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Fred's 1990 Volvo 740 GLE Sedan 
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Block is tucked away in the garage now, and cross member is cleaner than it was (still needs more love, though...).

Bad news: I mis-measured the sway bar and ordered the wrong bushes. I've asked to change the order, but it may have already left town.

The 760 front bar that I got was only 23mm, not 24mm. I must've measured one of the bent parts that are thicker due to being deformed. Fail.

Fred.

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Sun Dec 13, 2015 7:04 am
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Fred wrote:
Bad news: I mis-measured the sway bar and ordered the wrong bushes. I've asked to change the order, but it may have already left town.

The 760 front bar that I got was only 23mm, not 24mm. I must've measured one of the bent parts that are thicker due to being deformed.

Seller was nice and/or slow. 23mm on the way!

Picked up another eaton g80 rear for this yesterday: https://twitter.com/FredCookeNZ/status/ ... 4798893057
And brought it home in the 240: https://twitter.com/FredCookeNZ/status/ ... 0138101761

Then gave this thing some TLC:


Then took it for a short drive up the local "mountain" (hill made of volcanic rock) to enjoy the view and made sure the rears didn't fall off when I did a burnout. Success.

Lots still to do before I can relegalise this after xmas day when it expires:

  • All front end bushes - on their way!
  • Front brake rotors and pads - from 940 wagon!
  • Check wheel bearings while in there (probably OK, but...)
  • Swap out rear axle for locker variant with less worn handbrake shoes (handbrake has fore-aft play/is loose)
  • Destroy both rear tyres completely and replace with two new/used tyres - best pair on front
  • Fix up boot seal lip and reinstall seal (minor MIG welding and wire wheeling and rust killing)
  • Reinstall tail lights and bulbs and plug the wiring in (need to fix one stud on one light)
  • Scrub and rust kill some underside pieces that have suffered in storage with the PO - just surface rust
  • Swap out the bonnet latches for non-rusty looking ones: first impressions count

Can't/won't drive it much after xmas until this stuff is all done and a new WOF put on it.

Fred.

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Sat Dec 19, 2015 9:49 pm
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New bits: https://twitter.com/FredCookeNZ/status/ ... 5664820224
Before: https://twitter.com/FredCookeNZ/status/ ... 0534516736
After: https://twitter.com/FredCookeNZ/status/ ... 6067944448
Darkness: https://twitter.com/FredCookeNZ/status/ ... 6588834817
Baby hedgehog that came to visit: https://twitter.com/FredCookeNZ/status/ ... 4930244609

New bits were actually a meticulously combined set of old bits merged into harmony. Looking good! Now to get it driving well, too. I see some drag racing early next year :-D

Fred.

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Mon Dec 21, 2015 9:55 am
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Missed an update here a few weeks back... so here's a run down on what happened about 2 weeks ago...

Today (2 weeks ago) I pulled the "jumbo" brakes off of the 940 wagon that I'm decomissioning at the moment, and then I pulled the right front brakes off my 740 sedan, and then I replaced only the right front with the jumbo gear, and took it for a drive. The old ones were knackered, pitted, rusted, ruined, and shaking like crazy, but still worked, just not pleasantly. Turns out all the shake was from the right hand side gear, with the left being OK. Anyway, taking it for a drive was to see what the retard on each side was like post swap of only the right. IE, how even are the two setups purely from a hydraulic pressure to brake force perspective. I know the pads are obviously different, and could have played a roll in the outcome, however the result was: Nearly exactly equal. There was a slight tendancy for the jumbo gear to slow the car more, but only slight. Could just be the pads. There was discussion about master cylinder size/applicability here, too. I will have a measure up tomorrow, and check the masters in both cars, but it seems to me that they're probably not different, and certainly, the 740 pedal feel was unchanged, or unnoticably changed.

And a few pictures of the old ruined and new stuff:

Old ruined: https://twitter.com/FredCookeNZ/status/ ... 7177055232
Jumbo girllng: https://twitter.com/FredCookeNZ/status/ ... 5968238592
Jumbo rotors: https://twitter.com/FredCookeNZ/status/ ... 8666524672
ABS Girling back: https://twitter.com/FredCookeNZ/status/ ... 7735993344

Both sets of rotors were worn to maximum limits or beyond, but it was still an upgrade. I'll put fresh rotors and pads in it at some point in the future. How bad was it?

22mm rotor was 21.5 at the lip and 19.2 in the trough the pad left, with min thickness 20, it's safe to say these are dead.
26mm rotor was 26 at the lip and 24 in the trough the pad left, with min thickness 24, worn out, but still usable and OK.

IE, I went from 19.2mm to 24mm today, and when I replace them will go from 24mm to 26mm :-)

Next post, today! And yesterday, too.

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Wed Feb 03, 2016 10:24 am
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Yesterday I pulled the driver's seat belt out of the 940 and started pulling the stiff one out of the 740 to make room for it. Good work done.

Today I replaced the RHS strut bar and bushings with the used urethane setup out of the 940, this is how the old ones looked: https://twitter.com/FredCookeNZ/status/ ... 4029260800

Tomorrow LHS strut bar install and seatbelt job finished off. Possibly exhaust pull/swap underway, possibly not.

Fred.

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Wed Feb 03, 2016 10:27 am
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Today I replaced the left hand strut bar and bushings with the used urethane out of the 940. The old ones looked similar to the other side with as much play. It isn't quite "tomorrow" as I hoped in the last post, but it rained a few days in between, and I have to work outside at the moment.

I also added a battery mount clamp and some grease as the battery has been on the loose the entire time that I've owned it.

Exhaust and/or hand brake and/or driver's seat belt are next up.

Fred.

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Tue Feb 09, 2016 6:23 am
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https://twitter.com/FredCookeNZ/status/ ... 5946132480

Now I just need to get the rooted one out. I see the involvement of an angle grinder in our future...

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Sun Feb 21, 2016 5:31 am
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Wheels in the Suzuki on their way for new used tyres: https://twitter.com/FredCookeNZ/status/ ... 1307449344

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Wed Feb 24, 2016 12:08 pm
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Two new tyres fitted to wheels yesterday, and one of those fitted to the limping car yesterday, I forget. And today the other bad one came off and so did the caliper. Tomorrow the rear hand brake drum setups will come apart and get fixed up (if I can!) and the new used 940 exhaust will go on with a few minor touch ups. Today the old one came off, and I had to make a special tool to do it. A bit of a PITA. https://twitter.com/FredCookeNZ/status/ ... 1859435521

Also found this, however it came off more easily... https://twitter.com/FredCookeNZ/status/ ... 7606971392

I have some side by side pics of the two exhausts to show, but not uploaded yet.

WOF by mid next week, hopefully.

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Sat Feb 27, 2016 7:05 am
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Muffler condition:

https://twitter.com/FredCookeNZ/status/ ... 3818614785
https://twitter.com/FredCookeNZ/status/ ... 8135962624
https://twitter.com/FredCookeNZ/status/ ... 3207461889

:-o

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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Feb 28, 2016 12:58 am
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