88 740 Turbo Wagon, maybe it gets better this time

Whats up TB long time lurker first time caller, figured now would be the time to start documenting some of this stuff and as of recent I have found myself with a shell!

I had a 1991 740 Turbo Wagon Grey on black, a great candidate to fix and turn into a great driver, but as fate and poor tires would have it I ping ponged it going up a on ramp

Luckily I was alone and no one but the walls where involved ! A tow truck happened to pass about 5 minutes later, Waved him down and I was home for 60 bucks 25 minutes after the accident with my car and ofc if it wasn't for popping a tire (result of crash no the cause) the car would have driven home cuz volvo!

So that lead me to reach out to our current community in Jax FL and A member Adam reached out saying he had a shell for the holy 500 dollar number and off I went!

And Here she is the new shell that will accept some bits of the 1991 Turbo 740 + some bits from a 91 240 + T project I had !

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Super Stoked Body is nice and straight, came on IPD lowering Springs and sway bars all 4 hydras with caps !

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They where going to use the car for a v8 swap, but it is an OG turbo car ! So ofc I picked it up with the bay lookin like this

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Dats Cool Tho ! Not sure what Ill name her but as far as goals go!

* Improve current state
* Complete the Oxblood interior
* all working OEM options
* Drive able with a/c
* really just put the bit together so I can stop DDing my 77

Drivetrain info !

*bf230 from 91 240 w/ K cam ported 13c
*m46 + hydro setup pulled from an 85 760 Jurbo with 120k miles

Dats it will be cleaning and painting everything before going in, Resealing yes not rebuilding though, the block has about 115k miles on it !

Going to use this as I'm sure many do as a place to help garner some inspiration for consistent progress. I need to get in the habit of atleast an hour a day and it'll all be done before I know it !

Will update the thread later today with what I did today yeah yeah yeah something like that yeah yeah yeah Thanks guys yeah yeah yeah

Cheers
Conner P

Welcome man! Good luck with the project

Good to see another old 7er on the board- good luck man!

Wild how two years later here we are ! That whole Life thing I do suppose ! Luckily all good things, and while not able to work on my projects as often the time was well spent!

luckily some of the work that was needed got done, and it wasnt 100% untouched

And part of that required timing and luck !

Some of which was getting a 88 volvo 740 turbo in the Junkyard with a m46 low mileage too, looked like it had been just sitting for decades , I opened up the top of the case and everything is picture perfect, and lucked out with the hydro pedal assembly and whole set up was in there !

And of course everything was at the JY so a nice price and all the bits and bobs where there!

But of course I was going to be running lh 2.4 in this 740 so needed to be able to have a CPS notch, and instead of knocking the the chunk out of the M46 bell housing I swapped on an m47 housing I had about!

Bolted that to the repainted and sealed 91 240 block I had, swapped the heads from the turbo 91 740 on to it! And slammed jammed her in the whole ! Probably did that about this time last year , maybe a bit sooner or so ! I got the swap in place but did 0 to get it actually running on the lh 2.4 while maintaining the rest of the 740 functions

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Since the swap was in there and a bit over this year I had been messing with it a few hours and here there , dropped the tank and cleaned it ( used baking soda and vinegar with nuts and bolts thrown in there as tumblers ! and just shaked and baked! ), which is kinda nice on the 7 series wagons and them being plastic tanks is a plus it wasnt to cumbersome to handle !

Replaced the intank pump and whole assmebly because it was just shot beyond repair , and nice guy in ATL sourced me a very nice used unit with pump and all the attachments and what not. Photos need to be pulled from my old phone, the pumps where shot gross just bad!

Since all this had been done the car was still not running yet so after lucking out at the yard and getting the other side of the lh 2.4 plug I needed I got to work plugging it up !

A little bit of the trial and error here !

http://www.turbobricks.com/forums/showthread.php?t=365112

Luckily after a bit of tracing back had everything in there right but the wrong ezk lolol

and got it to fire on ether !

I still need to go in and clean up things to make it right and reliable , all the main wires for the LH are fine but need to mesh in the dash wiring , the plug in for that stuff is fairly near the lh 2.4 plug in just need to length a few things to tap them into each other.

