Johnno's Big Red Box '88 240GL

Johnno_ · 2024-04-13T03:27:01+00:00

So I'm pretty happy with my 2002 V40 2.0T after a two year long gradual tidy up. The wife wouldn't sit in it when I first bought it and now she is quite happ...

Johnno_

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.

Johnno_

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.

Johnno_

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..

Image description

Unscrew the shifter housing * lft it up, remove the various trim panels, unscrew the heater control panel.

Image description

Lift the carpet out. It looks like some leaves and fuchsia petals found their way between the carpet and sound deadener.

Image description

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.

Image description

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.

Image description

Service covers. Driver's side will need de-oxidizing & a good coat of silver zinc, passenger's side just a bit of a clean.

Image description

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.

Image description

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.

Image description

Johnno_

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.

Image description

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? Image description

Major Ledfoot

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

Johnno_

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.

jamesinc

Hey Johnno I got an '81 244 you can cut floorpan parts out of if you want

Johnno_

jamesinc

Yes I'll take you up on that offer. Still have to drop off the S40 grille too.

jamesinc

Johnno_ caveat on this one is that the car is in North Strathfield, and probably we will have to stick to using a reciprocating saw rather than grinder (also I don't own a reciprocating saw).

Johnno_

jamesinc

I don't have a saw either. North Strathfield isn't an issue, just off the M4

Ok I'll have a word to panel beater guy tonight and see what he would prefer. Fresh new non-OEM panels or ones cut out of a donor. Cost is going to be about the same once I get a cheap saw.

jamesinc

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.

Johnno_

jamesinc Yes that was pretty well what he said too. Easier to work with new ones. Another advantage is the new panels don't have a drain plug hole and are completely solid. So you don't have to worry about sealing in a new plug and having it lose the seal, leak and rust out over time.

Thanks for the offer. Still have to drop off the grille. Sent you a PM last week.

« Previous Page