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The Frankenwagon (`87 240 Wagon / `72 142 Mashup)

TouzinFish

Active member
Joined
Mar 12, 2017
Location
Boise, Idaho
In a continued effort to purge phone/desktop storage, I've been uploading the majority of my Volvo photos to Imgur/Flickr, in which case I might as well share them here.

Welcome to the Awful Frankenwagon thread!
Here, you'll learn how ***NOT*** to combine a 140 with a 240.


This was my first car, and the car I learned to work on. The beginning of my long road of owning 40+ Volvos.

2016-2017: The Early Years (Car was nicknamed "Moby")

Sold in 2017; bought back in 2020.

2020-2024:
The Later Years, Creation of the Frankenwagon (You can jump down to Post #9 if that's where you wanna be)
 
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August 2016 - Acquiring my first 240, nicknamed "Moby"

I've always liked cars, ever since I was a toddler. But for whatever reason (seriously, I have no idea why), I began liking Volvos in middle school. I didn't know anyone with a Volvo, nobody in my family was a car enthusiast, and local car communities leaned toward muscle cars and trucks (rural Idaho in the middle of potato fields, what do you expect).

Realizing how different Volvo was from American manufacturers, I was intrigued to start exploring their lineups over the years, and absorbed the information like a sponge. Eventually, I settled on wanting a Volvo 240 wagon.

Here's the crazy part: I was fourteen years old, and I'd never seen a Volvo 240 in-person. So, to me, it wasn't a dime-a-dozen sort of car; it was more like a total unicorn.

Not long after, we moved to Boise, where I started saving up my allowances to buy a Volvo 240. I did not have my drivers license (or even a permit), any tools, any car knowledge, or anything else useful, but I was completely determined to own one.

Finally, when I was fifteen years old, one came up for sale that was remotely in my price range: A white 1987 Volvo 240 wagon. The seller said it needed a lot of work and was being sold as scrap. Nonetheless, it had a clean title and was $300. Making the argument to my parents to drive me 3+ hours for a $300 parts car was tough, but they eventually caved and took me up there.

Being Idaho, the car was on a mule farm, surrounded by potato and corn fields outside of a small town called Council. Driving up the dirt road to the seller's house, I distinctly remember the excitement I had from seeing a 240 for the first time ever. And as a then-freshman in high school, this had been my halo car for nearly two years, so yes, it was a pretty big deal.

The inside of the car smelled a little weird and had stains. Turns out this car frequently hauled fresh-born mules around the farm, and then was a dog hauler with the occasional bale of hay. Otherwise, the car was mostly intact and did drive on its own. Although I didn't know anything about cars, a quick Google search recommended I have extra oil, antifreeze, duct tape, and zip ties. I gave the seller my $300 and off we went. The first stop was the gas station, where I had this photo taken of me:

Since I was too young for driver's ed, my Dad drove the car and I rode in the passenger seat. For the first hour toward home, I was probably the happiest kid in the world... a memory I'll have for the rest of my life. Why did that feeling only last for one hour of a three-hour drive? Because we broke down, that's why. The upper radiator hose had popped, spewing coolant all over the engine bay. Thanks to Google keeping me prepared, I duct taped the hose, refilled the coolant, and off we went... for another hour. Turns out, when you know nothing about cars, you don't know to notice when the car has no alternator. Remember when I said this was being sold as a parts/scrap car? Yeah, the alternator had already been scavenged by someone else. Hats off to the Napa battery surviving two hours (and however long it was sitting in the car before). We were able to pull off into a parking lot, but the discouragement really began to settle in. I had my dream car, but it couldn't even survive the drive home.

To expand on the whole I-didn't-know-anything-about-cars thing, I suggested we pull the 240 home with a tow strap. BUT, I didn't know that tow points were a legitimate thing, and proceeded to accidentally yank off the whole front radiator support from the 240 by tying the tow rope to an incorrect mounting point. So there I was, still over an hour away from home, with a broken-down Volvo 240 with a ripped-off front end.

The next day, I called the business owner of the parking lot where I'd broken down and explained the situation. The following weekend, the car was fetched with a truck and trailer to be brought home.

Since the Volvo was broken in the garage, it forced me to learn a thing or two. I purchased a couple of repair manuals, hit YouTube University, and began learning everything I could about getting the 240 back on the road. I was able to go to local junkyards that had 240's to grab parts and slowly began correcting my mistakes and replacing the missing parts from the seller. It took a while to find headlights and a grille, so I was stuck with duct taped headlights and no grille for a few months. Nevertheless, I got my driver license and began driving the car. As items broke, I hit the books to learn how to fix them. That's how I lived life in 2016 and 2017. Since the car was a big white whale, it was nicknamed "Moby." Here are some pictures I compiled along the way:

 
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June 2017 - Gradual Repairs

Mechanically, I replaced the brake pads, coolant hoses, radiator, water pump, thermostat, alternator, battery, belts, and valve cover gasket.

Cosmetically, I lived with duct taped, nasty headlights and no grille from August 2016 through June 2017. Finally got a decent set of lamp buckets from the junkyard, along with a grille.


When I replaced the valve cover and oil cap gaskets, I painted the valve cover.

Single-stage white turned out great with clay and polish.
 
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July 2017 - The End of the Early Years

August 2016 through July 2017 was a huuuuuuuge learning experience for me. I learned how to wrench on cars, made plenty of Volvo friends, joined Turbobricks, and was taught useful skills by Dennis (local retired Volvo tech who worked in Sweden building 240's in 1980), who's now a great friend and resource, and overall learned how to become a DIY car enthusiast. With time, my 240 was looking more and more presentable.

