Wednesday, May 01, 2013 - Brandon Weaver - ipd customer service representative
I’m very excited about the prospect of working with one of you on the ipd $25,000 Build Off. If paired with me you can be sure that you’ll be getting the assistance of the most tenacious, meticulous, thorough, intelligent and handsome ipd staff member. Working together we will make sure that your project goals are met and that most importantly you have FUN with this! It’s just an added benefit that we’ll completely embarrass the other participants and their inferior project leaders. Your project car better have a nice exhaust and clean taillight lenses, because that is all that the other participants will be able to see!
I’ve owned a variety of Volvos, including an 1800ES, a couple of 240’s, an 850 T5R, an S70 T5M, and a V70R. I’ve got an insatiable passion for Volvos, I love to learn, and I’m a researching machine. You can lean on me to help guide you through your build. I also have an unholy appreciation of illegal fireworks, so if we ever hit a snag in the project we can always blow something up. Blowing things up with fireworks is the best way to get the creative juices flowing, and losing a digit may be the competitive edge you need in order to get at that troublesome clamp.
We are team Cobra Kai. Except we don’t get kicked in the face by a hobbled competitor at the end. No, we sweep the leg AND put them in a body bag. End of story. No mercy.
Let’s go get ‘em!!
September 16, 2013
It's been a while since the last update. Needed a little break I suppose. It's good for the primer to get a chance to fully cure, at least that's what I'm telling myself.
Since the last update we welded up all of the front bumper trim holes, ground them down and put a skim coat of filler on them in preparation for the "flush" mounted 83-85 style plastic bumpers. Turned out good and I'm happy with it so far.
Had a friend stop by around this point of the project and give us a hard time about not stitch welding the engine compartment before painting. Thought about it for a bit and he was right. We don't ever plan on selling this car, so might as well do it while we are here. Put Bryce to work with the cordless drill and a wire wheel to clean out all the seams best he could to get them ready for stitch welding.
Then we used a sharpy and a tape measure to make 1" long marks about every 2" as a guide for the stitch welding.
Welding the seams wasn't very fun with the seam sealer inside creating all kinds of welding issues. I had to grind a few back down and re-weld them because they looked so bad. They are all okay now and will be less noticeable once they have paint on them.
The body is still being blocked out. It's currently on it's 2nd coat of high build primer. It will probably need to be blocked and primered again 3-4 more times for me to be happy with it.
Of course while all this bodywork stuff is happening parts are rolling in from the powder-coater and I picked up my first batch of new parts from IPD so we could start working on the some of the sub assemblies if we get burnt out on bodywork. I love looking at all of the shiny parts and can't wait to get to the point of putting them back on.
We layed all the parts out together to figure out what else we might need.
So far our list of parts from IPD so far is steering rack boots, inner tie rods, tie rod ends, ball joints, stainless braided brake lines, front control arm poly bushings, front wheel bearing kits, Volvo upper strut mounts, hood cable, clutch cable, brake master cylinder, poly rear control arm front bushings, upgraded in-tank fuel pump kit, 10mm H&R rear wheel spacers, engine bottom and top end gasket kits, timing bely kit, Volvo crank/cam/aux shaft seals, front crank pulley/dampner and poly accessory mount bushings. Not shown are the IPD adjustable torque rods and sway bars that we also have.
That's all the update I have for now. Hopefully the next update there will be more shiny stuff to show off. :-)
July 19, 2013
Well after several days of work sanding and primering and sanding and sanding some more and seeing not much change visually, we decided we needed a little motivation. So we got the oil pan, valve cover and engine block out and prepped them for paint.
The oil pan was pretty simple. We hand cleaned it inside and out with Castrol Super Clean, water and an older red scotch brite pad. We then scuffed the outside with a new scotch brite pad, a light misting of Castrol Super Clean, water and sanded any scratches out with a piece of 400 grit wet/dry sand paper. Dried it off with compressed air and it was ready for paint.
The valve cover was the same process as the oil pan, with the exception of the "VOLVO" letters on the top. We block sanded those with 180 and then 220 dry, then switched to 320, 400, 600 and 1000 wet. We then taped them off to keep the paint off of them and they will get a final polish after the paint has fully cured.
