Hi
Sorry for the lack of updates recently. Mat and I went to stay with friends in Spain for a week, but before and since then I have been busy on the car.
The custom interior project is coming on well now. I have been working on the front door trims.
In preparation for the conversion to 140 door trims, I had to move the electric window switches and design a new front speaker installation.
Rewiring the electric windows to move the switches to the centre console
I fitted old-type 200 electric window switches. Eventually, I will change all switches to the old type, then they will match better.
Front speakersI wanted fairly good front speakers, but I was reluctant to cut the 140 front door cards unless I had to. With some careful measurements, I worked out that Kenwood component speaker woofers could be fitted in the kick panel, where some 240s have a air vent. This leads into a box section through which water from the scuttle vent will drain, so obviously I need to keep the install water-proof.
I made holders for the speakers from plastic tubs, sealed and insulated on the outside with waterproof dynamat sound deadening, which will also help baffle the speaker.
It was difficult to cut a circular hole here, with limited access from the footwell. As you can see, I failed to do it neatly!
Test fitting the box to mark where the interior trim needs to be cut
I wired in the left cross-over unit behind the glovebox
On the right, I made a bracket from the dashboard fixing screws. The crossover, with its cover fitted, is at the top of the picture. Also shows the speaker aperture and mounting ring bonded into place.
The woofers fitted. (The tweeters will mount in the door cards)
Door cardsI covered the rear door card fitment in an earlier update.
The fronts were more work because the 140 had a separate quarter window, so the door card was the wrong shape for the 240 door at the front. To deal with this, I joined the top piece of the 240 card onto the 140 one.
Removing top of 140 card; cutting the vinyl and padding
The top metal part was held to the door card with staples which I removed
Removing the equivalent section from the 240 door card, to re-use. I bonded this to the 140 card, taking care the check it was aligned properly
Once the backing was firmly bonded and set, I dealt with the upholstery. Here I am making the neat final cut to the 240 vinyl. It is difficult to get a perfectly straight cut on vinyl because it stretches. I used non-stretchy tape to secure my straight edge onto the vinyl, then cut through tape and vinyl together
I bonded the overlap between 140 and 240 vinyl, and used masking tap to hold it until set
One of the 140 door cards was badly warped due to water damage. I removed the door pocket to deal with this
I soaked resin into the warped area, then weighted it on a flat surface whilst the resin set
The pocket backing was also done with resin, but clamped in the vice
I decided to use the redundant holes for the 140s manual window winders to mount my tweeters. The hole needed to be enlarged slightly
Once all door cards were assembled, I sprayed them with Gliptone leather paint, which is also suitable for vinyl
The 240 door needed extra holes drilling for the 140 clips, but luckily the Volvo pressing still has the drilling marks, so this was easy
Repairing and painting the 140 armrest upper mountings
Adapting the membrane
Door cards fitted. I'm pleased with the outcome - it has the retro-sporty look I wanted
WheelsI saved up for some decent tyres, so now I have the 17 inch Polaris wheels fitted. I'm just working out how to smarten up the centre caps
Well, that brings me up to date. More soon!
Cheers
John
