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Hurricane edition 1981 262c

Docsmitty

Got Greyhounds?
Joined
May 26, 2011
Location
MN
First post in what I hope is my long-term project / grail car. So, some background… my first car was a 1979 245, rust orange, gifted to me by my favorite uncle. He always had a thing for big old cars - he and my aunt had a series of Lincoln Continentals and VW buses. Being 16, I totally didn’t appreciate the car as much as I would today, and when I left for college it was given to a friend of the family.

Fast forward to 2011, my Uncle had post-polio (late life degenerative condition that almost everyone who gets polio later suffers from) and could no longer drive his 1963 VW 15 window, so I inherit that and get it back on the road. I eventually decided that it was too rusty for me to fix myself, and the crumple zone is otherwise known as your knees, and no amount of work makes that safer. So, a year ago I made the tough decision to sell the bus despite the massive sentimental attachment and invest in another car he would deeply approve of, a vintage Volvo.

I‘ve always had a thing for the 242 series, and when I discovered the 262c existed I had to have one. It’s just so ridiculous that Volvo made that car. Plus, it reportedly came to life due to Volvo execs seeing, of all things, a Lincoln - practically meant to be!

I reached out to a guy on FB selling his 242. It was in decent shape a couple states away, and I was pretty tempted. But then I saw he also had a 262c listed! It turns out the 242 was his own personal car, but the 262c was part of an estate he was helping to sell. The owner of a Volvo specialty shop in New Hampshire (Mark owned Royalty Automotive in Barrington NH - almost must have been a TBer??) had passed away unexpectedly and left his large collection of Volvos behind for the family to deal with. The guy I talked with on FB had worked out a deal to help sell the estate cars in exchange for the quirky shop 245. They had just reduced the 262c from $10k to $4500.

I started getting details on the car… it was swapped to a B21ft and M46, with a restoration done around 2011. Runs and drives, but sat for some number of years. Tires are shot, gas tank is krusty, needs all the expected maintenance. I knew I wanted a 262c, I knew I wanted a turbo redblock + manual swap rather than auto + PRV. Pretty much the only downsides were the tan interior (front seats and dash cap are in rough shape) and that it had been sitting for years.

A couple of the 138 photos they took of the car:
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Now that I’ve decided this is the car, I want to get it before someone else does. Of course, it’s an 8 hour drive, and I literally had surgery 10 days ago, but off we go! We decide to drive up that weekend, rent a U-Haul, and tow the car back. Of course, everything went exactly as planned… 🙄

We drive up to NH only to discover that there is no shit a ducking HURRICANE (Hurricane Lee) hitting NH that weekend. For those of you not from the northeast…. That generally isn’t a thing. In September. When I need to pick up my new goddamn Volvo! Mind you I’ve never towed anything before, let alone a car behind an empty U-Haul during a hurricane.

Next, U-Haul doesn’t have the equipment they promised. Ok, fine, there’s another U-Haul location 30 miles away that does, they’ll cover the mileage and gas, and we have just enough time to make it back before the shop foreman goes on vacation for the rest of the week. So we head over to the second location, where the new employee takes what feels like an hour to figure out how to hitch up the trailer. Thankfully the old timer who knew what she was doing reviewed everything and made sure they did it right.

We pick up the car, drive it back to our hotel, and decide to leave EARLY the next day in hopes of avoiding the worst of the weather. We made it back without much trouble, a little wind and rain but nothing tropical storm bad. And then it was mine!
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At this point I should mention that I know nothing about working on cars, so I’m pretty much learning as I go. I’ve started small with a couple of easy projects, but have quite the list in mind.

First up was dealing with the gas tank. It’s pretty ugly inside but not actually rusted through.
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I pumped out all the old gas and replaced with fresh, and while I wouldn’t say it’s running great, it does run!
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Before getting the bad gas out it would start, run for a few seconds. and then die, several times, until it caught. Now it starts and stays running on the first try, warm or cold. Still needs a proper stage 0, I’ve done the research and have started getting in the parts needed for that.

