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JW's 1991 240 wagon

still going strong!

Some small updates. Over the last 2 years it has remained my DD (and still is!). Worked on a few things to make it better suited for that.

IMAG2147_1.jpg


At a huge music festival campsite, ideal car for that! Loaded with bikes, camping gear, drinks, food, tools, etc etc! Saw more 240s there, damn hippies! :-P

Bought a Truetrack from www.bakaxel.se. Not installed yet :)

IMAG1882.jpg


High preload version.


IMAG1881.jpg


Turned a set of new bearings into set-up bearings. The material was surprisingly easy to cut (removed ca 0.03 mm IIRC) and gave a very good surface finish. Thanks Volzuki!


Autumn 2012 I repaired the rear brakes. Dust covers were ripped etc.

IMAG0050.jpg



IMAG0059.jpg


New inner tie-rods at that time too.


Autumn 2013 I replaced the front wheel bearings. They were filled with mud and the seals were worn.

IMAG2353_1.jpg



Found out why the rear end was so noisy:

IMAG2524.jpg


Severe cracks in the poly bushings of the torque rods. They were used since 2007 and roughly 30K miles? Replaced them and that improved things. Still need to make spherical bearing inserts for the trailing arms, those still have rubber bushings that are worn worn worn!

While I replaced the front wheel bearings it was time to give the calipers some attention as well. The inner pads were worn to the last 0.5 mm and the outer pads were still fine.

IMAG2491.jpg


IMAG2492.jpg


Pistons cleaned/polished, new seals, new covers, new bleed nipples, pads, mounting hardware etc. The braking imbalance between left and right mostly is gone now!
The pedal is slightly soft after a good bleed, not sure where I can find the culprit. I think the pads wear evenly now but to be honest I haven't really looked hard. Nothing was wrong when I changed wheels so. Oh speaking about wheels, I bent one of the Polaris rims. Pothole+high speed+very stiff sidewall = damage. Now cruising on borrowed Multi-X.


IMAG2502.jpg


Everyone likes shiny parts! :cool:


IMAG2519.jpg


For now good enough, never needed more brake. This only cost a little money and lets me go on for enough time. Then I can see what to upgrade to when the engine is making more power.

Other small stuff:
-Removed the cone filter and fitted a 240 Diesel airbox. Made the intake piping from some old stuff that I had laying around so i need to address that. Car runs much better now the AMM isn't soaked in oil. The cone wasn't to blame for that, it was the short distance between the PCV return and the AMM.
-Switched from E85 to normal gasoline/E10. First I didnt change the chip and LH adapted well to it. Now I made a new chip for better WOT mixture (around .80-.85 lambda is what I shoot for, was .75). Car pulls well even before the chip change, 5.9s 0-100 km/h with a careful launch (to keep the engine mounts and clutch in one piece). Found out that it is pretty well matched to a 535D haha.
-Brodit charger/phone holder installed.
-Stuff I forgot.

Plans:
-Better speakers (and small subwoofer in trunk)
-Some soundproofing (doors, floor, dash?)
-Spherical bearings in the trailing arms of the rear axle. Have designed something, just need to find time to make it.
-Install truetrack, paint rear axle
-Remove rust on right side near rear wheel
-Paint side trim on doors and attach one that is falling off
-Install the new shadowline stuff
-New windshield
-New/better catchcan. After new airfilter this was just ziptied near the radiator
-Install windshield washer reservoir.
-Some homebrew bracing for the front axle
-Repair bent Polaris rim


Right now the 240 has a few quirks and things to improve but nothing too serious. Gives me time for other projects as well! Multiple projects lined up, Amazon, 760 T6, maintaining the fleet of family cars, improving the workshop etc!

I can't resist to post a pic of one of the nice workshop upgrades, a real milling machine. At 4500 Lbs, 5,5 hp and over 3 feet of travel it is quite a serious mill. Now completely disassembled for repairs.

DSC02493.JPG
 
Not much has happened, except for driving!

Made a chassis brace that I have been meaning to do for a very very long time:

ugMAK3NJuB2jn8NzFjHOEz-qIs8HFKI7_6a7lKMgwzU=w1000-h947-no


-7wltFkxc8V-lJSZXiDt2AhlRcpNmAW7uDTr67BxQow=w1000-h947-no



The downpipe was made/designed with this in mind.

Need 2 more Inbus screws for the passenger side of the brace, clamping the tube like that is no good.
First short test drive feels good.

Thinking of adding a piece of flat floor to this brace and capping the front of the tubes (angled) to prevent them from rusting inside and me getting stuck when offroading. Maybe some more flat floor extending to the front of the car, everything that helps MPG is good. last fillups were 25-27 MPG so i'm already quite happy.



