1993 Volvo 240 Customization and Personalization Project
AUTOMOTIVE • MECHANIC • DESIGN • ELECTRICAL ENGINEERING
As a car enthusiast, I used my design expertise to personalize my driving experience with functional and aesthetic improvements. `This project included welding a custom 3-inch exhaust, installing racing brakes, custom upholstered door panels, and Apple CarPlay for better performance and connectivity.
Car Restoration & Upgrade
Designer & Mechanic
Albany, NY
2022 - Current
Automotive
Restoration & Modification
Motorsport
The Challenge
I purchased this 1993 Volvo 240 with the goal of making it both my daily driver and a show car. However, I quickly realized it had several shortcomings that needed to be addressed. The brakes barely worked, making it a pain to drive safely. The steering was unreliable, leading to poor handling and control. The suspension felt wobbly, affecting ride stability and comfort. Lastly, the interior just did not reflect my personality or style.
The Goal
As my first official project car, I want to learn every step of the process myself to transform this vehicle into a reliable, high-performance, and personalized machine that seamlessly blends functionality with aesthetic appeal. This means gaining hands-on experience in mechanical repairs, fabrication, and automotive design. From rebuilding the braking and suspension systems to customizing the interior and exterior, I aim to refine both the performance and visual identity of the car.
Additionally, I want to integrate modern technology while preserving the car’s classic charm, ensuring it stands out as both a daily driver and a show-worthy build. Through this project, I am not only enhancing my skills in automotive restoration and customization but also applying my UX design expertise to create a personal connection and immersive driving experience.
Installing new engine mounts with help from my Volvo friend Connor.
Process
Research: I have spent over 300 hours immersed in Volvo-specific resources and forums like Turbobricks (www.turbobricks.com/index.php), learning everything I can about these cars. I’ve explored their common issues, typical fixes, and the vast array of modifications enthusiasts apply—not just to Volvos, but to other car brands as well. Through this research, I discovered that there were countless paths I could take with my build, from OEM+ restorations to full custom performance builds. Before diving into any modifications, I realized I needed to define the car’s purpose—balancing reliability, performance, and aesthetics—to ensure every change aligned with my vision.
Project Planning: I decided that I want to continue utilizing this car as my daily vehicle but also want the capability to attend shows and the occasional track day. My goal is to create a balance—fast but reliable, comfortable yet performance-oriented. To stay organized, I created a detailed spreadsheet outlining every part I’ll need, including quantity, price, date purchased, and date installed.
I prioritized modifications based on necessity, focusing on safety and reliability first. When I first got the car, it had a broken headlight and a non-working turn signal, which were immediate concerns for both legal and safety reasons. Replacing those was my first task. Additionally, I changed the oil right away, as that’s a crucial first step when purchasing any used vehicle. While working on the oil change, I noticed that the engine mounts were extremely worn and close to failure. To prevent further issues, I replaced them next, ensuring the engine was properly secured before moving on to performance and aesthetic upgrades. By approaching the build methodically, I am ensuring that each modification contributes to the car’s overall functionality and long-term vision.
Interior Customization: Starting with door upholstery, I replaced the old fabric with the new fabric I decided to purchase from Joann’s. After initial challenges with a sewing machine, I pivoted to gluing on my fabric and folding edges to achieve a polished and durable finish. I successfully completed all four doors. Next, string lights featuring ghost and skull designs were installed along the headliner handlebars, adding a touch of personality and festive ambiance to the interior. The dashboard was upgraded with an Apple CarPlay touchscreen system, modernizing the vehicle with GPS, Bluetooth, and multimedia capabilities. The rear and door speakers were also upgraded to enhance sound quality, ensuring compatibility with the CarPlay system.
After removing the door panels, I measured and cut new fabric.
Two panels finished, two to go!
Here my car sits before the new door panels are installed.
Begin installing.
The driver side doors complete!
Passenger side doors complete!
Watch My Door Panel Installation Video
Custom Tail Light: One of the unique modifications I tackled on my Volvo 240 was the taillight project. The original taillights were outdated and didn’t align with the modern-yet-retro aesthetic I envisioned for the car. Additionally, they were prone to common issues like cracking, fading, and poor electrical connections. To create a more distinctive and reliable lighting setup, I explored various options, from OEM replacements to fully custom LED designs. After researching different approaches used by Volvo enthusiasts, I decided to modify the taillights to improve both their functionality and appearance. I plan to use the original housings, but 3D print a piece to reinforce the center, and mold clear acrylic over the housing to make a new tail light lens. repairing any cracks, upgrading the wiring for better conductivity, and installing custom LED bulbs for improved brightness and longevity. The end result is a taillight setup that enhances visibility, modernizes the car’s rear-end look, and adds a personal touch that sets my build apart from others. This project not only improved safety but also reinforced my hands-on skills in electrical work and custom fabrication.
Tail light concept sketch, inspired by the Porsche 964!
Arduino breadboard wiring test.
Testing moving text show mode for tail light LED panel.
Testing sequential right turn signal functionality.
Testing a braking light function.
Testing reverse light function.
Custom Exhaust: One of the most exciting modifications I’ve undertaken on my Volvo 240 is the custom exhaust system. The stock exhaust was restrictive, limiting both performance and sound. Given that my car is going to be turbocharged, I knew upgrading to a higher-flowing system would improve power, efficiency, and overall driving experience. After extensive research on exhaust design, I decided to pair a 2-inch stock downpipe with a custom 3-inch catback exhaust system (until I can get the turbo installed with a 3 inch downpipe). This setup will allow for better turbo spool, reduced backpressure, and a deeper, more aggressive exhaust note. I sourced 3-inch stainless steel piping, learned how to cut and weld the sections together, and carefully routed the system to ensure optimal clearance and performance. This project significantly improved throttle response and power delivery, making the car feel more responsive. It also deepened my understanding of exhaust flow dynamics and hands-on fabrication skills, bringing me one step closer to building a performance enhanced machine.
Measure and take note of any obstacles (gas tank, axle, etc.) and bends in the pipe.
Remove the exhaust, compare wiht new stainless steel pipes.
Practice MIG welding for the first time ever, using scraps.
Lay the pipes side-by-side, measure twice, mark, cut once. Sand to prep for weld.
Weld, sand the weld to check for pinholes, weld again, final sand, add next pipe, and repeat.
The new exhaust is complete! Side-by-side old vs. new pipes!
Here's what's been completed so far:
New rubber motor mounts
New rear shocks
New power window fuse
4 slotted drilled rotors
4 brake calipers
4 sets of ceramic brake pads
Rear brake shoes and cables for parking brake
2 adjustable torque rods from IPD
An adjustable panhard bar from IPD
4 new speakers
Newly painted trim pieces
All fluids flushed and topped off
Interior fairy lights
Custom upholstered door panels
Custom welded 3" exhaust
Installing new braking system, adjustable panhard bar and adjustrable torque rods.
Moving Forward: As of February 26th, 2025, I am in the middle of removing the stock automatic transmission and swapping in a 5 speed manual transmission. Installing a World Class T5 Transmission from a Foxbody Mustang, requires a new modified crossmember, a custom driveshaft, a Ford clutch, a flat Volvo flywheel, manual pedal assembly, clutch cable, clutch fork, a machined Volvo M46 bellhousing, and lots of time and effort. While I'm here, I will also be replacing my rear main seal, as it is a common oil leak point on the old Volvo B230 engines.