Next up was the Wagonmeister fuse panel upgrade, replacing the old pill shaped ruses with the blade fuse holder.
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As the precursor to stage 0 I ran a compression test and the results were good enough to move on… 135, 145, 140, 140
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Next up I got a Momo wheel and adapter from @89-240gl+t , and prancing moose horn button… nice to know there’s a little surprise hiding under the horn pad 🤣 Funny story, I’d read enough about pulling the wheel to know to leave the nut threaded so the wheel doesn‘t pull off straight into your face. Unfortunately I didn’t realize that I’d unthreaded the nut all the way and it was just sitting on top of the threads 💥 but thankfully it wasn’t so stuck on there that it did damage to my face coming off 🤦‍♂️
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I knew I wanted to go flathood, but finding those on the east coast is HARD. But! A 1976 245 flathood was posted to FB marketplace. The car had 68k original miles but was dirty and had been sitting, and the seller had no time or money to get it running - I really wanted to flip it on BAT, but they couldn’t produce a title, so I made a deal to part it out instead. My heart is still broken that I couldn’t save it. But, first time parting out a car! I learned a lot through the process and feel much more comfortable with some of the projects I have in mind.
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I also did some research on the power window switches, as the drivers window was sorta kinda working sometimes, and the passenger window was dead. I decided to try the switch refurbishing from step by step Volvo. Whew it was nasty in there (before and after below), but I cleaned them out and lo and behold! I have working power windows! Not just that, but the switch I assumed was the window lock out actually operates the power door locks that I totally didn’t know existed on this car! The driver’s door has an actuator as well. The key locks and unlocks both doors, as does the switch on the driver’s arm rest.
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This project didn’t go perfectly… when I was pushing a switch out of the switch plate my thumb slipped and got a pretty ugly looking cut. This is after a couple days and a couple thorough cleanings.
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My inspo for 262c styling is Brett Borders’ 262c (but keeping it redblock) and maybe in warm white (But not two-tone)
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Placeholder for more projects (other than stage 0) either pending or needing photos or both…
1. Hardwired tail lights - done! Need to get pics.
2. Lighting upgrade from Daniel Stern - WIP discussing parts.
3. Flat hood mount - my wife bruised a rib this weekend, same day I cut my thumb, so this is on hold. Plan is to run flathood with quad squares - I love that look and you don’t see it too often. Example inspiration:
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4. Refinished Geminis and center caps from @billy780 awaiting tires
5. Heckblende from @89-240gl+t - turns out my rear license plate bracket (7xx style) doesn’t fit it, getting a 240 bracket then will mount it.
6. Picking up a black bertone interior first week of October. While the tan dash and seats are rough, the pillars and headliner are pristine. My plan is to run the black interior below the window line, and tan above, to avoid the “cave” effect of full black bertone interior.
 

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Lighting upgrade in the works! Reached out to Daniel Stern Lighting to discuss options and source replacements. Ditching the sealed beams and upgrading indicator and brake bulbs.

DSL relay harness (still otw)
CIBIE H4 lens w/ integrated parking light with DSL 60/55 +250 bulbs
Koito H1 lens with Flosser 100w bulbs
Hella LED 3rd Brake Light
DRL module for front turn signals, Osram Ultra Life bulbs
Brighter bulbs for brakes, rear turn signals, and reverse (brought up the melty issue and he assured me this setup should be fine)
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Overall for the quality of service, amount of discussion and explanation, and quality of product I’m very satisfied - would highly recommend!
 
Well, to continue the hurricane theme… I’d had a trip to pick up black interior pieces from @DET17 for a month or more at this point. The plan was to fly to Charleston SC, drive to Asheville NC to pick up a cargo van, and finish the drive to pick up from him in eastern TN.

Unfortunately this overlapped with the weekend that Helene hit the south US. Asheville was completely flooded and the interstate was washed out on both sides of the city. We managed to reroute away from Asheville and still get to TN and even managed to fit everything into the minivan we ended up with (apparently Amazon had dibs on all the cargo vans)

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Here’s the haul… (nearly) two complete black Bertone interiors! I have a matchng black dash to swap in as well, and will leave the pillars and headliner in the current tan. Black from the window line down, tan above. Everything is in pretty fantastic shape, it will need to be cleaned and the drivers seat will likely be pieced together from the two.

2 complete sets of seats
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2 complete sets of door cards
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1 rear package shelf, 1.5 sets of carpets
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1 set of hard plastics (I think most of these are interchangeable with standard model parts?)
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Also, I need to stop planning trips around this car, and am accepting hurricane themed license plate suggestions.
 
Dropped the crusty old gas tank today! Glad I decided to replace it. It was worse inside than I thought.
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Also found some rust hiding above the tank so probably will figure out how to deal with that. The center support bracket was rusted through enough that the bolt tore out a section rather than coming loose.

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Figuring out the in-tank upgrade now too - looks like I need to trim the pickup tube as described, and get a short piece of fuel line to connect the pump. I tested the fuel gauge by hooking up the wiring and moving the float and the gas gauge finally works - glad it was the old sender that needed replacing.
 
Figuring out the in-tank upgrade now too - looks like I need to trim the pickup tube as described, and get a short piece of fuel line to connect the pump. I tested the fuel gauge by hooking up the wiring and moving the float and the gas gauge finally works - glad it was the old sender that needed replacing.
Make sure you get a piece of fuel line that is rated to be immersed in fuel. I made the mistake long ago of using regular fuel line. The gas dissolved the piece of fuel line leaving just the strands of reinforcement braid to float around in the tank.
 
Make sure you get a piece of fuel line that is rated to be immersed in fuel. I made the mistake long ago of using regular fuel line. The gas dissolved the piece of fuel line leaving just the strands of reinforcement braid to float around in the tank.
Thanks for the tip! Definitely was about to make the same mistake lol
 
Ended up removing the drivers side crash triangle and found more rust underneath 😭 This side is a bit more substantial. I was able to remove the flaking layer and probe the metal underneath, still solid, so plan is to remove as much of the surface rust as possible and then use a rust prevention product.
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Started prepping the new fuel tank and sender on Thursday. Installed the walbro in-tank pump in the sender and as I was getting the wiring ready it fell off at the top. Did some quick googling on how to solder today haha. Got it reattached with a minimum of mistakes 🙏🤞 and have the pump mounted and wired. Next step is install into the new tank, but will wait until I have the rust under better control before reinstalling everything.
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Amateur hour rust abatement! 🤣😭

This is the worst section of the rust..

First photo is after wire wheel, second photo is after chipping off the scale and treating with POR metal prep, third photo is after one coat of the paint.

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