1991 244 Build Thread by Smokeyfan1000

9 minute(s) of a 720 minute read

I removed the rear calipers, cleaned all the caked on brake dust, on the inside of the housing where the pads reside, masked off the pistons & seals . Then I painted them with red Dupli-Color Caliper Paint. I'm allowing a couple days for them to dry fully, in the Sun.

I also bought a new brake master cylinder. It's a FENCO Brand, a new unit not a reman/rebuilt one. Box says a product of India, but when I opened the box, the Master Cylinder is in a plastic bag, with a sticker on it that reads..Made In Italy.

I used one of these on my 79 245 back in late 90's and it's still holding, so IMO these are good master cylinders. It has a somewhat shiny and silver in color, special anti rust coating on it, and should brighten up the engine compartment a little more. Hopefully it'll stay this way for a long time. Looks better than the black paint on the OEM one , I think.

I will have to swap my 1991 triangular/with fluid level wires/sender OEM reservoir, onto this master cylinder though. This new MC has the older 240 style rectangular one. Shouldn't be a big deal IMO. Pics below:

















While I have to admit this is turning out a bit colorful, I just figured the finishes on the blue IPD parts, was most likely more durable than any paint I could apply to them afterward.

And most of the parts are/remain in, the color they were painted by the manufacturer(such as the IPD parts & Bilstein HDs) So other than hose clamps,the IPD sway bars(originally gold cadmium plated) & brake calipers, I haven't really painted much of anything else. The blue susp.parts came that color

So I just went with what color they were. And bought/painted, or modded, a few other small/minor parts to match/blend with, the IPD ones, such as the hose clamps and oil dipstick handle. Then finished the blue theme with the IPD Silicone hose kit.

I figured that at least it would have a "color theme" instead of many different colors for each part, and it would look better this way, rather than 14 different colors, or all painted black. Plus the blue is one of the colors used in Volvo's logo. At least it'll be different.

I am applying undercoating to most of the rear suspension bolt heads & nuts, so they won't rust, and re-painted the four sway bar mounting bolts, on the "sway bar side" to better match the sway bar's shade of blue.

After looking at a lot of pictures of Group A 240 race cars, and other 240 race going cars, I noticed they usually had a "color theme" of some sort. And I was going for ,somewhat ,of that appearance, and the appearance of a "what if Volvo had made a n/a R Sport 240 version".

Though it might not be to everyone's taste, at any rate, I am having fun, and I am modding the car as I want. And I feel that is the main objective of modding one's car, and what it's really all about.

At least it'll look somewhat sporty. This car has huge sentimental value to me as well. And has a interesting story behind it, on the drive home after purchasing it, which if I was to share with you, you most likely would not believe .

I've wanted this 244, since the first day I laid eyes on it, when it was new, in 1991.

8/11/11

I sprayed some 3M undercoating into a empty cake icing container, and used a modeling brush to apply it to most of the bolts/nuts/large LTA bushing's sleeves, and diff's brackets. This to circumvent them rusting.

I then decide to paint the 2 bolts & two nuts that hold the rear sway to LTAs with Rustoleum Sail Blue to match the sway bar.

The other day, I ordered the 1 3/4" round Volvo R Sport decals for the Virgo center caps from www.davebarton.com. They arrived today,thanks to Dave Barton, for his always speedy shipping!

I applied them to the rear & front sway bars. This in keeping with my "R Sport n/a 240 theme" that I'm doing to this car. I like the look it lends. I will probably apply one to the front strut to strut brace also, later on.

Yep, I know the 242GT was all that was offered for "hi perf" n/a 240s, but I'm doing it my way....

Hopefully the rear brake calipers will be dry/hardened enough to install late this evening, or tomorrow.

















8/14/11

OK, rear calipers on axle & loaded. Front calipers touched up on inside edge immediately behind pads, where I previously neglected to paint them. All 4 calipers now match in appearence..

Also touched up rotors on outer edges and front's "vents" are now fully painted as well. Also painted all four "wheel alignment pins" that screw into rotors/hubs yellow, for easy ID during "on side of road" tire change due to flat, and painted frt "rotor securing" bolts. Pics below:

Next part to install is Brake Master Cylinder. Then bleed brakes.

















I removed the old ATE Master Cylinder, rinsed out the triangular reservoir with some new, but old/opened Castrol DOT 4 fluid until all the sediment was out of reservoir & it was clean again. Dried it off, cleaned up all the fluid residue with GUNK brake cleaner fluid on a rag. Got reservoir's exterior spotless.

Removed triangular reservoir from old MC, removed rectangular reservior from new MC. Then they swapped places.

I then bench bled the new Master Cylinder in the vise , and used the ATE Racing Blue Dot 4 Brake Fluid. Bled it until absolutely no bubbles were seen.

Placed a ton of paper towels in the area under the MC, to catch any & all spillage. Then installed the new master cylinder, wearing the original OEM Volvo triangular reservoir w/ fluid level sensor, onto the brake booster.

Removed the plastic bleed plugs, one at a time and threaded on each line, one at a time. MC is now on the car, and I'll begin bleeding the entire brake system tomorrow.

I spent the rest of the day, going through all my wrenches, and organizing them, as well as sockets, rachets ,extensions and all other tools.

Having used these tools and having them scattered to hellenback, for over a year, had gotten me to the breaking point.

It was way past time to put unneeded things away, and get my tools back in order. Would you believe it took 6+ hours? I'll spend more time working quicker now, because I don't have to hunt for 15 minutes to find something. Nothing bothers me more than that.

I'll post pics of MC install after I bleed the brakes tomorrow. But the silver finish on it does look nicer IMO.

The hard work is done, and it should be easy & all down hill from here. That is definately something to look forward to, as I've worked my everlovin' ass off up to this point. WORD.