-oil dummy light
-temp
-tach
-battery charge

along with wiring the lh 2.4 to trigger to the stock 740 fuel pump relay to than just run the stock wiring and pumps from the 740, luckily all the wiring is there and intact !


When its done it should be all a simple turn key setup with minimal notice to any swaps or what not ideally, how I am going to stash the ecu and ezk in the foot well though is still a thing a need to look at as well , I dont want to extend the harness ideally but we will see its kinda tight down there with the hvac stuff!

Of course though while this 2 year span has passed, a move happened in the process and I might have moved the car in the process perhaps with the back of the drive shaft still attached in the car!

Volvo 740 Floor Repair Center Support Bearing

http://www.turbobricks.com/forums/showthread.php?t=365447




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It is defentily shot, and the under side is bad, you can not bolt up the center support bearing, the holes are toast, that hole chunk of frame rail on both sides, and going single drive shaft didnt seem like an option and scrapping the project due to my ignorance and own mistakes didnt seem like a good option either !

And with 0 welding experience repair was uncertain but hey yah gotta try !

So picked up a 90 amp mig welder from east wood !

https://www.eastwood.com/eastwood-90-amp-mig-welder.html

This thing is light, and small ! And to my delight a keggerator was gifted to me years ago but without the gerator part, but the CO2 tank was there and luckily still has gas in it! So was able to set this up on 100% CO2 !

Ill post some pics of my practice welds so humor can be had haha


And with some practice welding attempts over the course of a few weeks, off to the Junkyard to hunt for a floor board Replacement !

Luckily there and still as of writing this a 940 turbo wagon in the junkyard so I was able to go there equipped with a saw zaw and drill plus a few other various bits and bobs and secure the goods!

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and of course with replacement in hand and this great great day of thanks with a long weekend I wanted to try to get it in!

Boost season is getting here and I want to drive my car and go pswh pswh and show out this red interior !

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Luckily one of the PO has sound deadened the whole car and door panels already so I am excited while , extra weight itll be extra nice! A great warm winter rider in the making!

Was worried I didnt get a big enough chunk from the donor car but I think Im in there like swimwear ! Maybe worse case itll be off by a fractional mm or something but I think itll be good!

Will updated as the fitting process ensues tomorrow, trimming and shapping untill it all fits, than just tact tact tact and it should be good to go!

Defiantly snagged a hard fuel line and will need to replace that now in the process of cutting mine out, the worst part is I totally moved out of the way where if you didnt cut flat you on the floor they would have been missed but completely forgot and paid the price !

so it goes !

Nice to see the project wasn't abandoned!

Hopefully you cut the replacement panels larger than the hole in the car.. Ideally, you want to cut back some of the inner panels so the replacement frame rail section overlaps the existing floor, not ideal to have a single butt-seam for all layers of the repair.

Clear back all that butyl matting at least a few inches from the weld joint.

Just make sure to tack widely spaced welds & move around to join the floor skin & spread the heat, to minimize distortion & movement of the panels during the process. None of the individual factory panels are anywhere near the penetration limit of the welder. If you can overlap the rails, then weld the floor skin on the inside, and then weld the overlap rail seam from underneath.

Center bearing carrier plate is slotted to allow for adjustment but try to get it as close as possible to avoid noises and eaten bearings later on.

lookforjoe said:

Nice to see the project wasn't abandoned!

Hopefully you cut the replacement panels larger than the hole in the car.. Ideally, you want to cut back some of the inner panels so the replacement frame rail section overlaps the existing floor, not ideal to have a single butt-seam for all layers of the repair.

.

Click to expand...

When you say that I am not 100% sure of what you mean, I am not sure how I would get anything to overlap in this instance beyond cutting it all so that itll mate clean and square I suppose just butting upping against each other,

like cutting a frame rail at an \ than cutting the other one \ so they sit on top of each other ?

Apricate the look and thoughts ! I dont want to let this one go ! Gotta get back in a Swedish sled !

