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Hacked III: Third Time's The Charm (M90 940 Edition) (prev. Hacked II)

So when is the thread going up for Hacked III, the Search for Hacked IV?
Well, I'm going to have to get the thread title changed whenever I get around to taking some daylight photos of the car.

I was thinking that Hacked IV was going to be a nice, clean wagon to swap the M90 into, but I don't think I'll be able to find or afford a good 7/9 series wagon for a while.

That, and the PO of the 940 informed me that he would probably beat me to death if I parted out the car that had been in his family for 20 years, that he was reluctant to sell in the first place.
 
Well, I'm going to have to get the thread title changed whenever I get around to taking some daylight photos of the car.

I was thinking that Hacked IV was going to be a nice, clean wagon to swap the M90 into, but I don't think I'll be able to find or afford a good 7/9 series wagon for a while.

That, and the PO of the 940 informed me that he would probably beat me to death if I parted out the car that had been in his family for 20 years, that he was reluctant to sell in the first place.
Stakes are high for this one!

Honestly, 940 sedans are really nice. Drive it before dreaming of a replacement wagon.
 
Hacked III

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Okay, well here it is. My first redblock car.

I ended up scoping out this one very locally... I had been driving all the way out to Scarborough (the horror) to look at several cars, and was about to give up when I came across this one. A red '91 940 Turbo that the P.O has M90 swapped some time ago. Found it in Etobicoke, a mere fifteen minute drive away. I'm not going to say how much I bought it for... but it's a lot by my standards. That just seems to be 2023 Volvo pricing. After I committed to buy, I spotted a similar 940 turbo wagon for sale in Quebec for about $10,000, and I felt a little better about how much I spent.

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Will this one run and/or drive???
Drive it before dreaming of a replacement wagon.

Well, for starters, it runs and drives. The seller ended up driving it to me on Friday evening.

To be completely honest, my knee-jerk reaction after having driven it in "normal" conditions (ie; in a school zone with a 40 km/h limit and in stop and go traffic), I feel like I should have just spent less and gotten an AW71 car. I was spoiled by how relatively easy the D24 was to drive, before I took it apart and never got to drive it again.

I probably just need to get used to it again. Re-learning how to drive stick after dailying an automatic commuter car for several years is going to be something of a process. Especially given the fact that the 940 has an 850-R clutch and some kind of lightened flywheel, nevermind the fact that it has one-and-a-half times the horsepower that diesel wagon had.

There is a genuine temptation to put the AW71 back in it, but that would defeat the whole purpose of the car, wouldn't it?

Good to see you're not giving up. What's wrong with this one?

Surprisingly, no looming mechanical or bodywork nightmare this time, but it wouldn't be Hacked™ if there weren't a laundry list of things the car is going to need. Fortunately, I don't think it's going to need too much for safety. From what I can tell, it'll definitely need a new windshield (the one on the car is cracked in several places), and some fudgery with the gauge cluster. It's also got an SRS light on, which is due to something screwed up with the clockspring. The PO suggested to just break/pull the SRS bulb.

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Apart from that, it's mostly cosmetic? The paint is faded to hell, and worn through in some places. I'm tempted to buff whatever paint if left, then spray black over the hood, roof, trunk lid and fender tops to cover all the parts where the red is missing, but that might just look stupid. I was thinking Lancia Fulvia vibes.

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One thing for sure that's going to need addressed ASAP is the exhaust... the PO's story is that the original piece rotted out and he replaced it with Canadian tire scraps and offcuts to make...

...the SideSquiggle™

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It's loud, but not as obnoxious as I thought it would be. Still way too loud to sneak around my neighborhood trying to re-learn stick on an unplated and uninsured car. Probably will look into installing a stock used 940 turbo system (from the cat back, as it retains the factory converter and downpipe), or going for some kind of stainless aftermarket cat-back.

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There's some stuff going on in the interior. Surprisingly most of the electrics work, even the sunroof! The big annoyances here are the aforementioned SRS light and cluster issue. I haven't taken it apart yet to inspect it, but the cluster just randomly stops working sometimes, and you have to smack the dash to make it work again. Could need new caps, could just be a dirty ribbon connector, who knows. Definitely will need to fix that for inspection.

