A Cult Car

This is a blog on refurbishing a Volvo 240 Wagon-- a cult car that is legendary for its durability. The 5 speeds manual transmission in particular gets great fuel economy, 32.5 mpg is attainable at speeds of 60 mph. Both the sedan and the wagon have plenty of rear leg and head room, even for tall people. Additionally, a tall person can sleep in the back--it is 77" long if the rear seat bottom is removed.

Thick sheet metal make it durable--so is the motor. Volvo took a V8 truck engine cut in half, to make this 4 cylinder engine. It has bearings and rods are designed for much heavy loads and this makes the engine nearly impossible to kill. People can get literally a million miles between rebuilds with regular oil changes and normal preventative maintenance.

The 5 speeds cars are fun to drive. Their durability means it is a smart economic choice to put money into them--they will last indefinitely if maintained. Parts are cheap. They are easy and simple to work on. Police just don't ever pull them over. It is because they like to stay at legal freeway speeds and purr along at 60 mph--so police expect them to be driven slowly. Finally, they are safe--built around a full roll cage. These are the reasons why there are so many are still on the road today.

Wednesday, February 22, 2012

Center Console Arm Rest

I installed a center console arm rest that I got for free.  It is black and matches my interior.  Installing was a bit of a PITA and needs a little tweaking as it prevents fully releasing the parking brake.  In any event, I love it.  I drove to Washington DC on Monday and back that evening.  I found the arm rest comfortable and it held my arm is just the right position for operating the manual transmission.  It also had four drink holders, two for the front and two for the back seat.  The drink holders lack the flip down parts that prevent a drink from falling through.  However, they are perfect for a tapered paper cup.   I highly recommend this part if you can find one.

New Tires


Here are my new tires.  I bought Michelin Harmony Tires. These are 195-65R15's mounted on my Virgo Rims.  I held off on buying these until I found an extra rim so I could buy a full sized rim.  One problem I have is these tires are a little short so I lost some of my top end speed and the speedometer reads high.  I am thinking about taking these back and putting on 205-65R15's. The ride is great.  They corner well, and have a high tread wear rating.  I should be able to get as much as 100,000 miles on these tires, if they don't wear out due to the rubber breaking down from UV light.  In any case, having a full size spare will allow me to have a five tire rotation (these are not directional tires), and give me a bit more confidence on long trips.

Tuesday, February 7, 2012

Purchased: A 5th Virgo wheel for a spare tire

Not long ago, I scored a set of perfect Virgo wheels for $150.  These came with four over sized tires, two of which are nearly worn out.  The other two are in decent shape but are two heavy for this car, and also too tall.  A 5th Virgo Wheel cost $75, but gives me the option of a five tire rotation.  I will be able to swap tires all around and my wagon will look complete in any configuration.

I want to buy a set of five Micheline Engergy Saver A/S tires.  These tires are not in production at the moment. I've been waiting and hoping Michelin will start producing these again for the last six months.  If not available, I will buy Michelin Harmony tires, mount them up, and use a five tire rotation.  The Harmony tires are bi-directional offering greater flexibility in tire rotation.

Looking forward, what is next after this?  I'd like a larger fuel tank--instead of 15 gallons, I want to carry 30 gallons.  With Energy Saver A/S tires I should be able to achieve a range of over 900 miles.  I was getting 32.5 mpg on my last set of tires which were 60% worn which reduces rolling resistance.  I might see a slight reduction in fuel economy at first, but I expect it to improve as the tires wear in some.  I'm hoping to at least maintain that 32.5 mpg and hopefully improve it.  I'm sure in the long run I could see as much as 34 mpg with these tires and keeping my speed under 60 mph on the highway.

Other goals are installing two Ham Radios and two antenna mounts. And finding two four way switches for my power mirrors.

Instrument Cluster and Wiring issues.

I have had a few wiring issues.  I'm pleased to report replacing my instrument cluster was causing some problems.  Replacing it fixed that.  Another problem was the front turn signal was damaged when I steam cleaned my new engine.  So I will fiddle with that some and if that doesn't work, I'll replace it. 

The next issue is to fix the turn signal stalk and cruise control.

I also discovered there is a problem with the mass flow sensor which explains my high fuel consumption.  I dropped it at the shop for that.  I may ask them to take a look at the cruise control--just to wrap all that up.

My next projects will be to install an arm rest, and repairing the drivers seat lumbar support.