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canadian volvo 245 (LS swap)

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  • canadian volvo 245 (LS swap)

    photo bucket shit all over me, and with a recent knee injury i had some down time so i reuploaded all my photos to imgur and made a new thread. not too much new since the last thread, but atleast i can continue on where i left off.


    So before everyone gets upset, I've owned this car for awhile, and have a lot of progress pictures from some time ago, i'll start with that and slowly document the current LS plan.


    anyways on to the car. the car in question is a 1991 volvo 245 with a 2.3l 4 banger and a stock 5 speed. The story on the car is after getting into a hit and run accident where the other guy took off, My first volvo wagon was destroyed, So i went on the hunt and found this one. i was skeptical at first, i got a response to a "wanted" ad i posted on my local kijiji (canada's craigslist) I went to go look since the seller didnt have a camera or didnt know how send photos. when i get there its buried up to the rims in dirt in a field with grass mowed around it. they were actually using it as a green house and had little saplings in the small pots growing in the trunk section.


    this is the first one i had, only had it for 1 week.


    bent the frame rails way out of whack





    then i picked up the current 245. this is the only picture i grabbed when i got it home
    i told the guy if he got it out of the field and ready for a test drive i'll come back. so he did and a week later i bought her for $500
    at this point it had 503,000kms on the odometer



    on the way home from buying it the shifter linkage exploded on me, so first thing to do was turn some new brass bushings to replace the worn out nylon ones

    he factory "retaining sleeve" rotted off the linkage barrel so i replaced the pins with roll pins and put it all back together



    after the initial accident my grandmother (so thankful for her) gave me her 7th gen civic to drive while i get the other volvo on the road. so i spent some time gathering parts and making the 245 road worthy up at the shop.





    eventually i got her home, and of course we had a massive snow fall right after



    so i dug her out



    then went out and got my first taste of RWD fun



    eventually spring came, and i dealt with the ride height.




    scored a full set of GTA wheels for $200 just needed a mean repolish



    got them mounted and an alignment done.



    drove it like this for summer and loved every minute of it, its my first RWD car, and its been a blast having one fun with it. at this point it was a bone stock 20 something year old car with a set of wheels and lowered haha. definitely turned some heads though!




    I've never been one to baby my vehicles, so i snapped a pic after some "rally" driving on some farm roads haha the front cross member and front exhaust pipe took some nasty hits.
    [img]I've%20never%20been%20one%20to%20baby%20my%20vehic les,%20so%20i%20snapped%20a%20pic%20after%20some%2 0"rally"%20driving%20on%20some%20farm%20roads%20haha[/img]


    fast forward to fall, and a season of abuse, its maintenance time.
    beat the hell out of the sub frame all year, so i found a used but good one to replace



    got her back together and freshened up the front end just in time for the fall colours pictures




    of course after fall comes winter.. threw some new winters on the old steelies and spent more time sideways than i did straight.



    i only ended up in the ditch once, but thankfully my friends drive subarus... so they pulled me out.



    spring came again, and i put the GTAs back on, which was nice and refreshing, Also put some adjustable perches and 2.5ID springs in the back. the old cut ones would rub all the time with any weight in the car, this solved that problem



    some summer time photos (yea its not all snow in canada aha)





    so as time rolled on, and i learned more, and broke more stock parts i started really modding it.
    i kept destroying torque rod bushings (upper links in a 4 link) so i built some adjustable rods with heim joints at each end. All the heim joints i use have a teflon liner in them for maintaince free care, and durable life span. I also used LH threads at one end and RH threads at the other. this way they can be adjusted with out removing them from the car.



    next were some adjustable sway bar links with poly upper bushings to lower the bar back down.
    these were pretty simple. just needed to make the sleeve/spacers and get some threaded rod for the rod end.



    I also picked up this cheap fixed back race seat from a friend, its nothing special, but its probably my favourite thing I've done to the car so far, so much better feel for the road and corners. a lot more feel to the cars input.



    fall came again, and it looked pretty.




    got a set of these mere wheels for free so i decided to clean them up for a blingy set of winter wheels




    whipped up some adapters on a slow dat at work



    put some nice fresh conti winter tires on em



    the old pan hard rod got rusty, and decided to crack at the spot where it kinks to clear the diff. to get me home i just welded the crack. that didnt last long, but it gave me time to build a new stainless rod with adjustable heirs.





    then one day i felt a big clunk in the rear, turns out my rear axle bushings exploded. so for now i just replaced with stock ones

  • #2
    but machined a set of solid ones with spherical bearings in for the future




    i also picked up a new wheel, and turned a wooden shift knob (first time machining wood, came out pretty nice)



    heres where the fun stuff started happening. picked up this rusty rear axle and everything attached to it. The plan for this was to have something out of the car I could do work on. I also planned to weld the diff. but wanted a back up incase it wasn't gonna work for daily use.



    stripped it down and opened it up



    welded it up. its ugly, but those spiders will never move again



    made some dual calliper brackets






    cleaned up and painted




    rear axle bearing/bushings pressed in



    then started boxing the trailing arms



    then milled some tapped bosses for front heim joints





    after that i turned to the rear and made some better mounting points for my adjustable sleeves




    so as all this was going on in the shop, i bought this running truck for $300 for my new power plant. I went for a 4.8l specifically for the shorter stroke and faster revs.





    at this point in the dead of winter, I've done a lot of winter drifting and the clutch said "i quit"




    found some early "slim" bumpers at the pick n pull



    in preparation for the swap, i went grabbed a bunch of pallets and bought some floor boarding and built a floor in my portipal.