Super excited !

nordmaschine said:

Center bearing carrier plate is slotted to allow for adjustment but try to get it as close as possible to avoid noises and eaten bearings later on.

Click to expand...

In all honesty I am glad while this is not just replacing a part of the floor pan per say I am happy to know I have some wiggle room !

Going to be test fitting and cutting tomorrow!

whatshouldido said:

When you say that I am not 100% sure of what you mean, I am not sure how I would get anything to overlap in this instance beyond cutting it all so that itll mate clean and square I suppose just butting upping against each other,

like cutting a frame rail at an \ than cutting the other one \ so they sit on top of each other ?

Apricate the look and thoughts ! I dont want to let this one go ! Gotta get back in a Swedish sled !

Super excited !

Click to expand...

quick sketch to show what I meant - basically overlapping panels for strength. Repair panel would be inserted from below



EDIT - unless you dogleg the lower section and add a filler channel, there will be no way to weld that sandwiched section for strength

lookforjoe said:

quick sketch to show what I meant - basically overlapping panels for strength. Repair panel would be inserted from below

EDIT - unless you dogleg the lower section and add a filler channel, there will be no way to weld that sandwiched section for strength

Click to expand...

Ahh that makes alot of sense , but like you said the middle section will not be touchable , unless cutting it out to expose it from the bottom, and then welding that section back in !

Going to start trimming some stuff up and see what happens I suppose !

which it looks like the second set is saying that, so Ill try to work on getting it like that and see where I land !

whatshouldido said:

which it looks like the second set is saying that, so Ill try to work on getting it like that and see where I land !

Click to expand...

Yes - that way each layer is welded for strength. Good luck with the fitting & welding.

wellll!!!

Went about cutting and trimming and this was the end product !

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do you see what I see??

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This was on Saturday! And you can see from the photo it defiantly was not going to cut the bill, to many gaps and not really a good fit unfortunately, but makes sense as I went and got the patch before removing the old material, and this also led to me really look at how the floor is setup to see what the most ideal insertion would be and after some looking I think Itll be here!

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Far enough back the channel rail becomes 1 piece of flat metal, lowering the amount of areas of cuts that need to line up to help me out the most as this is my first time ever doing any weld work or body repair!

Sunday ! Today !

Figured since the first panel wasn't suitable I had to go get a new one, and this one better work because I have 1 more option after this and then no more till a fresh one gets rotated in and who knows when thatll be.

so off I went to the yard to do the dang thing !

and of course in my first trip out I forgot something and had to run back home , took a bit and went back , and when I did !

Saw this sweet thing in the parking lot did not see the owner though , but dang its a slick looking ride !

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What wheels are those ?? A FWD volvo wheel for sure , had spacers on it, M47 car too

So the 2nd run was off to a good start for sure,

off to the donor car I went and this is her in all her glory, same color as the first replacement panel funnily enough

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some of the tools I had brought with me, just enough

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This poor car was filthy , even written on the window " Move Next to Dumpster" dang thing had a rough last leg, forgot to get the mileage off the dash , this 940 was also a block mounted dizzy, and 1 pump fuel system !

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once got everything out of the way got to work cutting out my new chunk !

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Check the saw zaw for size

Took it back basically infront of the support that goes across the driver shaft tunnel underneath the car, the piece I assume that makes going 1 piece a pain the but with these cars!


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And there it is ! The guy at the counter had to ask how to ring it up, I think it might have been the oddest item of the day for him!

the best part for sure is this will be a easier fit with this much more material to work with, less angles and layers of stuff, got it right where the frame rails end !

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We will see what gets done this week!

Thanks again for the tips lookforjoe!

whatshouldido said:

Saw this sweet thing in the parking lot did not see the owner though , but dang its a slick looking ride !

What wheels are those ?? A FWD volvo wheel for sure , had spacers on it, M47 car too

Click to expand...

17" rims are called Arrakis. Commonly found on the S80 with T6 from about '99 - '02 or so.

Looks like a much better section to work with, glad I could offer helpful suggestions. I'm sure you will end ups with a solid repair, given your concerns over structural integrity!