The short block was a little more difficult. Since I didn't want to risk prepping gasket surfaces after it was freshly painted, we had to do it before it was painted. So we cleaned off all of the gasket surfaces and prepped the deck as if we were putting a new headgasket on. Not wanting to use water on freshly cleaned bare cast iron we used several spray cans of Berryman's Carb Cleaner in place of the Castrol Super Clean and Water from the oilpan and valve cover process. We started off with an old scotch brite pad and the carb cleaner, then switched to a new scotch brite pad and liberal amounts of carb cleaner with a final complete rinse with carb cleaner and then compressed air dried it off. We used an old dented oil pan, a spare front engine cover and taped up the rest of the parts of the block we didn't want painted. The block was Bryce's first try at painting with a gun (primer is easy and doesn't matter nearly as much as paint). He did the first few coats and I did the final "gloss" coat.
So with some bright and shiny motivation, we head back to the tedious block sanding...
July 12, 2013
With the body mostly stripped it was time to turn our attention to the paint and body work. The outside of the body had been repainted once before and it had small moisture bubbles almost everywhere. Not sure if it was from poor prep or contaminates when then were doing the bodywork before, but it means that we need to strip off all of the old paint down to metal to ensure a good foundation for our new bodywork and paint.
You can see the small bubbles (light colored spots) in this pic:
So we called the local media blasting place that does complete cars and they wanted around $600 to blast the paint safely off of the car. Since $600 was more than I budgeted for our entire paint job, that was out of the question. We would have to do it the hard way, ourselves. So armed with my old harbor freight $40 DA sander and $50 worth of 40 and 80 grit sandpaper we took turns stripping the paint off the car. We are replacing the door and hood with good original paint used parts, so those wouldn't need to be stripped down to metal, but the rest of the car we are using the original panels and they all needed to go to bare metal. We could use the DA for about an hour each before our hands hurt from the vibrations of the sander. It took us about 24 hours in total to strip the paint off this way.
Here it is in mostly all metal. We had a few comments about just clearing it like this...lol.
Luckily the car if fairly straight and the only real bodywork needed is on the driver side quarter panel. We'll address that with the help of a friend that is a professional bodyman. I prefer Bryce to learn from someone that has a bit more experience than me with hammer and dolly type work bigger than dings.
So for the rest of the car we used a little filler in the small dings we couldn't get a hammer and dolly on and then sprayed all of the bare metal in heavy build primer to start blocking the car back to straight. The trunk has a few high spots from people setting stuff on it I think. You can see the outline of the trunks inner structure are were the high spots are. The inward archers towards the top and the center support are pretty easy to make out.
So for the next week or so it will be pretty boring and tedious as we block sand the body back to as straight as possible by hand. Moving from the 80 grit DA to hand blocking in stages of 150, 220, 320, 400 and then finally 600 grit. It takes a lot longer this way, but it's really the best way as you can feel what you are doing much better than with power tools.
June 28, 2013
Bryce has started a FB page: https://www.facebook.com/BrycesSummerInOregon
The vinyl guy stopped by and took sketches/templates of the GT stripes for reproduction. It was kind of cool to see how they do that. Basically they just put sticky tracing paper over the stripes and scribble over the stripes which leaves an outline of the stripes. Pretty simple really.
After that was done we got to work stripping the GT for bodywork and the new parts. Car is about 80% stripped. It's getting a different drivers door and front fenders since they were available for free (Thanks Eric V for the door and RSI for the front fenders!). We are leaving it a rolling shell just to make it easier to move around if needed during bodywork.
June 21st, 2013
So Bryce has finally arrived here in Portland and the fun begins!
As mentioned previously, my friends are letting me use some space in the back of their shop to build the GT. Upon closer inspection, it was also where they did partial tear downs and stored core motors and transmissions. It was really messy and cluttered so some clean up work was in order before we could start on the GT. I figured it would be good experience for Bryce tearing down core motors and cleaning up so we jumped in head first. I think we tore down about 10-12 motors and did a lot of cleaning and re-organizing. It took a little longer than expected to be honest, but our work space is now much cleaner and a little bigger.
