Dan's Excursion/Beater Wagon.

crandandall · 08-18-2011, 01:17 AM

Picked up this 1989 245 a coulple years ago from Nick (6kyellowline). He needed to get rid of it before it got towed from his apartment complex. I offered to store it at my place for him, but he said that if I showed up with a 30 pack of bud light that I could have the car. Drove down to Davis with some tools and an alternator, installed the alternator and the car fired right up. I gave Nick his beer and drove home. The car wasn't in great shape by any means, the headligt bracket was broken, left rear brake caliper was siezed, and it had rust holes all over. I didn't really have a plan for what I was gonna do with it at the time, but I figured it was a good running b230 with LH 2.4 and an M47 tranny, if all else fails I could at least use the drive train. The car sat around for a little over 2 years and during that time I decided to make it my expedition vehicle/beater.

Here's what it looked like when I got it home.

A few showing the heinous rust holes.

First on the list was the suspension, I decided to use the stock front springs and slide the seats 2.5" up on the tubes. I had a set of Bilstein inserts, so I used those. The lower control arms are extended 1.5" For the rear I used Jeep cherokee front springs with some Pro-Comp shocks for the front of a lifted S-10. Got the springs for free from a coworker and the shocks were $35 from summit.

Spring seat separated from tube

Measuring

Welded

Assembled

Cut 1 1/2" from the ends off of a bent set of arms from my wrecked car.

Then welded them onto another set of arms, and boxed the arms all up.

Extending the arm 1.5" put the rear ball joint bolt directly under the sway bar link bracket on the arm, so I had to make these brackets to replace them.

Here's the arm all bolted up.

Here's what the rear suspension looks like with the pro-comp shocks. You can also see the cheesy side exit that I threw together after I cut the rear muffler off.

Here's the stock shocks compared to the pro-comp ones.

Once the suspension was done I had a bit of a fender gap that needed filling.

I picked up some 235/75/15 Goodyear Wrangler Radials for $75 each. That required a bit of "massaging" of the sheetmetal with a 3lb sledge, sawzall, and porta power, but they eventually fit.

Jerd · 08-18-2011, 01:28 AM

siiiiiick

loving where this is going. Im going to try and get your locker and 4.10s out tomorrow.

Jerd · 08-18-2011, 01:28 AM

siiiiiick

loving where this is going. Im going to try and get your locker and 4.10s out tomorrow.

slow240 · 08-18-2011, 01:37 AM

exhaust through the hood. NOW!
plus gangster roof rack and light bar.
LOVE this car, so much win already!

crandandall · 08-18-2011, 01:59 AM

The stereo consists of an Eclipse CD3200 head unit, Alpine MRP-M450 monoblock amp, Alpine MRP-F250 4-channel amp, CDT CL-61 6.5" components in the lower portion of the front doors, Eclipse 4" components under the stock grilles in the front doors, CDT CL-6 6.5" two ways in the rear doors, and an Eclipse 12" Sub. The CDT speakers are driven from the 4 channel amp, and the 4" speakers in the front doors are driven from the head unit. I used 1" spacer rings as mounting "pods" for the 6.5's, for the 4 inchers I had to make a 1/4" spacer from some plywood that sandwich between the speakers and the doors.

I started building a rack from 3/4" EMT conduit (ala slammed145). The rack will serve double duty as a cargo/bike/snowboard/light rack. I have 4 Hella 550 driving lights that will mount up front (hence the slight kick up on the front). I plan on making attatchments so that I can use Yakima bars and accessories for bikes/snowboards. The overall dimensions are 94"L x 43"W x 5"D. Not quite finished yet, but it's coming along pretty well.

So that's pretty much how it sits now. Definitely have some future plans for it, not in any particular order.

-G80 and 4.10's from Jered
-Quick and dirty +T
-Finish Rack, mount lights
-Mount auxillary battery, isolating relay and controller, and fuse/relay block for electrical accessories in spare tire well. (Have)
-Mount Hella 700FF's on front bumper. (Have)
-Build prerunner style front bumper/skidplate
-Build rear tube bumper/tire carrier/hitch

Ansel+ · 08-18-2011, 02:07 AM

I like this.

