Doing wagon things. 6 bags of cans and bottles for Return & Earn.
Johnno's Big Red Box '88 240GL
3 months later
Had quite a few small jobs to do on Big Red before the Oz Volvo Nationals. Unfortunately, an expensive bit of centre stainless bumper trim now lives somewhere on the side of the M4……… courtesy of some non-OEM bumper clips. Never noticed it blowing off.
Long box of bits from GCP. Also got some original OEM clips from IPD.
Bumper & grille off to fit it up. It was very unmanageable with bumper on.
Several nervous checks on the way to Canberra and back. It seems to have stayed on so far. Thanks to @nugget_940
for making her look so good! Downloaded this from his big group of pics.
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Other jobs….
Working overdrive lamp.
Pair of front mudflaps.
Look the part!
An old AUS international sticker had UV faded into the duco over the decades.
So a new replacement was in order.
There was no spare tyre. So a new spare wheel and tyre courtesy of @ramrod
Painted some new beige trim knobs from beige to black.
21(!) new pliable trim clips required for the rear door trim.
Number plate covers. Oz Volvo Sticker and a quick wax on Friday night.
Last but not least. Probably the most SATISFYING job so far. New bailey channel for the driver's door. The old brittle one was broken in parts, folded at weird angles on others and whistled worse than Alan SSSSearle at speeds above 70kph.
Out it comes.
Took out the window with some help by "The apprentice".
I found the missing grab handle star washer missing from when I bought the car. It had had been re-purposed as a bloody window armature washer! The bodgie shit I am sometimes finding on this car still makes me laugh!!!!
I did find the old teflon washer in amongst a pile of "found bits" in the bottom of the door some months back. So the correct washer is now back home.
Old bailey channel was stuffed.
New soft pliable channel went in like butter. Very satsfying.
Greased the window slots and fitted it all up.
The ride down to Canberra was MUCH quieter and pleasant. only a tiny bit of wind noise from the mirrors now.
6 days later
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Oz Volvo Nationals 2024. She came out all right.
Next one I'll leave the windows open and have the engine bay tidied up.
When I picked up the spare wheel from @ramrod, he asked if there was anything else I was in need of. "A black handbrake console?". He said he didn't have anything but when I arrived, he had arranged a few spare wheels on his driveway & he also manage to find a box of consoles. They were pretty dusty and I chose the one with intact bits. Told him I was very,very happy and he had made my day.
Didn't get a before pic but it was looked pretty funky…..like the steering column trim (left). It tidied up well with some soap and water, a stiff brush and treatment with 303 protectant. Turned out very nice.
Took out the front seats. 4 x 13mm nuts holding in each one.
Lots of crud underneath.
A 17mm bolt holding in each seatbelt.
Phillips head for the console.
Disconnect the courtesy light and seatbelt warning light and slide out.
And just a moment ago decided to get a side by side shot and found the intact one is an older style compared to my newer broken one……. Bugger 
So still on the hunt for a "newer" black centre console!
Anyway, I've got some more to write up. Took out the carpet, underlay mats and treated some rust. But outta time, have to go & do some night shift.
Bugger, I’ll see if I can find the correct cover in uncracked condition
Sorry about that, they look identical to the naked eye
Wow, I never noticed they were that different, until now.
The early type had the seat belt receptacles housed within; the later type had a coin box.
Does the back end of the handbrake lever foul on the earlier type of console?
Morning BG
Yes, they are shaped differently such that the mounting holes won’t align.
ramrod Bugger, I’ll see if I can find the correct cover in uncracked condition
Sorry about that, they look identical to the naked eye
No apology needed, I didn't know either so it's just as much my fault. I just found out when doing a side by side yesterday. I should have realised earlier as the new cubby wasn't fitting. .
If you don't have another it's Ok I'll just pass it along for the same price you gave me. It's a very nice console.
Major Ledfoot The early type had the seat belt receptacles housed within; the later type had a coin box.