With all those tear downs fresh in Bryce's mind, I had him strip down his motor to a short block and do an initial basic degreasing.
After getting the motor degreased, we sprayed the cylinders, crank and rods with WD40 and bagged it up until we can come back to it.
Next we got the GT out and gassed up the pressure washer for some fun in the sun. I sprayed the entire car down with Castrol Super Clean to help cut through the years of abuse that was growing on it. A good thorough pressure wash from head to toe to get us started.
That's all for now. Updates will come much more regular now with a lot more progress (hopefully) since we are situated and ready to start really going on the project.
June 14, 2013
Not too much going on the last couple of weeks. Just trying to get a few things in order before Bryce shows up for the summer.
I did make it to Pick N Pull during the half price weekend to get a good used 1994 b230f "squirter" block for the project though. It was from a lower mileage non-turbo 940 that was wrecked. The non-turbo motors seem to be less abused and with our modest power goals it should be plenty stout enough. While I was there I also spotted a 93 245 with a good used late model style a/c pump and power-steering pump with integrated reservoir. I bolted those onto the 94 motor and bought it as a complete motor. Since it was missing the exhaust manifold and most of the "complete motor" parts, the guy at the counter was nice enough to give me the cheaper "long block" price. So the good used core motor and the 93 245 power-steering and a/c parts cost me $140 and some change. Quite the bargain, but it was a lot of work pulling it by myself and wheeling it all up that huge hill. Luckily my friend happened to stop by right as I was about to load the motor into my car as I was wondering how I was going to get it in there by myself!
I also pressure washed the good used M47 transmission I got for it since I had the pressure washer out for something else. It came out surprisingly well for not really scrubbing on it yet. At the very least it's much cleaner to move around for now.
That's about it for now. Bryce should be here in 7-10 days and we can hopefully get started on the car!
May 30, 2013
Things are starting to get crazy. Lots of stuff going on to get ready to kick this project off. A few changes, a few items have showed up, a few items have been ordered and some used parts have been sourced.
I have asked a favor of my good friends at R-Sport International to rent/barter me a space in their large shop to have room to build the car comfortably. For those of you that don't know, I helped start RSI with a couple friends originally and though I am no longer there, I am still good friends with them. So a big thanks to Mitch, Ben and Eric for letting us do this. The car should now only need to be moved once (for paint booth) which makes things a lot easier and faster.
Next up is that the car has changed slightly. RSI has come across a solid and straight 1979 242GT with no drive-train. This is a fairly rare car and shell to start with. It's a GT first of all, but it is also a 1979 that has no spare tire wells and no sunroof. A fairly rare 240 that a lot of Volvo enthusiasts would love to have. It's still a 242 and will still have essentially the same build, but now we have a theme to build around. RSI was nice enough to sell it to us for the price they found it for and with all the goodies all ready on it, it was quit the bargain at $500. It will still be getting a mild b230 based turbo motor. These will make for some nice "before" pics when it's all done. :-)
We have decided on a paint scheme finally! It's a slight twist on the original GT colors and stripes. Still easily recognizable with the stripes, but much brighter and attention grabbing. For those in the Turbobricks community that know me, orange has always kind of been my signature color. Bryce remembers my orange and white 242 so we were leaning towards doing white and black GT stripes on an orange car. Thankfully I talked to our project leader about it and Brandon suggested using silver instead of white to have a complete flip of the original GT colors. I painted a 242 in Forza4 with the stripes to get a good idea of how it will look. Bryce and I both love it!
Wheels and tires have been ordered. We are going with staggered 17x8 and 17 ESM 004's (BBS LM replicas). Tires will be 245/40-17's all around. I have helped a friend with this exact set-up recently and on a lowered car it's a tight fit but doable. The front's will use H&R 25mm adapter style spacers (the GT already had these on it!) and the rear will be longer studs and a 10mm spacer (brand yet to be determined).
