My motivation at work is lacking, so here's some pics of my latest project on my '93 Volvo 945 turbo.

I originally bought this car as a fun side project, but once my son was born it magically turned into the family-mobile since it was the only vehicle that could haul everyone. However, it rode like shit. I originally thought it was due to the IPD sport coils I put on and the horrible mid-west road conditions. So, I put the stock coils back on and it still rode terrible. Now, I think it is due to the 20-year-old dry rotted bushings and Bilstein shocks/struts I put on. (I'm turning into James May. I put Bilsteins on the Volvo and my Dakota, and I hate them. They have 'tested at the Nurburgring' sticker on them. I'll never buy Bilstein for a road car again.)

Anywho, so I'm ripping out the entire suspension and brakes from the car to replace anything that needs it. Here's the list of stuff I found wrong so far:

  1. Blown and wobbly ball joint on pass. front side
  2. Cut rubber boot on pass. front tie-rod - leaking grease
  3. semi frozen slide pin on pass. front caliper bracket
  4. frozen slide pin on driver front caliper bracket
  5. sheared off wheel stud from driver rear (knew about that from recent tire rotation)
  6. worn out driveshaft bushing
  7. tear in pass. front brake hose (not leaking think it's just protective cover)
  8. tear in pass. front brake caliper piston dust cover (not leaking but still bugs me)
  9. Dry rotted bushings everywhere!

So, I will be replacing some wheel studs, the front ball joints, tie-rods, front lower arm bushings, front strut rod bushings, rear trailing arm bushings, rear torque rod bushings, and driveshaft bushing. I have new OEM-style Sachs shocks and struts. I also got stainless steel brake lines and caliper rebuild kits for all four corners. I will cut one full coil off the front spring and will probably cut about the same off the new 30% stiffer overload springs I bought for the rear to give it a good appearance while still having a decent ride. I also bought an IPD lower chassis brace to stiffen things up. Wheel hubs, rotors, and brake pads are recent, so they'll be reused. I also already have an adjustable panhard bar and polyurethane strut rod to lower are bushings, so those will be reused. I'm leaving sway bars alone until I can just buy the IPD sway bar kit. I'm also going to powdercoat the calipers and suspension components. Why? Cuz I can!

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And here's the pics for far. I'll update as I get more disassembled.

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