Greg's 79 245GL Barn Find

carnut222 · 2018-07-29T03:42:39+00:00

After cleaning it up, it sat in mum's shed until July 2018, when I finally got it shipped down to Daylesford where we live.

carnut222

And to balance things out, a DOG pic (too many cats on here LOL!)

ds245

carnut222;c-161320 wroteAnd to balance things out, a DOG pic (too many cats on here LOL!)

. Another little puppy ?

carnut222

Finally got motivated to get the wiring pass-though hole in the driver’s door pillar. Used a smaller drill bit to drill out around the perimeter, then a file to shape the hole. Also did some surface rust touch-up and will prime and paint body colour, even though nobody will ever see it under the carpet and trim LOL!

alphax

Very nicely done. I'm in the process of a complete interior overhaul on my 83 240 including fitment of elec windows, central locking etc and was pleased to find it already had a large grommet cut out in the body and doors! It just used a large flat grommet with a tiny hole for two wires.

Canoe

ds245;c-161356 wrote
carnut222;c-161320 wroteAnd to balance things out, a DOG pic (too many cats on here LOL!)

. Another little puppy ?

Whippet? "Whippet good"!

carnut222

Canoe;c-161868 wrote
Whippet? "Whippet good"!

Yeah, our whippet is good until she sees another animal (including dogs) then she goes berserk. She has only ever befriended another whippet, a greyhound and mutt about her size. Something in her past unfortunately and at 9 years old I don’t think we’ll be changing it.

carnut222

Did a bit of priming on the RH side inner hinge pillar, sill, and B-pillar after fixing things up and sealing. Will go back over with matching yellow even though it’ll never be seen. Gotta do things more or less right! Once the inner bit is painted I can reinstall the insulation and start putting the dash structure back in and route the wire harness, then reinstall the dash panel. Still undecided about carpet - whether to buy new black carpet or try painting the tan carpet from the 93 sedan. Guess maybe I could sell the tan carpet to offset cost of new black stuff and save $$ and hassle painting it. Anyone need good tan carpet from a 93 sedan (would also suit wagon - just trim around the rear seat squab brackets). Lemme know!

carnut222

Got a bit of colour on the inner pillar and sill. “Good enough!” Was thinking I can start installing the interior, but bugger, need to get the door back on and aligned, but first need to paint and install a new lower hinge, and the list goes on!

Ex850R

Wow,so little strength in body.

I'd be putting a cage in at this point!

carnut222

Ex850R
Wow,so little strength in body.
I'd be putting a cage in at this point!

Yes, the 240s were not designed with side impact in mind! I believe that’s what ultimately led to the end of production of the 240 model as the US and other markets started with side impact protection requirements (other than the static side intrusion door beam strength requirements that were brought in during the early 1970s in the US).

Angus242164

Compared to most other cars designed at that time they have a strong door, pillar and sill structure.

The 700 series added a channel under the floor and tailshaft to tie the base of the B pillars together, and from memory the B pillars were made of thicker steel.

Each generation is a bit safer than the last, and back then Volvo was putting in a lot more effort than most other makes.

Ex850R

At this point it would be easy to get some gal sheet folded up to make channel and run it across and lattice maybe on floor,down the pillars by cutting slits in it and sliding it in. Fill voids with expanda foam. But I'm like that.....

carnut222

Ex850R
At this point it would be easy to get some gal sheet folded up to make channel and run it across and lattice maybe on floor,down the pillars by cutting slits in it and sliding it in. Fill voids with expanda foam. But I'm like that.....

Not building a race car so will leave it alone. I might shove some foam stuffer blocks up in the pillars (ones I took out of the 93 sedan C-pillars). I’m not a fan of expanding foam in sheet steel as it could retain water and cause corrosion depending on the type and location. Probably would be OK in upper pillars as long as you don’t use the stuff that expands too much as it might buckle the tin! :)

carnut222

Slowly plodding away on the car. Got a better lower driver’s door hinge and painted it. These hinges have a small grease fitting that looks like it would require a tiny needle to fit in the hole, with possibly a visible ball bearing? See circled area on hinge. I thought I had a grease needle fitting but can’t find it in the toolbox...need to have another look. I can’t recall ever having any luck greasing the hinges through this port. Anyone else done it?

Also did a hack job painting the outer driver’s hinge pillar and rear face of the guard. Too cold and the paint ran and bubbled. Bugger. Will assess after it dries. May be good enough.

Reinstalled driver’s side dash panel end support, and drilled additional hole for passenger side dash panel end support, and installed. I think I can install the dash panel cross brace, tunnel support braces and steering column now without interfering too much with my ability to get the driver’s door bolted on and adjusted.

FWIW just found this tip on greasing door hinges. I will have to look for my tools!

https://www.brickboard.com/RWD/index.htm?id=1182527&show_all=1

carnut222

Found my grease gun fittings right where they should have been...and successfully greased the hinges. What a difference!

Paint on the driver’s hinge pillar doesn’t look horrible in pics - guess it will do. Also used the touch-up brush to hit a few chips and scratches in the engine bay where I didn’t re-spray. Once the engine is back in with all the wiring, plumbing and components I think it’ll look OK.

Disassembled the driver’s door as I’m going to swap everything from the 93 sedan plus install power window mechanism. Typical 240 door with multiple fatigue cracks on the inner panel (circled areas)...will have to do a bit of strengthening. Also need to put some Dynamat or the like on the inside of the outer skin as when the RH side doors were replaced they just brushed some tar-based stuff on them and they sound really tinny. Coffee break time!

alphax

Coming along nicely!

carnut222

alphax
Coming along nicely!

Thanks Michael. Seems like progress is glacially slow, but there are a thousand tiny things to get right, so it all takes time. One thing leads to another, and to another, and so it goes!

alphax

I know what you mean. I'm switching the whole interior to Black and Grey on my 240 at the moment with various other changes to seats, electrics, dash, insulation, stereo etc. I reckon it will take as long as the engine swap, lol!

Thanks for sharing the door hinge lube, will have to do the same. I found much of the window reg and door lock mechanisms completely dry or had old waxy dry grease (worse than no grease). Have fitted elec window regs with a combo of a little moly grease to the reg teeth and silicone grease on the plastic slides with the little nylon washers. Work great now!

carnut222

Made a bit more progress today. Got the RH side sill and hinge pillar sprayed with cavity wax and installed plugs and blanking plate over fresh-air vent (can’t use it on later cars as the computer sits there). Covered the floor repair with stick-on foil-backed butyl patches and reinstalled foam underlay deadener mats.

Installed new ignition switch, dash centre console, cross-brace, steering column and shaft. Next step will be the foot and face ducts and vacuum hoses, then lay the wire harness into position. Seems like progress.

Also did a bit of repair work on the driver’s door to try and address the cracked inner panel. Best thing would be to cut out the inner panel from the 93 sedan door and patch it in, but I hate to ruin the perfectly good 93 door...well it could be cracked too as I haven’t pulled the trim panel off yet. More work to do on that door before I can reinstall it.

carnut222

Got a pic of the blanking plate for the fresh-air vent hole. Bracket from 93 computer mounts over top of it. The brown runny stuff is rust protectant/cavity wax.

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