Engine is just sitting there in the car so I can move it around for the next week or so... Have been stripping the front of the car and cleaning it. I'm amazed how clean and original this car is. In all the front end parts, not a single piece of hardware was missing or different from stock. Normally a flat-head self tapping screw or an odd bolt would have found it's way in there over all this time!

I'm rebuilding the manual pedal box I have at the moment and modding the firewall to suit. I'm using a Wilwood Master Cylinder so will have to get a a little creative.
















External with remote reservoir
Will that firewall end up flexing? Or will you get a thicker plate there for the clutch master cylinder somehow?
They all flex on the older volvos.
We welded a 6mm plate into my ke20 for the clutch master cylinder. It was solid after that
It doesn't seem all that weak there to me, as the master bolts up to an area where there are sheet metal folds around mounting points. Bolting in a spreader plate might be a good option. Thanks for the input.

I repaired the clutch pedal last night. The hole for clevis pin was a little worn. Drilled out the pedal, knocked in an oversize steel plug made from a hardened bolt, welded it in there, machined it flat again and drilled the hole for a 5/16th clevis pin to match the Wilwood M/C. Then sanded and painted both pedals.












5 days later
Engine about to be removed for the last time... Pressure washing entire underside.



Almost finished up the Ford 8.8" housing



Which wheel would you say is the heaviest here, and by how much?



Any guesses?


Looking great.
The diff housing jig is excellent!
I'm going to guess the large steelie but I'd be interested in hearing the weights.
Thanks Ash, a mate of mine did a great job building that jig.

The weight of those wheels is very interesting. I don't have the overall numbers with me at the moment, but the differences (and lack of difference) is surprising.

The Alloy wheel is a factory EVO 7 17x8. It's 1.8kg heavier than the Volvo 15x6 steel wheel. The 17x7.5 Ford Kuga steel wheel is just 100 grams heavier than the EVO 7 wheel!

So.. I learned a few things.

- Big wheels weigh a lot
- Alloy wheels aren't necessarily light
- Steel wheels aren't necessarily heavy compared to alloy wheels

Would be interesting to compare to some proper light weight racing wheels
Ive found that, my 17x7 and 8 3 peice brs poison rims weigh less than 15x6 volvo steelies and alloy. But the tyre makes a big difference i find. On trucks/buses, with a re tread on vs clean skin, the Alcoa weighs a heap more.
Vee_Que;79188 wroteIve found that, my 17x7 and 8 3 peice brs poison rims weigh less than 15x6 volvo steelies and alloy. But the tyre makes a big difference i find. On trucks/buses, with a re tread on vs clean skin, the Alcoa weighs a heap more.
Interesting... Yes, I would imagine Work wheels etc to be very light weight. Would have to beneficial in several ways. Too fancy looking for this build though :)

Engine ready to come out.

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Engine out.

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Manual pedal box is in. Bracket made for electronic throttle pedal.. Factory Volvo mounts almost made for it!

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alphax;79248 wrote
Vee_Que;79188 wroteIve found that, my 17x7 and 8 3 peice brs poison rims weigh less than 15x6 volvo steelies and alloy. But the tyre makes a big difference i find. On trucks/buses, with a re tread on vs clean skin, the Alcoa weighs a heap more.
Interesting... Yes, I would imagine Work wheels etc to be very light weight. Would have to beneficial in several ways. Too fancy looking for this build though :)
For me, they cost 550 and I get a better choice of rims. Plus people think steelies means sleeper most of the time now anyway.
Yeah you can't beat that... just not the vibe I want on this particular 240
Sorry. Meant tyres. But yeah, it wouldn't suit a 240 like they suit a 740. Looking forward to more progress though.
Oh ok, gotcha.. thanks

More progress.. engine mounts are finished.
There is another identical set of mounts ready to go if anybody is interested.



Bushes pressed in



GM sump has been modified for clearance. PN is 19212593



Big thanks to Daniel and the guys in Geelong for laying some of this groundwork and making the engine mounts available.

This weekend will be a big one... Some very early starts. Goal is to massage the trans tunnel as needed and have the engine sittng in there by Sunday afternoon... in order to determine shifter location, exhaust options and carry on.

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