'Vivian' 1979 242GT

Paul_Roodenrys · 2018-11-15T11:07:33+00:00

Good luck with the build. I'm glad that you are going to use a Volvo motor in Vivian. While I can marvel at the abilities of people to put all sorts of m...

Paul_Roodenrys

Wow, I can't believe that it was in February that I last posted an update. Work has continued at my normal snails pace. I have wired up the Haltec EFI following the advice in the posts above. It was not as daunting as I thought but I'm yet to try to start it up so I've got no idea if I've done it right or not. One bonus was wiring the fuel pump into the original fuse box and saving having to pull out the carpets to run the Haltec loom wire to the pump. I've also removed the belt driven fan and replaced it with an aftermarket 850 electric fan in a 740 shroud as reported by other contributors to this fine site. I put in an IPD order for the fan and some other bits thinking that it wasn't too expensive, before adding freight (getting a bit up there now) and then forgetting to convert to US dollars. Ouch. Freight and exchange rate hurt. I'm now trying to work out where all the fiddly bits go, matching the vacuum lines, sorting out the fuel line (as I removed the under car fuel pump). One part I've spent a lot of time with is working out the airfilter, I've gone with a flexible intake hose and an SAAS enclosed airfilter pod. It is all very tight and I'm not sure if I'm going to be able to fit in the wiper bottle and the charcoal canister. I find that these little details take way more time than they should. The charcoal canister is a good example. The 240 canister has a line from the fuel tank which appears to be hard plastic, then a vacuum line to the throttle body but there is also an outlet at the bottom of the canister. I think it is a vent or drain but I really don't know. I could use the charcoal canister from the 740T but it is much bigger and more involved again. Any ideas or suggestion would be very welcome. The next big challenge is the exhaust. I had thought I might get a Martelius exhaust but once again freight is a killer, about $1300 landed plus a catalytic converter. The down pipe and cat from the wagon I took the motor from seems to be in sound condition so think I will see if I can use that as the basis for a system. I'm hoping to spend a bit of quality time with Vivian now that my part of the state is in lockdown, I'd really like to have her running by Christmas and back on the road next year.

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Thought I'd throw in a gratuitous airhead Beemer photo. The 200 series and the airheads have a fair bit in common, simple but robust and long production runs. I saw a nice Beemer on the airhead facebook page the other day with a 240 sedan in the background.

Paul_Roodenrys

Two questions regarding keeping things legal:

1) Can the carbon canister be close to the battery? There is a perfect spot to relocate the canister under the battery tray. I'm wondering though that seeing as its purpose is to catch stray fumes from the fuel tank that there may be a reg that says it can't be that close to the battery.

2) Is it legal to run the exhaust under the rear axle? Most exhausts loop over the axle and then curve round connect to a second muffler and exit left. It looks to me that I can have a straight pipe with two mufflers with the tail pipe running under the axle and exiting right.

Any thoughts would be very much appreciated.

VolvoHordz

I'd suggest switch over to the charcol canister style/mounting location used on later 240's. Requires three new holes into the chassis rail but other than that mounts straight up. Thats what I have done with my 242.

Legal to go under axle, thats how many 240's are currently gettong around. However, it is a delicate balance between scraping on the road or having the axle hang up on it on full droop.

I cant picture how going over or under would limit number of muflers or tip location?

carnut222

Not a legal expert, but I think you’ll be OK on both items. Volvo offered the 2-series with under-axle exhaust depending on year/trim etc. so it was factory on some cars. There may be ground clearance requirements for ADR, so just make sure you meet those with the exhaust...I think it’s lower allowable clearance for exhaust since it’s considered flexible if you hit something.

Paul_Roodenrys

Thank you for the feedback, I'll look up where the latter model 240s had the canisters and go that way. I thought with the straight pipe I would have both mufflers before the axle and it would be less complicated to keep a straight exhaust tip. I need to keep it simple. ?

The car is standard height at the moment but who knows what the future holds. Maybe I should have another look at going over the axle. I didn't think of it hanging up on the exhaust on full droop.