    got the engine on the stand and started stripping the long block



    threw some paint on it



    this is a HUGE part of the build here. up until this point the 245 has obviously been the daily driver. so I had to pick up a dedicated daily. this fell in my lap for a steal at $1600
    1.8t 5-speed 4motion fully loaded.



    so with a new car to drive me to work, i rolled the 245 in to the tent and started digging in.
    at this point the old b230f had 587,000km on her.







    first obvious issue was the deep truck pan. so i made some measurements and got a 7qrt pan that was 6" deep.



    hung the motor in the bay



    everything lines up perfect (note i circled the engine mount bolts that line up perfectly with the cross member.)




    picked up a Gm T5 out of a camaro and a bell housing to match.



    gonna have to do some trimming around the shifter hole.



    started on the mounts. i used the STS mounts for inspiration. i got the engine sitting exactly where i needed it. then measured measured and measured. then started making the parts to build the mounts


    turned some sleeves and black poly bushings. then coped some box tubing




    welded up



    then made some base plates for the cross member. milled the pocket out so the tubing sits 1/2" deep then welded around

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    • #3
      mounts all welded up and painted




      bolted in the car





      after that i had to deal with the shifter hole. so i cut the factory hole out to reuse it. once i had it cut out, i cut and bent the tunnel until i had it where i needed it. then tacked the stock hole back and started pulling and filling metal back to the hole.





      then mounted the hand brake lever and tried to make the carpet fit as good as possible





      after that i modified the stock trans cross member to use with the T5 mount. the mount is right above the stock location so i lucked out there.






      240s use a one piece strut tube/front spindle setup. Which means there's only a few very expensive options for coil overs. And a lot involve cutting/welding the stock spindles. I was on the hunt for a more traditional setup where the spindle attaches to the strut with two bolts. Often used for camber adjustment as well. I couldn't find much and the volvos forward mounted steering rack was posing an issue. But after peeking under the front of a 1989 Mazda RX7 it had everything I was looking for. The two bolt strut mount, the forward tie rod mount, a common ball joint attachment and being rwd there's no splined hub assembly.


      Plan is now to run rx7 brakes/ball joints/coilovers and reuse the Volvo tie rods.



      also got my harness all trimmed down

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      • #4
        Love this build, your making it look so easy.
        Insta Mintyhinrichs

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        • #5
          Looking good, interested to see how you make the RX7 stuff work.

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          • #6
            Originally posted by jayjaypea View Post
            Looking good, interested to see how you make the RX7 stuff work.
            Same actually. Lol I don’t think it’s been done before. I just kept checking under RWD cars at the pick n pull, and finally found something that might work for this setups I’ll have to weld a plate on the 240 control arms and re drill them to match the rx7 ball joints. Then I’ll probably use rx7 tie rods to keep it standard at the knuckle. Then make some inner rod pieces. After that it’s just getting the coil overs and making a strut tower cap to match. Hopefully the length of the coil over won’t be drastically different lol

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            • #7
              So, after much back and forth with friends about different trans/flywheel/bell housing setups i got myself a sachs 1050.




              first problem. this flywheel didnt didnt fit inside my SBC bell housing. so after more talking found out a friend use the same setup in his elcamino and used a BBC bell housing. so with a trip down to see Rick at Nova Automotive and of course he had one laying around.
              I also scored this strut brace at the junk yard. its not a direct fit, but if i cut the ends off and make my own mounting points it'll be a trick little piece

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              • #8
                This is an awesome project, I love it!
                Definitely following, and hoping for some big rubber "muscle car stance"

                FB: @DumbassCarCrew - IG: @fruttolo_dumbasscrew

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                • #9
                  Such a great thread!
                  Instagram: @Eurow

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                  • #10
                    If i were to buy a volvo, this would be the only one i would get

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                    • #11
                      In for so much more!
                      Lucas
                      Daily: 2004 Pontiac GTO. . . . . . . . . Daily Econobox: 2009 Mini Clubman Cooper
                      Originally posted by LCG
                      High 21! It's like a high 5 but includes both hands, both feet and a boner.

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                      • #12
                        lots of updates soon. been off with a busted knee for about a month now. but its almost healed up, and ready to start some work.

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                        • #13
                          money and time has been a little tight after my daily snapped the timing belt and wrecked the head.


                          but anyways I've still been plugging along. i made some cuts to the fire wall, to push it back and allow for some space behind the intake manifold. then boxed it in and finished it off.



                          with the intake now fitting, i test fit the hood. it JUST closes with the truck manifold. which i have decided to keep for now.



                          installed a new straight steering shaft to gain some clearance against the headers, this is a huge help compared to the large rubber dampened stock shaft.



                          poking around the engine bay, i noticed one of the push out grommets fit the heater pipes. since the OEM location was on there drivers side directly behind the head, there was no way i could run hoses from it. so i relocated the hoses over to the passenger side cut out and it works perfect!



                          last but not least, i needed to gain some scene points! but really, the bay needed paint over some welds and rusty spots. the car is a long way from making it to any sort of paint booth, so she got the krylon treatment. i figured id do something bright to have some fun. it looks like crap-ish. i painted it in -20 weather but eh its not a show car, its a go car. the engine bay is gonna get dirty anyways.

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                          • #14
                            Cleaned and shaved the stock truck manifold



                            Side by side with the stock one

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                            • #15
                              This is one cool volvo! Love the effort and time put into this

                              In for more
                              IG @Hansolbakken

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