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You might notice the extremely rare factory dealer option NOS beer can boost gauge.... yeah, it's just some thing the PO whipped up. Fortunately, that hole isn't just cut in the dash, it's from where the factory tweeter would have gone, so it's reversible.

Normally for Hacked™, I'm looking for some kind of big mechanical triumph... making a field car run and drive, a big engine swap, something like that.

(note: has never happened successfully, unless you count me spending 8 months to do a belt job on a D24)

This time, I don't really know if I have any crazy long-term plans for the car, if I keep it manual. My criteria for a project Volvo was that it needed to have/be one of the following;

-Manual
-Turbo
-'90+ with 13mm rod B230
-LH 2.4

And this car is all of those things. Plus it has Hydras. How could I not buy?

The PO also has a couple 16v heads, which would be really cool, but I'm fairly confident a B230ft +16v build would never work out, given my limited space and time. This could be a case of 'just drive it', and/or some minor stuff a la redblockpowered stage 2 turbo tune, with a better intercooler, exhaust and cam.

We'll see.

Oh, did I mention it's yet another A/C delete car?? Some of the factory lines and most of the ducting is still there, and the PO included the old compressor, so maybe that could be a neat long-term project?
 
I will happily take the M90 off your hands, that way it won't end up cluttering up your garage. Give you more room to work. ;)
If I had a lift, space and some help, I would seriously consider just putting the automatic back in. Something is wrong with me.

At least then I'd be able to fix the leaky rear main seal...
 
You might notice the extremely rare factory dealer option NOS beer can boost gauge.... yeah, it's just some thing the PO whipped up. Fortunately, that hole isn't just cut in the dash, it's from where the factory tweeter would have gone, so it's reversible.
You don't need a real boost gauge anyway. Check the beer can against the cluster gauge, then delete the beer can. On my cluster, the end of the white boost bar is about 16psi. 3 o'clock, past the entire Turbo print, is 21 psi(ish)

See my build thread for everything you should do to your 940 :oogle:
 
You don't need a real boost gauge anyway. Check the beer can against the cluster gauge, then delete the beer can. On my cluster, the end of the white boost bar is about 16psi. 3 o'clock, past the entire Turbo print, is 21 psi(ish)

See my build thread for everything you should do to your 940 :oogle:
Seconded. Don't look at my build thread though. That's classified
 
You don't need a real boost gauge anyway. Check the beer can against the cluster gauge, then delete the beer can. On my cluster, the end of the white boost bar is about 16psi. 3 o'clock, past the entire Turbo print, is 21 psi(ish)

Yeah, it's a pretty big eyesore to me, and I plan on getting rid of it. The car currently has a manual boost controller set to ~12 psi, and I'm probably going to delete it for the time being and return it to stock-ish boost, while I re-learn to drive stick (my hope is that dealing with ~165 horsepower is slightly easier than in the neighborhood of 200).

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I'm also getting rid of this godawful cone filter, and putting the factory airbox back in.

I'm also a little scared of the fan situation, it's got some kind of electric one with no controller, apparently there's just a switch somewhere to turn it on, and I don't know which one it is...

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I've also been warned that the wiring (not including a fuse) might start a fire, so that's fun and cool and good.

See my build thread for everything you should do to your 940 :oogle:

I'm sorry, did I miss the part where you cut up a 940 sedan and converted it to a wagon??

It's kinda fun to be a part of the 940 club, even if I have no goddamn idea what I'm doing or looking at half the time. It took me a while to figure out that there isn't a white plunger hood release mechanism like on a 240, it's actually just a better-hidden lever.

Seconded. Don't look at my build thread though. That's classified

My car is literally the same specs as yours, just 100% more sketchy and hacked up. I got the heckeblende thing to flex on you though.

I dunno. This week I have to get it registered, for which you need an appraisal if the car is over 20 years old in Ontario.