I've been in the Turbobricks community for a long time and I have made a lot of friends over the years. It is pretty neat that even though we are sometimes on separate sides of the US or world, our friendships born from our love of Volvos have become so strong. One such friend is Ben Kaplan of Kaplhenke Racing. He has generously donated one of his strut braces and rear axle spherical bearing kits to our project. Thanks Ben! We are looking forward to getting the brace powder-coated to match and installing the super slick rear axle bearing kit. :-)
I also purchased a known good used M47 5 speed transmission, crossmember and driveline for $200. Pictures of that next week. Greasy parts... Yay! lol
Looking forward to Bryce getting out of school and up to Portland so we can get started cleaning and dis-assembling. Once it's all apart and we have a good look at everything, we can make our big IPD parts order.
Thanks again IPD for making this happen for us!
-Patrick and Bryce Dickman
|"We have decided on a paint scheme finally! It's a slight twist on the original GT colors and stripes. Still easily recognizable with the stripes, but much brighter and attention grabbing."||"I painted a 242 in Forza4 with the stripes to get a good idea of how it will look. Bryce and I both love it!"|
May 3, 2013
Thank you IPD for selecting my son and I's project for your Build Off! We are very grateful and excited about this project. With your generosity we hope to make this a very special time in our lives that we can remember forever.
Bryce gets out of school for summer break and should be here in Portland by June 1st. He'll have to return to California for school around August 1st so that gives us 2 full months to get the car completed. I don't see any problems with getting that done with the help of my friends who are also all excited to help.
I'll have this month for me to track down the motor, transmission and other key parts we want to use before Bryce gets here. Some of the items I will need to source from Pick n Pull type yards I will have to do with out Bryce because he isn't old enough to enter those places yet. So my goal for this month is to locate all those parts.
We already started discussing what new parts we want to use (wheels, seats, etc.) and we are still working on finalizing a basic overall look/paint job for the project. We have a couple ideas that would be unique, but at the same time would be easily recognizable by any Volvo enthusiast.
I have received several calls, texts and posts supporting us from family, friends and the Volvo community. It's been a bit emotional the last 24hrs to see everyone wanting to help in any way they can. We feel very fortunate and lucky to have such good friends and to be part of the Volvo community.
We'll be in touch again soon!
Patrick & Bryce Dickman
Team Brandon - Patrick and Bryce Dickman
May 1, 2013 - Build Off Submission
My oldest son, Bryce, turns 16 at the end of this year so I have been planning and talking to him at length about building his first car, a Volvo 242 Turbo. The plan is to build 90-100% of it here in Portland this summer while he is out of school and stays with me. I plan on devoting essentially all of my time for that 2.5 months to showing him how to restore and fix up a 242. It will be a tough schedule to teach, learn and build, but I believe we can get it done. Worst case scenario we could finish most of it and tie up all the loose ends as he visits other times during the year. The majority of the project will be done from June 1st to August 10th. I want him present and to do as much of the work as possible. This I will not compromise on. I will not build it for him. I believe hands on learning is the best way to teach and it will make him respect and take care of the car if HE built it. It will be a great bonding experience for father/son and I can pass on my knowledge and love of building cars to my son. This is not a forced thing, he loves cars and is really excited about it as well.
I have located a good base 242 Turbo to start the project. It needs basically everything, but the body is solid and straight.
First order of business will be to strip it and prepare it for paint. Remnants of the interior will be removed and any possible rust areas will be treated. The current drivetrain and suspension will be removed and most parts/bolts will be sent to the powder-coater/plater as needed. He also wants to swap to the 86+ front fenders, 86+ core suport and a flathood so that will be changed as well. Body will be sanded and prepped for paint. Me and a professional painter friend will then show him how to lay paint at my friends shop. He is undecided on color but likes Laguna Seca Blue and a few copper/bronze metallics. With the body mostly stripped and in new shiny paint we can give it a fresh coat of undercoating.
With the basic shell done we can begin re-installing the suspension with new wear parts and upgraded performance suspension parts from IPD. Brake system will be checked and items replaced as necessary. That will make it a roller and we can then multi-task on body trim re-assembly and a motor.
Motor will be a good used B230FT that we reseal and make look pretty. Maybe the following summer we can build a hot rod long block and slip it in, but for now a good B230FT is more than enough for a 16 year old. Transmission will be a simple m47 5 speed. It will be 2.2 or 2.4 LH for a cleaner looking engine bay, reliability and maintenance. Most likely a slightly upgraded turbo, intercooler. and a full 3" exhaust. Power goal will be 200-250rwhp range.
