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Johnno_ I've been there with my 240. If I had a thread for that work… it would be huge 
Love your work and attention to detail 
850 T-5R Wagon Improvement Thread
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CATH UP WHILST FAMILY WAS AWAY (CONTINUED):
My partner and daughter were away in Tassie so I made use of this time to install all the parts I've been hoarding over the past few months.
It was fun until I ended up doing too many hours, but great progress and I wrote this post as I'm sitting at Melbourne Airport waiting to board a plane and reunite with my family for Xmas.
Keeping it straight to the point as always:
Replaced skirt plugs as skirts were previously sprayed without removing plugs:
Whilst I was under there I fitted rubber plugs where missing:
Noticed one of the bolts holding the bush plate in was incorrect length and head size so replaced with correct 14mm bolt.
Also replaced some engine cover bolts that looked a bit average
Installed some fuses from another wrecked 850 so that they all look the same - white text and confirmed correct fuses were in correct slots. I also noticed the blank slots for example the rear heated seats (my car doesn't have these) have terminals so I wonder if all the wiring is in place like other accessories 
Collected more parts from Volvo. This shot really makes the older generation cars look very small
Installed the later style chime relay. This blue relay replaces the original relay that clicks continuously if you don't belt up. The new relay does other functions such as door open and key in ignition chimes.. This chime is easier on the ear. More of a 'bong bong'
The last of the firewall clips have arrived:
High horn was replaced in recent years but cracked. Replacement horn tested and fitted:
Broken door jam clip replaced!
Image description
Front shock tower bolts are non factory. Being OCD here.... but only took 2 mins to replace
HEADLIGHT WORKS:
My original. Plan was just to install the headlight wiper kit and electrically adjustable headlight hardware.
This got a little out of hand and ended up with a full strip down of the headlights, clean, paint globe cover with heat resistant paint, paint and source missing glass clips.
Other issues found:
- Wiring insulation has mostly fell off - Gone hard and brittle. The wire strands have green oxidation so looks like to remake an entire harness. This means sourcing correct wire, colour and terminals. Looks like Jay Dee has most of what I need.
- Reflective parts need vacuum metalising - I've reached out to a company in NSW but perhaps it's cheaper to just buy new ones
I'll also need to make a harness for the electronically adjustable headlights… long term project haha or if anybody has one I'll happily buy it haha
Photo Dump:
Took it for a blast up arthurs Seat. Loves it under load with the 5 cylinder roaring 
After all my efforts my left headlight motor is rotating the wrong way. I think this might be because I disassembled it for some repairs but must have put it back together incorrectly and it's 'home position' is wrong.
This is super frustrating as the right side was an absolute pain to install. That's another 2 hours or more to correct 
Whilst I was in doing the headlights I removed all the components on the left side of the engine bay and gave it a deep clean (including gearbox) . This single stage paint really soaks up the dirt
Also painted any components that looked a bit sad - bolts and cruise control bracket
ARTHUR'S SEAT RUN:
Monumental efforts! Well done!
AUDIO PT.3
I received the key piece to my audio puzzle: The original Volvo 850 T-5R 4x40w amp.
In summary…
- So now all speakers are in order.
- Dash tweeters upgraded as per previous posts
- Genuine volvo remote
- GROM Bluetooth audio kit
- Excess wiring removed etc etc
See you next year
It's all worth the effort mate , looking good 
TRACS FUNCTION:
This ties back to an earlier post where I cleaned all the ABS speed sensors and cleared codes etc.
The final check was to try test the TRACS (traction control) system. This morning wet conditions made for the perfect testing ground. A few U - turns later and a little bit of throttle proved the system works and everything is in order.
I could hear the ABS module pumping, trying to slow down the spinning wheel and it would regain traction
It's very crude and only works up to something like 40km/h but this would come about pretty quick if single spinning.
Turns out the switch on the dash must be turned on to activate TRACS. So off is the default setting. Unlike modern cars that are wrapped up in safety these days.
SUCCESS!!
I'm pretty sure if you press the button and the warning light comes on in the dash , that is tracs disabled .
Mine is definitely the opposite and that aligns with the owners manual from memory but I must double check this when I get home
Push the TRACS button and light turn on means my traction control is turned on
Maybe different in the R?
9 days later
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HEADLIGHT WIPERS PT.2
Maybe I regret installing the headlight wiper kit. I spent a couple of hours removing and fiddling with the right side motor to try get it rotating the correct way. This involved discovering the correct gear orientations (this took a lot of time and referencing against the left motor)
Finally got it and then I damaged the right side wiper arm so I've added a new one to my skandix cart, along with caps and t-piece valve
Wish me luck haha
Does sound familiar , when you think you've just sorted it out and bang something else brakes .
Good luck mate , you'll get there
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SKIRT & REAR BUMPER:
Looks my right skirt has been repaired at some stage in it's life and the slot for the rectangular plug was missing so I measured and cut the slot out for siad plug.
I've absolutely no idea what this plug does but there's 2 on either skirt.
I also did a rear bumper realignment. Bumper brackets are new but it looks as though the internal bumper foam can sag slightly which in turn causes the bumper to sag. Has anybody else experienced this?
I've managed to insert a wedge at the top of the foam (between foam and inside of bumper)
You can clearly see the difference here:
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Still works for carrying big loads about, although I was super cautious loading/unloading haha
Looks like I need to get reshaping my passenger wiper arm which is nearly colliding with the bonnet when in the home position
The wipers still clear the entire screen as the passenger only lefts where the driver's side has already cleared.
5 days later
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PETROL CAP RELEASE:
My petrol cap release has only worked 50% of the time so I went in to inspect and lubricate so I could then monitor it.
As you can imagine I found some broken clips on my journey so replaced them as I went.
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GCP & SKANDIX ORDERS
I made use of the Black Friday sales, got most parts to finish off jobs I've started. I can start winding down on this mini restoration as I've managed to tick off a lot of items already.
Such items are:
- Door cards & related parts
- Handbrake cable & hardware
- Engine guards (one option has a duct to send cold air up to the turbo)
- Fuel tank gaskets & pipework
- Headlight wiper upgrades
- Misc items that were required
morch_66479 As you can imagine I found some broken clips on my journey so replaced them as I went.
I found it amazing the difference some new pliable fasteners make to the overall 'feel" of the car
morch_66479 Maybe I regret installing the headlight wiper kit. I spent a couple of hours removing and fiddling with the right side motor to try get it rotating the correct way. This involved discovering the correct gear orientations (this took a lot of time and referencing against the left motor)
Admire your tenacity on this, you're a brave man! Usually one of the first things to fail and get deleted. Like you took me ages to work out how to synchronize my rear wiper.
Thanks for the kind words. It's keeping me busy. Another skandix order arrived today too.
The 240 rear wiper issue is something I went through but I resolved it by removing the arm. Then cycling the motor and then reinstalling when in the home position.