However, this 240 was really showing its age, and when my parents announced we were moving back to Idaho City (one of my childhood towns of 400 people), they gave me the option to continue driving to school in Boise for better academics. With how worn out the `87 was, I worried about it handling the 2+ hours of daily school commuting. So, I casually started browsing for a replacement 240. First, I looked at this `86 that Dennis was patching up as a beater (it later returned to Dennis as a parts car, who sold it to me in 2020).

I then stumbled onto a blue 1990 wagon. I was driving on a road and glanced over to see a house with its garage door open, and the blue wagon was sitting in the garage. I stopped and chatted with the guy, who turned out to be a friendly coffee roaster who, funny enough, bought the car from Dennis after he'd rebuild the engine a couple years prior. Mechanically, the car was in great shape aside from the AC, and the best part: he was open to selling.

Having a nicer 240 on the hook, I listed the `87 and sold it to a local coffee roaster named Django. You read that right, I sold a 240 to a coffee roaster just to buy a 240 from a different coffee roaster. I guess coffee roasters like 240's?

Here's the `87 nose-to-nose with the newly acquired `90.
 
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November 2019 through January 2020 - Beginning of the Later Years

In November 2019, Django reached out and told me he "intended to sell Suzie Bishop" (his nickname for the car). Now by that time, I'd moved on and owned over a dozen Volvos, but I couldn't help but be struck with heavy nostalgia for that particular Volvo - after all, it was my first car. Plus, he'd put his fair share of work into it, and the car was even a movie star; I'll have to go find the movie title, but it was driven by the main character. Naturally, my fund for car shenanigans was precisely zero when Django reached out due to school bills and life, but I was able to get a second job to buy the car back. Working a couple hours every night as a janitor at a hotel, I was able to buy back the car on January 31st, 2020.

I tried recreating the photo from when I first bought the car in 2016:
 
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In retrospect, I shouldn't have bought the car back. A couple of the mistakes I made:

Mistake #1: I was remembering the car for all the positive memories, discarding that it was still a POS.
Mistake #2: I overpaid by a LOT.
Mistake #3: I bought it back, sight-unseen.

Here's why Mistake #3 was a big deal: He'd filled all the car's drainage channels with spray foam, including the rocker channels and cowl drains. I'm unsure why he did it, but the car was rusting out VERY fast as a result. I was able to drill a couple holes through the foam to let the standing water drain, but I realized the clock had started before the car was too rusty to drive.

So, over the next month, I took the car on a few trips to enjoy it the best I could.

But then Covid hit, and my classes were all either canceled or moved online, I was laid off when the hotel shut down, and quarantine began. Naturally, I began using this time to start hunting for another Volvo project. I'd decided on a Volvo 145, but there weren't any for-sale within a 300-mile radius of me. But then, one day, a good local friend and Volvo genius decided to sell the front clip from his 1972 Volvo 142R (1972 Volvo 142 on the chassis of a 1999 Volvo V70R with a V8 from an XC90) - some of you may recognize it from Instagram or prior IPD shows.
 
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Anyway, I bought the parts and planned to either put them on the garage wall or store them for a future 145 project, but an idea hit me: Since my car was rotting out at an alarming rate, why not let it go out with a bang? Since a 140 and 240 are similar from the A-Pillar back (besides the bumper, taillights, trim, and side mirrors), I could simply make my 240 wagon look like a 145. Sounded easy in my head.
 
February 22, 2020 - The Frankenwagon is Born

So, I decided to somehow hodge-podge something together. On the plus side, all the 140 panels from the 142R were already cut or manipulated, so no harm in modifying them further.

The same night, I started tearing apart the wagon. Between the rust and my yank-off-the-front-of-the-car incident from 2016, most bolts were a fight. With a hefty can of PB Blaster and some patience, the whole front end came apart within a couple hours.

I knew the front end of a 140 was shorter than a 240, but I didn't realize the front end of a 140 is actually a LOT shorter than a 240.
The overall length of a 145 is 182.7" (I know that can vary a couple inches depending on the bumper style).
The overall length of a 245 is 189.9" (again, can vary depending on the year for the bumper style).
Check out how far the inner fender walls poked out from the front of the 140 panels:

Considering the car's AC didn't work, I removed the condenser and trimmed the inner fender walls (and engine bay tub? I don't know what to call it) far enough back to let the 142's panels rest on the car. On the 142R, the wheel arches were heavily cut to fit the big wheels and fender flares, so they looked a little goofy with my stock springs and 14" wheels. An additional hiccup was that the front of a 240 is taller than a 140, so the body lines didn't line up as well as I'd hoped. In short, the car looked awful. Terrible, terrible, TERRIBLE initial fitment done:
 
February 23 - April 1st

Not long after I began the creation of the Frankenwagon, a local 240 owner called me to request some work to be done to their car after they'd rear-ended someone. I was able to use the Frankenwagon's original parts to piece his car back together.

Unfortunately, as I was wrapping up the last few details, he hopped in his car and drove off without paying me. Lame.

Anyway, I was pretty upset with myself for my terrible Frankenwagon creation, so it was stored for a while next to the Ranger project and became a low priority.

Finally, in the beginning of April, I had a free weekend decided to tackle it again.

I worked on trimming the metal a little more, and while the 142 panels weren't lined up well, they were sitting very snug and comfy.

The front shroud was cut and narrowed by the previous guy, so I had a nasty gap on either side, between the shroud and the fenders. I used sheet metal screws to hold everything together until a welder friend could swing by.
 
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