shut. I like 242's without the trim much more and so that dirt would not get behind the trim and start rusting again. After welding I ground the welds down and covered with temporary primer.
But before the welding could even happen I had to remove the bitumen undercoating from the inside. Should have used a respirator, as it is quite nasty stuff and wont come off any easier way than slight heat and mechanical scrubbing. Residue was removed with paint thinner.

 

[adomz]

That's ace!

Makesm eanxious to do stuff to my 242 aswell. Still way too much to do and nowhere to make it all happen....

Keep on chugging!

ADam

 

[Ne7RideR]

Awesome project!

How did the car drive with the KLR T2 cam and 16t turbo? I have the same setup on my car but haven't driven it yet.

 

[juss]

Awesome project!

How did the car drive with the KLR T2 cam and 16t turbo? I have the same setup on my car but haven't driven it yet.

Thanks!

It drove really good, nice powerband from down low. I ran 1 bar boost and on the dyno it was 200kw / 260ish hp at the wheels.
In the end i could not get the idle completely smooth but that may have been the cam itself. Or might be the fact that I am not a pro at ecu tuning.

I still could tune the same thing, as the drivetrain went to my winter beater / slash sunday cruiser during summer time until the 242 is finished.
A Volvo 740 from 1984

This week it has been a little bit slower due to the fact that I occasionally make some extra money through my own company, currently working on a C70 T5M which has a clutch release bearing issue and some stage 0 maintenance before the season.

But still at some point when I did not have a right socket for the C70 axle then I started on the lower lip. Left side piece cut out, some little cutting and shrinker action and I had made a small repair panel.

 

[juss]

Almost a week later and i have continued on the trunk floor lip. Piece by piece it is slowly getting there and i am quite satisfied with it so far. With the second piece i made a mistake of cutting out a little too much material and the piece itself had fairly complex contours to make and match up with the old piece. It's a boxy car but does have different shapes along the body So for the rest of them i shaved the paint away to really reveal how much rust pitting the section has.

Also small job in between the usual stuff. A colleague of mine wanted to change out his E36 race car end muffler, as the old one lost its material inside it and rattles horribly. So i thought it would be the perfect opportunity to practice TIG welding. Stainless steel muffler, with stainless pipes. But currently i don't have the possibility to back purge so it has some sugaring in it.

 

[Chuck W]

You're doing some great work.

We have that same motor in my wife's '97 855 (Replaced the dying B5254T it had). What are your plans for it?

 

[Ne7RideR]

You can get this stuff called Solar Flux which is a paste or gel for welding stainless without a purge. I've never personally used it but one of the welders at work has recommended it.