Once again, a big thanks for your suggestions.

jamesinc

The IPD kit I run is under axle but they change the pipe profile under the axle basically flattening it so it's more oval to increase clearance

Paul_Roodenrys

Thanks James. I change my mind on what I should do more than most people change their socks. One of the reasons its taking so long to get my car finished.

volvodriverman

I can comment that the martelius exhaust is a decent fit & the over axle 3" system they offer does fit quite well. The downpipe is for lhd cars and doesn't fit around the steering shaft.

Major Ledfoot

Factory configuration for 1979-84 shows an over-axle style [13] + [19], and also an under-axle style for Canadian-market cars, [14] + [20].

Paul_Roodenrys

Thanks Volvodriverman, I've heard from a few people that the Martellius is good. It's more the cost. If it wasn't so damn expensive to freight.

Thanks Ledfoot, the diagrams are interesting. The old wagon had enough exhaust bits for me to bodge something up short term though from the cat back tit has more holes than a balloon at an echidnas birthday party. I'll get it sorted eventually. I hope.

Ex850R

Paul_Roodenrys
Thanks Volvodriverman, I've heard from a few people that the Martellius is good. It's more the cost. If it wasn't so damn expensive to freight.
Thanks Ledfoot, the diagrams are interesting. The old wagon had enough exhaust bits for me to bodge something up short term though from the cat back tit has more holes than a balloon at an echidnas birthday party. I'll get it sorted eventually. I hope.

Why not patch together exactly what you want roughly so it doesn't fall apart, muffler bandage on top of decent tack welds then go to decent exhaust shop or find a metal fabricator on marketplace and get them to jig it and build a new one.

Paul_Roodenrys

That's a definite possibility too Snoopy. There is a very good young welder not far from me who could weld it up. Another suggestion is to bodge something up and take it to a good exhaust shop that will test out a few different combinations to get the right note. I think if I bodge something up it might help me work out the best way to go. Thanks for your suggestion.

Ex850R

If he is good get him to tack it in the areas you may change or put joints in so modifying is easier to tune the note

Paul_Roodenrys

I've been thinking that that is the best way. Putting it on a trailer and taking it to a good exhaust place is going to be a real hassle but would probably be the safest bet, a Martellius is expensive with freight and I'd still have to change the dump pipe to accomodate the steering shaft and get a cat, I'm also not sure I want or need a 3" pipe. I'd also like to get the perfect mix of note and being just loud enough to enjoy without making it unpleasant on a long drive.

On the subject of catalytic converters are 100, 200 and 400 cell cats all legal in NSW? Is it true that the more cells the cat has the more efficient it is?

Paul_Roodenrys

I need to replace the fuel lines from the tank to the hard lines. I've removed the under body pump which has a hard line from it to the engine and i'd like to use that fitting to join a new line. I'm hoping someone here can tell me what size male fitting I would need as I will order fuel hose and fitting from Rocket Industries or Superflow. A picture of a short pice of line with the fitting is below. I think this bit cam from the 740 donor car but it screws into the hard line female fitting.

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Paul_Roodenrys

The job is slowly taking shape now.

The turbo motor looks like it belongs in there.?

Paul_Roodenrys

Exhaust bits have arrived and I've started to assemble them. I'm using the down pipe and cat from the Jurbo donor car so I've stayed with the 57mm pipe. I need to drill a 22 mm hole in the dump pipe for the new O2 sensor. 22mm is big drill bit.

Paul_Roodenrys

Bung for o2 sensor also needs to be welded onto dump pipe.

Paul_Roodenrys

Everything looks like it should fit ok. I'll get it welded into two sections. Muffler and resonator are smaller than the 740 exhaust set up but hopefully it will have a good note but not be too loud. Edging ever closer to start up.

timbo

Looks good.

I use Step drills for drilling the 02 sensor bungs. I have a set of s.p tool step drills and some cheap aldi ones that have survived quite a bit of abuse

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