BrickLove · 08-18-2011, 09:29 AM

The turd lives!! I thought for sure that car had been crushed a long time ago. Good job breathing new life into it. Needs more speed dents.

andysbeta · 08-18-2011, 10:56 AM

Didn't think 235 75's would go, but they do! And talk about brain damage - a 30 pack of nastyness got you that? What a deal!

Harlard · 08-18-2011, 12:48 PM

I approve

amerbritcan · 08-18-2011, 08:17 PM

From the one pic of it lifted, it looks like the back isn't as lifted as the front. Otherwise, I heartily approve.

ZoomSpeed · 08-18-2011, 08:51 PM

This is going to be beast! I demand off road trail pics!

wagonfetish · 08-18-2011, 10:00 PM

Quote:

Originally Posted by amerbritcan

I heartily approve.

+1
I like the re-purposing of the old, bent control arms. Cheap and easy.
Can we get a profile shot of one of the old street tires sitting in front of the 275's? Please?

crandandall · 08-19-2011, 12:57 PM

Quote:

Originally Posted by amerbritcan

From the one pic of it lifted, it looks like the back isn't as lifted as the front. Otherwise, I heartily approve.

The back does sit a bit lower than the front. I'm going to put some 1" pucks between the upper mounts and the frame rail to level it out. The jeep springs lifted the rear about 1.5". Also, the profile on the front fenders has changed quite a bit because I stretched them out almost 2" to cover the tires, so the fender gap is larger than it would be with unmodified fenders. The front track width is ~3" wider.

bigbret · 08-19-2011, 01:38 PM

I like this.

Group A · 08-19-2011, 11:31 PM

Sweet jesus what have I started.....

How is the up travel at 2.5"? Any bottoming up ?

Jerd · 08-20-2011, 02:42 AM

Seriously i would be slightly concerned with not having enough droop travel. But im sure if theres a problem Dan will solve it.

crandandall · 08-20-2011, 12:20 PM

Quote:

Originally Posted by Group A

Sweet jesus what have I started.....

How is the up travel at 2.5"? Any bottoming up ?

Quote:

Originally Posted by Jerd

Seriously i would be slightly concerned with not having enough droop travel. But im sure if theres a problem Dan will solve it.

I haven't actually put it through the ringer yet, but going down the road it seems to be ok. I'll probably end up extending the strut tubes if droop travel becomes an issue. I think i'm going to cut 1/2 coil from the front springs to level it a bit and help with the travel in the meantime.

Jerd · 08-20-2011, 12:44 PM

Sounds like a good solution.

I forgot to mention that i like your stereo setup i need something like that in my DD. Is that what was in the blue wagon?

Jerd · 08-20-2011, 12:44 PM

Sounds like a good solution.

I forgot to mention that i like your stereo setup i need something like that in my DD. Is that what was in the blue wagon?

idrive_MD · 08-20-2011, 01:14 PM

You sir are crazy and I like it!

crandandall · 08-20-2011, 02:03 PM

Quote:

Originally Posted by Jerd

Sounds like a good solution.

I forgot to mention that i like your stereo setup i need something like that in my DD. Is that what was in the blue wagon?

For the most part it's the same setup. I used better, larger speakers in the doors, and the sub isn't in the buttcheek like it was because the box was broken. Once I build a tire carrier/bumper I'll build a box to go in the spare tire well. I hate having a big box taking up my cargo/sleeping space.

crandandall · 11-15-2011, 09:56 PM

Updates. Had some time to get some work done on this thing finally. Installed the 4.10 gears, G80, poly motor mounts, and strut brace.

Lopped about half of the flyweight off of the locker and cut out the teeth to make the speedo work.

Poly mounts, these are BMW e30 mounts that I bought from Ireland engineering about 5 years ago. I put one of the heat shield/oil deflectors from a turbo car on there to help keep the mount in good shape.

Installed the strut brace that I've had for a while. It's been on the last three cars i've had, it works pretty well.

Work continues on the rack. I didn't like the kick up for the lights on the front because it made the thing sit super high off the roof, so I made it drop down to keep a lower profile. Here's a couple pics of test fitting.

Before I reworked the light hoop area.

And after

I welded these plates in so that I could use a set of Yakima load bars with shear blocks. This will allow me to use Yakima snowboard and bike attachments.

