JJs Project Thread - 240 GL Estate

[Problemchild1976]

The other job I’ve done was to replace the outer window scrapes / seals



As you can see they were pretty bad and very brittle

Got a replacement new set from here

https://www.partsforvolvosonline.com...oducts_id=9939


To remove the old one it’s a bit more complicated than a modern car

The scrape is 2 parts - a metal channel and the seal itself.

The parts are just the seal

You need to remove the whole piece to replace

First you need to release the metal clip at the door handle end



Then you need to leverage off the whole piece

The set comes with a plastic trim removal tool and this is used to leverage off from the clip end and working along until it comes off





Once off you can see it’s made of 2 parts - the seal and the metal piece that clamps onto the door skin and has the channel for the seal to slide into.

The old seal is clamped in place by these dimpled sections so need to prise this apart to be able to slide the seal out






To replace the seal, I used silicon lube in the metal channel and some on the seal to enable it to slide in nicely

Once it’s in, cut to length



Then replace the whole unit back onto the door - using a rubber mallet if necessary



Then re-bend the end clip to lock it all into place


Looks good….




Rears are the same just shorter



JJ

[Problemchild1976]

Originally Posted by Moomoo

If the plastic is similar to water waste pipe in composition, I wonder if that melt/ weld glue plumbers use would be any good.🤔

Potentially - let me see what my little plan brings about

JJ

[Moomoo]

Originally Posted by Problemchild1976

The other job I’ve done was to replace the outer window scrapes / seals



As you can see they were pretty bad and very brittle

Got a replacement new set from here

https://www.partsforvolvosonline.com...oducts_id=9939


To remove the old one it’s a bit more complicated than a modern car

The scrape is 2 parts - a metal channel and the seal itself.

The parts are just the seal

You need to remove the whole piece to replace

First you need to release the metal clip at the door handle end



Then you need to leverage off the whole piece

The set comes with a plastic trim removal tool and this is used to leverage off from the clip end and working along until it comes off





Once off you can see it’s made of 2 parts - the seal and the metal piece that clamps onto the door skin and has the channel for the seal to slide into.

The old seal is clamped in place by these dimpled sections so need to prise this apart to be able to slide the seal out






To replace the seal, I used silicon lube in the metal channel and some on the seal to enable it to slide in nicely

Once it’s in, cut to length



Then replace the whole unit back onto the door - using a rubber mallet if necessary



Then re-bend the end clip to lock it all into place


Looks good….




Rears are the same just shorter



JJ

Important job to do. All mine are done and the 32 year old doors are dry and rust-free.👍

[Steve 940]

Originally Posted by Problemchild1976

So tried another fix for the damaged door pockets this week…

When I collected the car they were superglued and had foil tape in the back - and they didn’t last long

I initially got some araldite and that didn’t work very well (it struggled to even dry)

I think tried a plastic specific 2 stage glue and used to support pieces and while that stuck well, it just didn’t bond and the glue was easy to just peel off

So my final attempt was to get my hand on some plastic weld glue



I’d read great reviews about it and found someone had used it on the door pockets with some success. It’s still like superglue but hoping it binds way better!

I cleaned all the old glue off and gave the surfaces a bit of a sand and applied the glue and clamped and also reused the braces I’d put on before



Left overnight and it seems to have bonded better (you can’t see the white strips when in the car)



I have a plan to create a better and more useful support - watch this space

JJ

Hi JJ,

Hope you're door pocket repair works, fortunately I haven't needed to do this on my 940 yet!!

If glueing doesn't work, perhaps try a few layers of fibreglass mat with resin on the reverse side of the pocket, I think you can get colour pigments to add to the resin making it a bit less unobtrusive.

Main thing I believe is to key the base surface very well first, and perhaps also include a stiffener, old steel rule would be ideal, within the mats to further strengthen.

Cheers
Steve

[Problemchild1976]

Originally Posted by Steve 940

Hi JJ,

Hope you're door pocket repair works, fortunately I haven't needed to do this on my 940 yet!!

If glueing doesn't work, perhaps try a few layers of fibreglass mat with resin on the reverse side of the pocket, I think you can get colour pigments to add to the resin making it a bit less unobtrusive.

Main thing I believe is to key the base surface very well first, and perhaps also include a stiffener, old steel rule would be ideal, within the mats to further strengthen.

Cheers
Steve

Yeah I have some fibreglass - it’s so messy it always puts me off

JJ

[LRRWK]

How's progress now?

Still on the Up I hope...?

[Problemchild1976]

Originally Posted by LRRWK

How's progress now?

Still on the Up I hope...?

Yeah it’s all going well - I feel like the car is still using a bit too much fuel and running a bit lumpy

I find that turning the pulley by hand that there is a massive drag on the power steering pump

JJ

[Othen]

Originally Posted by Problemchild1976

Yeah it’s all going well - I feel like the car is still using a bit too much fuel and running a bit lumpy

I find that turning the pulley by hand that there is a massive drag on the power steering pump

JJ

Hi JJ,

Have you done a compression test to see if all the lumpiness might be due to a mechanical problem? If not that may be a good idea: eliminate one thing at a time.

Alan

[BicycleBoy]

Originally Posted by Problemchild1976

Yeah it’s all going well - I feel like the car is still using a bit too much fuel and running a bit lumpy

I find that turning the pulley by hand that there is a massive drag on the power steering pump

JJ

So.... slack off & remove the power steering belt and see if lumpyness vanishes? If pump is dragging the crank....

[Problemchild1976]

Originally Posted by BicycleBoy

So.... slack off & remove the power steering belt and see if lumpyness vanishes? If pump is dragging the crank....

Good plan

JJ