Yes, the newer coinbox/cubby is a little bigger and doesn't fit. There's also a curve cut out on the bottom rear on the newer panel to bolt in the seat belt receptacles. Slot for the newer seat belt mounting bracket, plus the mounting holes as Ramrod mentioned.
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So there were a couple of floor sealing plugs loose that Stu noticed when it was up on the hoist. Had a quick look by lifting the carpet and sound deadener. I'd have to remove the carpet for some temporary repairs.
Next…… vacuum the carpet. Love the Bunnings Ozito shop vac, it was last year's Xmas present from the missus..
Unscrew the shifter housing * lft it up, remove the various trim panels, unscrew the heater control panel.
Lift the carpet out. It looks like some leaves and fuchsia petals found their way between the carpet and sound deadener.
Front carpet has worn through at the heel 7 is looking tired so I've ordered some new plush style from Knox Interiors in Melbourne.
Passengers side sound deadener mat looked sound but smelt 38 year old "musty".
Driver's side sound deadening mat looks like signs of water ingress and the rubber/vinyl cover was cracking. Zinc oxide stains from the galvanized service cover underneath. Plus it smelt…..really bad.
Service covers. Driver's side will need de-oxidizing & a good coat of silver zinc, passenger's side just a bit of a clean.
Drain hole and floor panel plugs.
The driver's side was rusty and looks like some bubbling under the bitumen deadener. Also a couple of extra rubber plugs have filled a couple of holes.
Passengers side was much better with just some surface rust. looks like a bit of a spike on a drain hole which I'll flatten out.
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While up on the hoist, Stu also pointed a triangle cut out of the floor and a bit of metal patched on top covered with liberal amounts of sound deadening spray. He said I'd probably need a new floor pan as it was close to the driveshaft mount.
A quick peek under the rear carpet and saw a heap of white silicon. Put the carpet down and pretended "not to see it".
Out with the rear bench and carpet.
Pulled up the rear sound deadening and Voila! Stu was right, I'm going to need a new floor pan here. Still trying to work out if the patch panel material was a 20litre drum and what brand it was.
Wide angle view of the floor. Good in places…..not so good in others.
Not sure what those round plastic plugs are. Maybe some Endrust or similar access holes for rust prevention? Or are they factory?
Ugh, that floor pan repair is a bit of a bodge….
Choices - you can cut a replacement out of a wreck; they're pretty much the same from 74 to 93. Or is your want brand new panels, VP Auto stocks replacements, as does Brookhouse (UK), but Wolf (US / Canada) doesn't cover 140s/240.
What are you planning to use to replace the hard, white putty used to hold those floor drain plugs in place? I have number of them which need to go back on the 142.
Oh yeah, btw - those 2 screws which attach the bottom of the centre console to the backing plate (forward of the transmission shift lever)? Don't lose 'em - those screws are unique to that part of the 240, and aren't used anywhere else on the car or on other models. (Unlike many other 240 and Volvo fasteners in general, the same nuts, screws, washers and bolts are often used in multiple places all over the cars and are commonly used in a wide range of models). /trivia
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Major Ledfoot Choices - you can cut a replacement out of a wreck; they're pretty much the same from 74 to 93. Or is your want brand new panels
I'm going to get new ones. Looks like VP & Brookhouse supply Klokkerholm made panels. Also found an alternate supplier.
I have a couple of alternative for the plugs. Found some 65mm blanking grommets which fit perfectly but will probably not withstand rocks etc. I'll get s a photo tomorrow. JB Weld epoxy adhesive would probably be best. Their silicion adhesive has kept the bumper on so far. My panel beating colleague at work who is going to repair it may have some other alternatives.
Thanks for the tip on the screws.
Hey Johnno I got an '81 244 you can cut floorpan parts out of if you want
Johnno_ I think if cost is the same I'd go with the new stamped parts, as these pans while they aren't rusted out, they aren't perfect and the panel beater would spend more time prepping them than new parts.
I think for a floor pan I wouldn't lose sleep over it being a non-OEM panel, if the shop has to massage them a bit to get them to fit right, you'll never know it.