Volvo 240 Stage Rally

[EricE]

Well figured I would throw my build up. So forme, like many of us the want to play with cars on gravel started young when I spectated a few events with my dad when I was much smaller. Got to go for a ride after one of the events with one of the competitors and was pretty much sold.

Fast forward a decade or so and here I am with a 240. Very lucky to have gotten it for free from my cousins after expressing interest in it. It was going to me or the scrapers so better off with me...maybe

So about a 1.5 years of teaching myself to work with metal as I built this thing and here is where I have gotten. The goal is basically a giant ford escort. Towers, 4 link, panhard. Motor will remain stock for now until I have a few more bucks. I have been gathering parts for this and it will stay naturally aspirated.

Tossed the volvo 1031 and went for a toyota 8 inch which I think i've seen a few folk on here stick in various projects. 4.88 cw&p with a supra lsd. The lsd will have the breakaway torque increased with a weir shim kit.

Gearbox is a mustang t5 with v8 ratios (2.95 first) I rebuilt it with new bearings, syncros, fork pads. This will do for now but will probably look into a proper close ratio box when it comes time for a motor.

For now just a photo of when I brought it home and I appologize for the low quality photo. Im still playing around with what works for size/quality to post on this forum.

Suggestions, advice and comments always welcome! I am here to learn!

[EricE]

Re: Volvo 240 Stage Rally

So I think I got a handle on this photo thing so I will throw a few more up.

The car has done quite well for 25 years of calgary winters but sadly they salt the roads to death out here and it had taken a bit of a toll on this car with 300,000km on the clock. Both rear rocker panels were gone as was the structure on only the drivers side door oddly enough. Got lucky and scored some patch panels for the rockers from an old high school shop teacher amoung many other things. Sorted the door area with just some sheet metal plate.

[Stu.C]

Re: Volvo 240 Stage Rally

Wow, it's years since I've been in one of them... and I remember it felt heavy just being in the rear seats Be very interesting to see how it turns out

[mario r h santos]

Re: Volvo 240 Stage Rally

Good luck with the project mate.

It will be good to see something different for a change.

Cheers,

Mário Santos.

[EricE]

Re: Volvo 240 Stage Rally

Thanks for the kind comments guys! Stu.C its nothing to write home about in stock form and driving the car around prior to the teardown I would have to agree... drove like a pregnant cow. But nothing some good suspension and weight reduction won't take care of. I've heard that well under 2700lb is very common as a rally spec. So hopefully with a canadian spec cage I can get there. Anything under 2700lb I will be happy.

Its definitely different around here but when you poke around and discover that its one of the most popular f cup cars it doesn't seem like such a odd idea!

To get the volvo love going...

https://www.youtube.com/watch?v=NAH8Au5drf4

So to continue on which updating the last years worth of work here is some more photos. Built my own towers. They are designed to accept ford sierra bilstien coilovers. Also got the beginnings of the cage in there.

[EricE]

Re: Volvo 240 Stage Rally

So towers were installed




I then drove it around with just the cage and shock towers in it. Partly because I wanted to/ needed needed a car and also to give my self time to think of some details to take care of before paint. Something of a poor mans dry build. As it was winter I had lots of fun with this.

Then once again around december or january it came apart again.

Cut out the big bulges (known as butt cheeks in the volvo world) in the boot floor. Some research showed that they get destroyed with longer travel + gravel. After running the suspension through its full travel I believed it.

[EricE]

Re: Volvo 240 Stage Rally

Then built my own 4 link boxes. I was originally going to use escort boxes/ links but figured it would be a bit small for rally use in this car.

[EricE]

Re: Volvo 240 Stage Rally

So in they go. Using escort dimensions and adjustings slightly as needed. I recall needing to narrow the placement of the boxes by an inch in order to avoid the need to cut into the framerails. This is probably due to the fact that the bushings going in them are nearly double the width of the group 4 escort ones I got initially.



Rebuilt and test fitted the t5...



Cut all the brackets off the toyota axle and welded new ones on.

[EricE]

Re: Volvo 240 Stage Rally

After discovering that the now 1 peice driveshaft hit the tunnel I had to alter the back portion of it. Then painted it. aaahhhhh, there is light at the end of the tunnel.

And that pretty well takes this to where the car is at today.

[Graham]

Re: Volvo 240 Stage Rally

cool and nice to be different

[lukem30]

Re: Volvo 240 Stage Rally

very interesting, some nice work too

[Moisty]

Re: Volvo 240 Stage Rally

Nice work, I've got a soft spot for the Volvo as my first car was a 242 Gt and it went well on the gravel.

[rwd2ltrfiesta]

Re: Volvo 240 Stage Rally

Ooh I like the ethos.
Big barge hanging its Ares out on gravel. Yes!!!

[Roadsport]

Re: Volvo 240 Stage Rally

These things can be soo fast when set up right. Several Finnish rally championships have been taken with these. Finishing in front of BMW's Escorts Corolla GT's Starlets the lot...

[EricE]

Re: Volvo 240 Stage Rally

Thanks for all the positive compliments! Can't wait to start throwing gravel!

Roadsport I can't help but to notice that your from finland... Any tips on setting these things up? The ultimate goal is eventually something similar to a decently built f cup car but thats going to be a while.
Just curious do you know if anyone is using the 16v head for rally over where you are? What is the typical power of f cup cars?

Sorry if I bombard you with questions. Its a rare oppertunity for me to speak to someone who has actually possibibly been around finnish prepped volvos.