Savings and Gains
- example 240 model
A 240 cabin floor pan has in some areas two separate layers of
steel, then a glued down sheet of bituminous tar, then foam backed
sound deadener mats, then carpet. The 'foam backed sound deadener
mats' are very heavy, being easy to remove (or to refit). The
bituminous tar, being glued down, is hard yakka to remove - Method -
hot air gun and paint scraper.
1kg = 2.2
lbs OR 1 lb = 0.454 kg
- Foam backed sound deadener mat on
upper 240 engine bay firewall = 2kg. Now you can hear the injector
soleniods clicking away.
- Foam backed sound deadener mats -
rear floors, front floors and transmission hump = 10.74 kg (23.6
- Bituminous tar - rear floors,
front floors and hump = 9.75 kg (21.45 lbs)
- Bituminous tar - boot and under
rear seat areas = 4 kg (8.8 lbs)
- Bituminous tar - total of inside
front and rear doors = 2.32 kg (5.1 lbs). Doors sound tinny with
tar sheet removed.
- 242GT Font doors Bituminous tar
lining = 865 grams (1.9 lbs) per door (save 1.73 kg or 3.8 lbs for
- SUMMARY - All insulation removed
from around the 240 chassis = 30 kg
- Door panels - cardboard moulded =
1.5 to 2 kg each
- Whole Door 244 rear = 24 kg with
door panel. Intrusion bar = 1.7 kg, Glass = 2.8 kg,
therefore glass is only 12.4 % of door weight, Remaining weight is
steel. Glass alternative is Lexan polycarbonate, the
difference is only a few hundred grams for a lot of fittment
effort and cost.
- Front bonnet 244 flat hood =
- Radio & wiring (save up to
3.5kg depending upon model), Speakers are heavy too.
- Windscreen water container and
pump - water is heavy, 1 litre = 1 kg or 2.2 lbs
- Rear Seat upper = 9 kg / Rear
Seat lower = 6kg. Total rear seats = 15 kg (33 lbs)
- Heater / circulation fan assembly
9 kg The heater core with water = 2.4 kg
Studies have shown a weight
increase in the order of 100 lb or 45 kg will increase
the time it takes to complete the 1/4 mile by about 1/10th of a
second. (Quote by someone). Presume this applies to a weight decrease
also, the aim of this discussion.
Depending on your determination, and what model 240 you start with,
you can save the first 30 kg relatively easily, but the next 30 kg
gets harder with either a comfort compromise, or increased $ expense
as you try to save weight by using alternate lighter parts. For
example, Volvo front seats are not light, but if you spend $500-700
each for two light race seats you'll save around 25 kg.
Weight removed by fitting newer model parts
or modifying existing parts
B21/230Lighter weight water
(one pulley is machined off)
Volvo Radiator plastic
end tanks - shown inside is a hollow copper tube assembly
that attaches to an auto trans. Newer genuine radiators use Al Alloy instead as its far lighter and cheaper to make. Most radiators have this
ato trans cooling core, unless you specifically seek a manual gearbox version which
doesn't have. The tube consists of two thin cylinders welded together with a large internal diameter for cooling water circulation to enable the heat transfer from
one end to the other.
So if you have a manual
transmission, save yourself extra weight of Cu 375 grams
plus 40g for nuts, so 405g or about 1 pound.
Radiator (manual trans)
#9142703, rubber seal for bung #1378869, bung
bar upgrades - 'Commando'
type vs lighter 1981-on
- K-Jet injection replaced by EFI
parts, save 6 kg
- Steering rack - newer all-alloy
cased 'Camgear' 6 kg vs 8.5 kg aluminium alloy/steel case. Huge
weight saving again if replacing early cast steel version with
- Late model F&R bumpers - see
- Starter motor - save 50% with
newer slim (Volvo/Bosch) compared to old style starter. #
- Radiator - Plastic tanks /
Al.Alloy core - save 50% over old copper type
- Gearbox - M45 instead of
M46+Overdrive / alloy M47 or Supra perhaps
- Race style seat or seats (FIA or
SFI approved), 2 light seats save approx 25kg
- Late model front apron (vertical)
support save 0.5 kg or more (sits under bonnet catch and supports
horns), Remove one of the two horns
- Water pump and alternator pulleys
are dual in a Volvo - machining off one of each can save 40%, plus
reduce belt friction losses.
Weight added by Improvements
- Swaybars larger diameter 26mm IPD
(measure them, the steel bar is bigger than 25mm). Comment, a lot
heavier than say 21 mm bars.
- 2" diameter tailshaft (standard
on an auto), smaller diameter on a manual.
- 3" Exhaust system - 3" tube or
pipe is noticeably heavier than 2 1/4" dia. tube.
- Rims - larger diameter and wider
rims means more metal and more weight. But more grip with wider
- Tires - bigger and/or wider sizes
are usually heavier (to fit your big rims!)
- Radiator cooling Fan -
Viscous (mechanical) VS Thermofan (electric)
A Volvo plastic/metal combo viscous fan weighs 1.9 kg. A 16"
electric thermofan with brackets weighs 2.5 kg, so a big thermo is
heavier. However, when fitting the thermofan you remove the Volvo
fan shroud and that weighs approx 530g. So in the end the net
weight gain of the thermofan is very little, around 100 grams.
Balanced by reduced drag on the engine, the thermo fan would come
out way ahead in the efficiency stakes.