There car will be lowered on either coil-overs that we make ourselves or if time/money is an issue we will use IPD Sport springs. Bilstein HD's at all four corners. IPD sway bars and chassis braces. Wheels are leaning towards BBS LM replicas in 17x8 with 245's all around.
Interior will be a nice simple mostly stock interior with some Sparco front seats and a nice but modest stereo system. I'm really good at restoring original interiors so I'd like to pass on to my son how to clean and make everything look close to new again. The seats and stereo will make it more "fun" for a 16 year old.
I have most of the parts of the build broken down and itemized.
- $300 base car
- $220 Hood/fenders/core-support (from PnP)
- $100 Plastic bumpers (from PnP)
- $4-500 for paint and paint supplies
- $250 for a good used b230ft (from PnP)
- $160 for a good used m47 (from PnP)
- $300 performance clutch kit
- $90 G80 LSD (from PnP)
- $170 for new flush windshield
- $140 New headlights (ebay)
- $70 new turn lamps (ebay)
- $105 new taillights
- $400 245/40-17's
- $700 17x8 ESM LM replicas
- $400 CD Player with ipod/blue-tooth, 4" door speakers, 6 rear shelf speakers, 12" sub and an amp (crutchfield)
- $300 exhaust materials for building 3" exhaust
I priced out all of the parts on your website like poly bushings, ball joints, tie-rods, strut mounts, brake rotors/pads, engine gaskets/parts, bilstein hd's, sway bars, springs, panhard bar, torque rods and chassis braces and it came out to $2700 and change. That would cover all of the needed mechanical wear items and include several upgrades like the sways and like.
So build estimate is $6900. I always add about 10% for items that are unforeseen or stuff that you simply forget.
So final total to build will be approximately $7500.
I think it could make for a good story that your customers would enjoy reading about. A good old fashioned father and son project that also shows and passes on the fathers passion for fixing up cars. It will also be a good source of information on how to tackle a fairly nice driver restoration on a Volvo 240. Maybe a little over the top for some, but parts of the info can be used for anybody fixing up or restoring their 240 no matter the level of depth or quality.
Though most of the knowledge and skill set to build a Volvo 240 like this is my own, it will require the help of several of my friends and family. I have talked to them for the past week to confirm with them that they are all willing to help in my small window of time and they have all agreed and are looking forward to it!
If we are accepted your $5000 donation to the project will be greatly appreciated and make the project much nicer than I could afford on my own. We look forward to working with you to make this something really special for all parties involved and anybody that follows along.
Patrick and Bryce Dickman
Picture of the basic idea and look my son wants (from a car I built for someone else a couple years ago)
|Donor car for my son's build||"It needs basically everything, but the body is solid and straight."|
|"Motor will be a good used B230FT that we reseal and make look pretty."||"Interior will be a nice simple mostly stock interior with some Sparco front seats and a nice but modest stereo system."|
Friday, May 17, 2013 - ARTEM LOJKIN
Hi,try to find m46 or m90 gearbox. m47 will not hold the power of b230ft.
Saturday, June 01, 2013 - DAVID BELLO
On my b230ft swapped 242 I kept the m45. The clutch is my only problem now :) but i have heard about the m47 chewing up gears. Maybe team leader has heard about that too. But i am so happy you found a GT! And having Kaplhenke and RSI support shows the "volvo for life" community. Cheers
Sunday, June 02, 2013 - CARTER BOURGONJE
Wow, I really like where this is headed!
Monday, June 03, 2013 - ANONYMOUS
Thanks for the update Pat! The Forza4 renderings look awesome!
Friday, June 21, 2013 - MICHAEL HOWELLS
M47 will hold the power fine.
Wednesday, July 24, 2013 - ESTEBAN CURIEL
nice i cant wailt to see it finish!!! (Y)
Thursday, July 25, 2013 - RAYMOND HATTON
Absolutely Outstanding !!
Friday, July 26, 2013 - ROBERT S LORD
Hi Patrick! A really impressive project. Missed you at Davis this year and I now see why. The B23ft engine is now in my 245 wagon and all set up for the track.