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240 GLT saloon restoration project

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Old Jan 24th, 2021, 11:44   #21
Juular
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I've not updated this in a while, as progress has been slow thanks to the very cold weather.

So with the lower hinge repaired I wanted to test fit the door just to make sure the gaps were OK before going further.

I made an extra reinforcing bracket under the hinge just to make sure.



Access to the top hinge is basically impossible with the dash in place so I pulled it out which was surprisingly straightforward. Then continued to strip the rest of the interior.





With a bit of help and a lot of adjusting to the hinge and striker and adding some shims to the hinge, the door was closing nicely and the door gaps seemed pretty good.



I then celebrated by taking the door right back off again.

I marked the hinge positions first though.



Rather than finish off and close up the A-pillar I thought I would start dealing with the sills, floor and outrigger as the access to them would be better from above while it's all open.

Every job here is dependent on another. The outer sill attaches to the rotten inner sill, which is attached to the outrigger, which is attached to the floor. The outrigger is also held on by the transmission mount, and the floor and outrigger are also very near the fuel lines which I don't want to be cutting and welding near.

So before any further repairs take place it's time to start stripping things off the car.

Fuel tank off.



Pump and lines off.





With the explosive bits out of the way it's time to take stock of what needs done.

The part on the sill where everything meets.



The floor above that.



And with some prodding.



The other end of the outrigger is also bad.



In general the floor needs patching.



Thought I best build myself a garage!


Last edited by Juular; Jan 24th, 2021 at 11:48.
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Old Jan 24th, 2021, 12:17   #22
Juular
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Attacking the floor.





The chassis rail runs under there and needs some TLC.









Same here.







Next the tranny mount needs removed.



And while it's off I may as well clean it up.







Onto the outrigger floor section, finding the spot welds.



Cutting them out.



The outrigger then just pulls off.





Building a replacement.





Which goes in the homemade panels pile for cleaning and painting.



Rebuilding the floor.



Onto the nearby sill. Some amount of junk came out!



Replacing metal.





New metal Shaped for the drain section.







New section of step created.





That's where I'm at just now. Progress is hindered by the temperature outside regularly being down to -5!


Last edited by Juular; Jan 24th, 2021 at 12:25.
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Old Jan 24th, 2021, 12:42   #23
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Excellent work there, thanks for posting all the photos.

Since you have the dash apart already and are therefore most of the way, whilst you’re there I suggest you pull the heater box out and clean the fan and lubricate it’s bearings- you could replace it, but if it’s working well there’s no particular need to. It’s also worth flushing the heater matrix- I left mine overnight full of anti limescale stuff which shifted a lot of gunk from within it, alternatively if you know someone with an ultra-sonic tank that will work well too.

Cheers
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Old Jan 24th, 2021, 18:17   #24
volvo always
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Your doing a fantastic job on it. Enjoy seeing you save the Volvo I have never tried welding and don't have access to power where I live. My 240 Outrigger was the same and got welded for £50.

Your job is so much better. Had it re-welded 2 years later as rusted through on welds! Sold car around 2 years ago. Now have a 1996 940.

James.
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Old Jan 24th, 2021, 19:15   #25
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Fantastic - you are a braver man than I am Gunga Din.

That is a marvellous refurbishment job, well done, I’m really looking forward to seeing the finished car.

Alan
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Old Jan 24th, 2021, 22:35   #26
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Wow! This is incredible.
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Old Jan 25th, 2021, 07:04   #27
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Quote:
Originally Posted by mentepazza View Post
Wow! This is incredible.
Yes indeed, Juular is pretty handy with the MIG welder.

Chapeau! to Juular for doing all this in the colder conditions of Northern Britain as well.

Alan
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Old Feb 22nd, 2021, 12:57   #28
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More bits repaired.

Inner and outer sill finished at the front.



It may look a bit tatty or ragged but everything will be ground flush and tidy.

Important drain hole kept in place.





Passenger floor finished off.





Which allows me to fit the home made outrigger.



Plug welded from above.



Fits millimetre perfect, very happy.





Coat of zinc. It will all get cavity wax and a final coat of something durable.



The passenger floor is now finished and totally sound. Just needs paint and soundproofing etc.



Next job.. dealing with the rot at the outer sill/ step area and joining it all up with the A pillar.
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Old Feb 22nd, 2021, 13:07   #29
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Fabulous - well done.
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Old Feb 22nd, 2021, 13:51   #30
Laird Scooby
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What Alan said! ^^^^^
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