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Ideal.
 
never thought I'd live to see this day but it is truly a glorious day ´༎ຶ ͜ʖ ༎ຶ `
 
Can I just point out that learning to drive a manual transmission is way easier than swapping an auto back into this car successfully? That said if you make the mistake of removing it from your car I will definitely drive up to Toronto and buy it off you. I'd even bring an AW71. I'll throw in a BW35 for free since you like autos so much.

That fan is very confusing to me... 900 chassis e-fans aren't hard to come by and fit the space. I wonder what the previous owner was thinking?
 
Can I just point out that learning to drive a manual transmission is way easier than swapping an auto back into this car successfully? That said if you make the mistake of removing it from your car I will definitely drive up to Toronto and buy it off you. I'd even bring an AW71.

Do you mind swapping it for me in my driveway while I watch? :lol:

That fan is very confusing to me... 900 chassis e-fans aren't hard to come by and fit the space. I wonder what the previous owner was thinking?

Based on what's going on with the rest of the car, I'd imagine it was the cheapest and closest to the door at the JY. I did figure out that it's connected to the power antenna switch.
 
Glad to hear the diesel ended up running as it should. Your efforts on that came to a good ending.

Nice 940! You will discover after putting on a few miles that 7/9s are the way to go. 240s are lame by comparison! A 940 has all of the good of a 240 but none of the bad.

That red paint should respond well to a good cut and buff. :-)
 
Glad to hear the diesel ended up running as it should. Your efforts on that came to a good ending.

Nice 940! You will discover after putting on a few miles that 7/9s are the way to go. 240s are lame by comparison! A 940 has all of the good of a 240 but none of the bad.

That red paint should respond well to a good cut and buff. :-)
Thanks. I'm planning on paying the new owner of the 245 a visit in a month or two, whenever I get the 940 to a point where I can drive it on the street, ostensibly for a photo op :lol:

Supposedly he's fixed basically everything wrong with that car, he replaced most of the wiring harness, did a lot of suspension work and replaced the steering rack. I really want to drive it again.

You should 100% keep this car as a m90, you really won't have a better setup than that IMO for casual and fun driving.

Yeah, I've talked myself into it. Being under 25, I'm only going to be able to afford to insure it as a seasonal/occasional car, and it's really not daily material anyways.

I got the car registered and the ownership properly transferred yesterday after work... next steps are fixing the gauge cluster issue, insuring it, a trip to a windshield place and then pray it will pass inspection.

Then I can get plates and drive it around. Speaking of which, I need to get a new set of plate holders... the studs all broke off when the PO removed his license plates.

**Minor update not requiring a thread bump (9/12/23);

The fan is attached to a 25a fuse!
I don't see a reason to replace it right away, since this was originally a mech fan car, and doesn't have a lot of the wiring to make an OEM 940 E-fan work. This one is sketchy but at least functional. I just didn't want it to burn the car down.

It's probably going to be a bit before I get back to the car, I crunched some numbers with upcoming expenses, and I don't really have a lot of money to throw around for a little while... the car will probably be sitting for at least a month before I can afford to get back to it. Between this car and insurance payments on the Focus (my piece of shit daily), it didn't occur to me that I had spent probably half of my total earnings from the last six months. Ouch.

The car has a leak from the rear main seal, something the PO made me aware of prior to purchasing. It's not profuse, but it drips from time to time. Depending on when I get back to it, I'll have to remember to change the oil, or at least top it up. I still have a giant stash of Mann filters for a redblock, a bulk order which I made around the time I had the 144, for some reason.

I did pull the gauge cluster on the weekend, my plan is to shotgun all the caps (replacing them with properly heat-specced ones, but that involves making an annoying Mouser order), clean up the connectors and reflow some of the solder joints (I can see a few cold ones on the board). Those are the only surefire things that I'm aware of and can cause some of the cluster issues that might fail an inspection.

Unless I can somehow find a very cheap policy to put it down as a daily, I forsee this thing being insured as a seasonal or occasional driver. Realistically, I probably only want to be driving this thing on roadtrips to Guelph on the weekends, on fun, moderately fast and slightly twisty country roads. A lot more appealing than bumper-to-bumper city driving if I had to daily it. Either way I can't afford to insure two cars for ~$14,000/year on my current policy.
 
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