And here's a short video of me making sure the locker works.

wisturbo · 11-15-2011, 10:07 PM

Excellent! The rack system you put together looks incredible! This is a project full of gnar!

Harlard · 11-15-2011, 11:17 PM

noiiiiice!

brendon_ak · 11-16-2011, 01:04 AM

fantastic car! I'm hoping to lift my 244, but I'm going to space the front strut rather than relocate the perch. Don't plan on running burly tires like you, so I should be good.

Love it!

08-18-2011, 01:17 AM	#1
crandandall Turbobricks Low Life Join Date: Feb 2004 Location: Portland, Oregon	Dan's Excursion/Beater Wagon. Picked up this 1989 245 a coulple years ago from Nick (6kyellowline). He needed to get rid of it before it got towed from his apartment complex. I offered to store it at my place for him, but he said that if I showed up with a 30 pack of bud light that I could have the car. Drove down to Davis with some tools and an alternator, installed the alternator and the car fired right up. I gave Nick his beer and drove home. The car wasn't in great shape by any means, the headligt bracket was broken, left rear brake caliper was siezed, and it had rust holes all over. I didn't really have a plan for what I was gonna do with it at the time, but I figured it was a good running b230 with LH 2.4 and an M47 tranny, if all else fails I could at least use the drive train. The car sat around for a little over 2 years and during that time I decided to make it my expedition vehicle/beater. Here's what it looked like when I got it home. A few showing the heinous rust holes. First on the list was the suspension, I decided to use the stock front springs and slide the seats 2.5" up on the tubes. I had a set of Bilstein inserts, so I used those. The lower control arms are extended 1.5" For the rear I used Jeep cherokee front springs with some Pro-Comp shocks for the front of a lifted S-10. Got the springs for free from a coworker and the shocks were $35 from summit. Spring seat separated from tube Measuring Welded Assembled Cut 1 1/2" from the ends off of a bent set of arms from my wrecked car. Then welded them onto another set of arms, and boxed the arms all up. Extending the arm 1.5" put the rear ball joint bolt directly under the sway bar link bracket on the arm, so I had to make these brackets to replace them. Here's the arm all bolted up. Here's what the rear suspension looks like with the pro-comp shocks. You can also see the cheesy side exit that I threw together after I cut the rear muffler off. Here's the stock shocks compared to the pro-comp ones. Once the suspension was done I had a bit of a fender gap that needed filling. I picked up some 235/75/15 Goodyear Wrangler Radials for $75 each. That required a bit of "massaging" of the sheetmetal with a 3lb sledge, sawzall, and porta power, but they eventually fit. __________________

08-18-2011, 08:51 PM	#11
ZoomSpeed Board Member Join Date: Sep 2009 Location: Vancouver, BC	This is going to be beast! I demand off road trail pics! __________________ 1989 Volvo 240 Wagon - +T, Cut iPd springs, Koni shocks, front dual sway bars, Short shifter, Truetrac. - The Autocross Champ and Winter Drift Machine ----- 1989 Saab 900 Turbo - Aero wheels, Modded APC - The Summer Highway Blaster ------------ My 240 Build Thread

08-19-2011, 11:31 PM	#15
Group A 240 Ninja Join Date: Sep 2004 Location: Portland, Oregon	Sweet jesus what have I started..... How is the up travel at 2.5"? Any bottoming up ? __________________ - Patrick Dickman "dumb enough to start and stubborn enough to finish" - Karl Buchka "I'm not Willy Wonka, I don't sugar coat shlt."

08-20-2011, 01:14 PM	#20
idrive_MD Board Member Join Date: Aug 2011 Location: Belcamp, MD	You sir are crazy and I like it! __________________ 1989 Volvo DL Wagon, Auto Silver Exterior with Blue leather...auction find for $650! Build thread here 2004 G35 6MT Brembo Coupe, big fat wheels and tires with suspension and exhaust work. 2011 Kia Forte SX 5-door, 6spAuto loaded, the wife's car.

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08-18-2011, 01:28 AM	#2
Jerd Board Member Join Date: Mar 2008 Location: Vancouver WA	siiiiiick loving where this is going. Im going to try and get your locker and 4.10s out tomorrow.

