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Old 06-01-2021, 11:26 PM   #1
76RA24
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Default 1990 245 (millennial falcon)

I have been polluting the VanCity volvos thread with my updates... figured i should just do a thread.


brief history.
bought wagon in 2015 for 600$ approx. 390,000kms
day1 with dads 740


some issues.. bad alternator, no valve cover gasket, exhaust leaks, no guibo joint

leaky fuel pump


Guibo whats that




good points were it was manual rwd wagon.


swapped alternator at farm proceeded to drive 30kms home with no guibo and virtually no valve cover gasket... smokey.

ordered parts from ipd some were bought local.

got the car on the road proper in a couple weeks..

lots of road trips for work ... lots of miles put on had to install some Moog overoad springs


installed Mazda 3 seats at some point



popped a head gasket on my bday one year downtown Van that was fun towed back to mission for dirty replacemnet

re-did headgasket couple months later proper.

at some point I put in a G80, met a Levion at the auto recyclers..



many suspension bushings... some failed new ones. dont buy cheap.

did bilsteins HD, new brakes
need new strut casings mine were 90 with the welded spacer

new ones were still crusty

My old springs were done... the other struts came with better springs.


but got it all cleaned up.


pretty much brings me to now when i had a week off to look for a water leak and ended up cutting rust.

that was 4 months ago...

still finding more.

here is rust repair gallery.

https://imgur.com/a/Zqiu9gK

Last edited by 76RA24; 06-02-2021 at 10:49 AM..
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Old 06-02-2021, 09:29 AM   #2
Scaramanga
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Impressive work with the rust repairs! Well done!
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Old 06-02-2021, 10:11 AM   #3
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IMGUR blocked at work but props on the name
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Old 06-02-2021, 10:22 AM   #4
76RA24
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How the hell does Rust start here....


seems to never stop... photo dates accroding to phone say i started this about 4months ago.
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Old 08-20-2021, 11:49 AM   #5
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progress has been slow.

I dont like working in the heat. give me the single digits temps again.

rear inner using the weldthru copper stuff... I dont like it as much as the weld thru zinc. but the zinc was sold out at local shop.




dressed down and sealed.


working on the replacement buttcheek


might be the last hole on the inside of the car.



still not sure how I want to address that hole in rear upper crossmember.

I feel like dropping the tank and lowering the axle will be my best method to reach... but getting really tired of not having the volvo on the road.
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Old 08-22-2021, 12:04 PM   #6
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What year Mazda seats? Easy swap or wielding required?
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Old 08-22-2021, 01:31 PM   #7
76RA24
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2004-2005-ish seats.

will take some pics of the base since the seats are out.... dont recall any welding.

I did have to drill out some big rivets to remove the mazda sliders and removed the side airbags...
filled the void with some EVA foam

I am using the original Volvo sliders.
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Old 08-23-2021, 01:20 PM   #8
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Mazda seats...

made flat steel plate adapters..




weld one rust hole...

two more appear.


fun times....
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Old 08-23-2021, 01:56 PM   #9
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Great work, and "millennial falcon" is just an awesome name.
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Old 08-24-2021, 11:22 AM   #10
76RA24
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tackled the cross member rust hole...





also where the hell does the water get to this part to rust it out?
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Old 09-03-2021, 01:02 AM   #11
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Well interior floors done.







Rear butt cheek replacement.



Fun is coming to an end.
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Old 09-09-2021, 11:33 PM   #12
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Went slow

Ran out of welding gas again.





Now to deal with some other crusty bits.

All “seems” like surface rust.

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Old 11-12-2021, 03:43 PM   #13
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got the rear belly pan rust stripped and converted...

went on the front fender and bent lower grill valance...



was not impressed that it was bolted and spot welded..




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Old 12-22-2021, 03:14 PM   #14
76RA24
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painted pretty.

thinned tremclad with acetone and sprayed.





Local parts shop mixed some rattle can silver using the gas door a color match.
still need to put some clear over it... though.


coming along...

got some parts ordered that will be stuck in the US as border crossings became a testing issue...
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Old 01-12-2022, 02:06 PM   #15
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still trying to get some parts across the border...

applying some sound mat.





slow progress but progress.
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Old 01-14-2022, 02:36 AM   #16
76RA24
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AC mostly removed




Heater control valve swapped.


Will clean and lube the heater fan since dash is apart

Last edited by 76RA24; 01-14-2022 at 02:41 AM..
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Old 01-20-2022, 10:20 PM   #17
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finished the AC removal.


put some clear on the passenger fender... should be ready to bolt back on this weekend.
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Old 02-15-2022, 10:24 PM   #18
76RA24
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reassembly.

front bumper bit tweaked.





Dont remember if this came from the volvo or not?
any one have ideas?

looks to be a dead pedal... maybe from the wifes mk4 VW



Interior has sound mat installed..


one layer roofing stuff another layer of vinyl flooring insulation I had from a reno.


Power washed carpets... washed the mazda 3 seats, new seat heaters.... so close.
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Old 02-17-2022, 03:00 PM   #19
76RA24
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printed up a template to drill holes for power mirrors.


also printed some heated seat blanks for the aftermarket heated seats. will probably paint black when ready to install
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Old 02-17-2022, 07:55 PM   #20
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Good job on the rust repair!

Get some 3m cavity wax and the wand kit and blast it everywhere you can, especially where you welded, and it should last a long time
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Old 02-18-2022, 03:07 AM   #21
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Well done! Keep it up
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Old 02-18-2022, 06:23 PM   #22
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I love how thoroughly your going through this one! Keep up the good work. Good save.
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Old 03-01-2022, 12:03 PM   #23
76RA24
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think your done with the welder.... nope.
Left.

Right




3D printed the front speaker housings for 5.25" speakers.


didnt have any heavy poly for the water sheilds things on the doors so used more foam stuff.



and brace all the old speaker holes with more 3d print
should have printed a bit thinner but ohwell...


fronts got some aluminum braces



Might have to look for door cards in the future.

Last edited by 76RA24; 03-01-2022 at 12:10 PM..
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Old 03-07-2022, 02:15 AM   #24
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Quote:
Originally Posted by 76RA24 View Post

Dont remember if this came from the volvo or not?
any one have ideas?

looks to be a dead pedal... maybe from the wifes mk4 VW


Goes left of the clutch pedal, covers up all the wires that run down the firewall under the A pillar.
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Old 03-07-2022, 11:50 AM   #25
76RA24
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Goes left of the clutch pedal, covers up all the wires that run down the firewall under the A pillar.
Just got it fitted last night!

carpets and adash are back in ... progress.

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