_1IGnxDlYRNypfR5sC1A81HiWjg6tfTv_gnJrBLSIw0=w1000-h500-no


300.000 km now. ~50.000 on the +T.


4,500lbs is a lot!

Glad to hear the old girl is still kicking. :)

And I added some more:

UO5aGRtn1zNLz0hcW3HiMFwjb-wfOKFwiLsHBDrWgGw=w533-h948-no


6000 lbs. Nice for coilovers, flywheels, wheels, etc. 10 hp, 21x60. Last months changed all oils, cleaned lots of things, VFD retrofit with complete rewiring, repaired many little things, some new nuts/bolts/screws, new wipers, saving up for digital readout but at this size that is an expensive affair!

EDIT1: resized pics finally.
Edit B: not much of the list of last year has been tackled. No new winshield, no attached trim, lost another piece (waiting for paint in the workshop). I did repair most portions of the underbody coating and applied new stuff. Attached some loose interior stuff with rivnuts instead of crappy self tapping screws in the floor. Oh and the Polaris rim is fixed, all is good now.
 
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Very impressive workshop you have. Wish I knew how to work the mill, or lathe for that matter.



Which one did you buy? Did you install it yet and if so, how do you like it?

Hi Arno, Thnx! The workshop is a work in progress, I have the machines but I need to clean up or re-organize more often to make the shop/me more productive. Operating these machines isnt too difficult :)
Last weeks I have been working hard finishing lots of small stalled projects (or selling) so i am freeing up more and more space in the shop. Feels good.

The Truetrack is the 588 high preload model. Not yet installed in the 240, but my brother has the same in his 760. Works great. No noises. On backroads or with one wheel on sand other on tarmac it is still possible to accelerate hard, and/or make nice drifts on gravel. Even when driving away slowly on gravel driveways you feel the truetrack, the inside wheel wants to spin faster and leaves a trail.
Maybe not the real deal LSD for race use but for our use perfect, no maintenance, strong :nod:
 
Some small updates. Over the last 2 years it has remained my DD (and still is!). Worked on a few things to make it better suited for that.

IMAG2147_1.jpg


At a huge music festival campsite, ideal car for that! Loaded with bikes, camping gear, drinks, food, tools, etc etc! Saw more 240s there, damn hippies! :-P

Love your DD. Looks alot like mine. :-)

<a href="http://s1084.photobucket.com/user/Beachee/media/My%20cars/Volvo%20240%20-86_zpsqnh1re5l.jpg.html" target="_blank"><img src="http://i1084.photobucket.com/albums/j414/Beachee/My%20cars/Volvo%20240%20-86_zpsqnh1re5l.jpg" border="0" alt=" photo Volvo 240 -86_zpsqnh1re5l.jpg"/></a>
 
what a nice mill :)

Thnx, there is one on Ebay.de now (Tos FA3). If only mine was working, I stripped it down to the bare castings for repairs and paint. Still some work to do! :-P

21x60 is a pretty nice size. Doesn't look that big in the pics.

Yeah, the picture is a bit deceiving, the chuck is a 315mm version.

Forklift for scale:

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CgIrjOiMYJHrRJhALpnPwAbg2vzkpVsZRh3XRfwyfVg=w1000-h720-no


Still working on the VFD retrofit and locating a noise from the gearbox. Already made some parts with it, precision and power seem to be good! :cool:
Note the dual feed tailstock with fine-feed and rapid lever etc. Some pretty cool features for a conventional lathe.

Love your DD. Looks alot like mine. :-)

Wagon (wheel) twins! Am I correct that your 245 is black? a rare color, only seen a few! :cool:
 
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Hello
Yes, it's black -86. Came with a tan textile interior. But it was changed with a blue............. Will be changed with a custom black interior from Edison Bender soon. The pictures is 2 years old by now.
Is not your black too? :-) Engine? My is a B230FT.
 
Hello
Yes, it's black -86. Came with a tan textile interior. But it was changed with a blue............. Will be changed with a custom black interior from Edison Bender soon. The pictures is 2 years old by now.
Is not your black too? :-) Engine? My is a B230FT.

No mine is 412 tropical green :)
Depending on light source; sunlight, fluorescent, clouded, it looks either green, blue or almost black.
Sounds good!


Some small things, after 5 (or 6?) years I finally took the time to fit the 850 passenger seat.
Took some measurements off the driver side bracket, improved it a bit (lighter, more rounded edges) and made it with the waterjet at work. Nice to have around :cool:

IMG_20150921_103836.jpg


Bends + Partz (and good time to clean the carpet!)


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Weldz


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Paints (zinc rich coating+black)


IMG_20150923_180354.jpg


Readyz (with working seat heater via relay!)

The leather had suffered a lot from 5 years in a dusty storage with plenty of birds+bats flying around. Some elbow grease and classic leather care (for saddle etc) products made it look as new.
 
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