08-18-2011, 01:59 AM	#5
crandandall Turbobricks Low Life Join Date: Feb 2004 Location: Portland, Oregon	The stereo consists of an Eclipse CD3200 head unit, Alpine MRP-M450 monoblock amp, Alpine MRP-F250 4-channel amp, CDT CL-61 6.5" components in the lower portion of the front doors, Eclipse 4" components under the stock grilles in the front doors, CDT CL-6 6.5" two ways in the rear doors, and an Eclipse 12" Sub. The CDT speakers are driven from the 4 channel amp, and the 4" speakers in the front doors are driven from the head unit. I used 1" spacer rings as mounting "pods" for the 6.5's, for the 4 inchers I had to make a 1/4" spacer from some plywood that sandwich between the speakers and the doors. I started building a rack from 3/4" EMT conduit (ala slammed145). The rack will serve double duty as a cargo/bike/snowboard/light rack. I have 4 Hella 550 driving lights that will mount up front (hence the slight kick up on the front). I plan on making attatchments so that I can use Yakima bars and accessories for bikes/snowboards. The overall dimensions are 94"L x 43"W x 5"D. Not quite finished yet, but it's coming along pretty well. So that's pretty much how it sits now. Definitely have some future plans for it, not in any particular order. -G80 and 4.10's from Jered -Quick and dirty +T -Finish Rack, mount lights -Mount auxillary battery, isolating relay and controller, and fuse/relay block for electrical accessories in spare tire well. (Have) -Mount Hella 700FF's on front bumper. (Have) -Build prerunner style front bumper/skidplate -Build rear tube bumper/tire carrier/hitch

08-18-2011, 02:07 AM	#6
Ansel+ ABG Join Date: Aug 2009 Location: Portland, Oregon	I like this.

08-18-2011, 10:56 AM	#8
andysbeta thrsh Join Date: Jun 2003 Location: Mancos, CO (no longer the Central Valley Smog Bank)	Didn't think 235 75's would go, but they do! And talk about brain damage - a 30 pack of nastyness got you that? What a deal!

08-19-2011, 01:38 PM	#14
bigbret Campin in your backyard. Join Date: Sep 2007 Location: South San Francisco, Ca	I like this.

08-20-2011, 02:42 AM	#16
Jerd Board Member Join Date: Mar 2008 Location: Vancouver WA	Seriously i would be slightly concerned with not having enough droop travel. But im sure if theres a problem Dan will solve it.

08-20-2011, 12:44 PM	#18
Jerd Board Member Join Date: Mar 2008 Location: Vancouver WA	Sounds like a good solution. I forgot to mention that i like your stereo setup i need something like that in my DD. Is that what was in the blue wagon?

11-15-2011, 09:56 PM	#22
crandandall Turbobricks Low Life Join Date: Feb 2004 Location: Portland, Oregon	Updates. Had some time to get some work done on this thing finally. Installed the 4.10 gears, G80, poly motor mounts, and strut brace. Lopped about half of the flyweight off of the locker and cut out the teeth to make the speedo work. Poly mounts, these are BMW e30 mounts that I bought from Ireland engineering about 5 years ago. I put one of the heat shield/oil deflectors from a turbo car on there to help keep the mount in good shape. Installed the strut brace that I've had for a while. It's been on the last three cars i've had, it works pretty well. Work continues on the rack. I didn't like the kick up for the lights on the front because it made the thing sit super high off the roof, so I made it drop down to keep a lower profile. Here's a couple pics of test fitting. Before I reworked the light hoop area. And after I welded these plates in so that I could use a set of Yakima load bars with shear blocks. This will allow me to use Yakima snowboard and bike attachments. And here's a short video of me making sure the locker works.

11-15-2011, 10:07 PM	#23
wisturbo ⒼⒺⓉ ⓇⒶⒹ Join Date: Aug 2004	Excellent! The rack system you put together looks incredible! This is a project full of gnar!

11-15-2011, 11:17 PM	#24
Harlard Hurlurd?Harland?Bueller? Join Date: May 2007 Location: PDX	noiiiiice!

11-16-2011, 01:04 AM	#25
brendon_ak Board Member Join Date: Jun 2011 Location: Salem, OR	fantastic car! I'm hoping to lift my 244, but I'm going to space the front strut rather than relocate the perch. Don't plan on running burly tires like you, so I should be good. Love it!