Operation Get Out of its Own Way

[PKFIRE]

Thought it would be a fun project to add a turbo onto my 1990 Volvo 240. I've replace most the suspension and placed a larger pump into the vehicle recently. I also replaced the Computer and Dizzy with ones out of a Volvo 740 Turbo. Also larger injectors out of a Volvo 850 Turbo. Now it's finally time to add the + Turbo to it.

http://imageshack.us/a/img856/5892/kpws.jpg (http://imageshack.us/photo/my-images/856/kpws.jpg/)
http://imageshack.us/a/img7/7583/1erw.jpg (http://imageshack.us/photo/my-images/7/1erw.jpg/)
TD04 Turbo
http://imageshack.us/a/img35/1623/o3cg.jpg (http://imageshack.us/photo/my-images/35/o3cg.jpg/)

I'm just happy to get the exhaust manifold bolt off tonight with no problems!
http://imageshack.us/a/img4/9630/xaf7.jpg (http://imageshack.us/photo/my-images/4/xaf7.jpg/)

[2Fast4You]

That is definitely different, can't wait to see the end result.
What made you go this route?

[rtvickers]

Cool project Joe. Good luck with it.

[firestang70]

Cool project.

[PKFIRE]

Spent some time tonight pulling off parts. I removed the air box, intake hoses, exhaust manifold with the down pipe, the fan, shroud and drained the oil. I also visited facemelter71 at Volvo of Cincinnati who help locate some exhaust fastners I needed for the build.

http://imageshack.us/a/img200/8807/lx0r.jpg

http://imageshack.us/a/img845/6453/6s64.jpg (http://imageshack.us/photo/my-images/845/6s64.jpg/)
http://imageshack.us/a/img32/6199/ojpl.jpg


http://imageshack.us/a/img23/7949/w9aq.jpg

[PKFIRE]

That is definitely different, can't wait to see the end result.
What made you go this route?

I bumped into adding a junk yard turbo set up on these cars about 3 years ago. I always thought it would be a fun project just to add one and make the car a bit more fun to drive. Stock the car ran 18.6@73mph and after a VX3 Cam and larger exhaust it went 17.4@79. Not sure what it's going to run after this upgrade but it will be fun to find out.

[PKFIRE]

Cool project Joe. Good luck with it.


Cool project.

Thanks guys.

[jeep45238]

That looks so much easier to work on than the '03 S60 I did a cylinder head job on...

[PKFIRE]

That looks so much easier to work on than the '03 S60 I did a cylinder head job on...

These cars are very easy to work on. There's a ton of room and most things you can take apart with a 10mm wrench or socket.

[facemelter71]

Glad I could help. If you need anything else,give me a shout. I dont get email notices anymore from PM's,so If I dont get back to you call me at the store.

The number at my desk is:
513-603-3429

[PKFIRE]

Glad I could help. If you need anything else,give me a shout. I dont get email notices anymore from PM's,so If I dont get back to you call me at the store.

The number at my desk is:
513-603-3429

Noted, Thanks again!

[PKFIRE]

I work on the car today. I was able to drop the oil pan without having to drop the crossmember. Kind of win for me but I will instead drill into the block for a oil return since if I add anything to the oil pan I will have drop the crossmember.

[PKFIRE]

Spent sometime with the Volvo. I had to make another visit Volvo Dealer where I met Kevin KB1 for some maintains parts and the replacement of a brittle return hose into the oil pan. As much as I wanted to I wanted to leave the intake manifold on to replace the oil separator box but I just didn't have clearance to get it out. Now I'm finally putting parts onto the car.

http://imageshack.us/a/img854/7159/vydh.jpg (http://imageshack.us/photo/my-images/854/vydh.jpg/)

Tight fit but the e-bay intercooler fits nicely with the hose going right into the engine bay.

http://imageshack.us/a/img163/3930/ums7.jpg (http://imageshack.us/photo/my-images/163/ums7.jpg/)


http://imageshack.us/a/img163/3930/ums7.jpg (http://imageshack.us/photo/my-images/163/ums7.jpg/)

http://imageshack.us/a/img196/4595/llkn.jpg

[PKFIRE]

http://imageshack.us/a/img585/5219/a5x3.jpg

Wiring up an extension for the Mass Air Flow Meter

http://imageshack.us/a/img10/7543/6zj6.jpg

Starting to design a 3" Down Pipe for my +T in Inventor. Decided just to make one myself.

[PKFIRE]

I been able to put more time on the Volvo in the few days. The oil pan is mounted back on, the turbo drain pipe is ready for a new hose I will placing on it. I was able to place the new T for the oil line to turbo.
http://imageshack.us/a/img829/7528/kbxx.jpg
I have a 45 degree 2" to 2.5" hose coming to connect these two pipes.
http://imageshack.us/a/img42/668/inrl.jpg
New T and oil pressure switch. I will have to replace the bullet connector with a 5/16" faston connector.

http://imageshack.us/a/img203/7755/o04a.jpg
This was sitting on my front door yesterday. 3" universal 409 Stainless kit.
http://imageshack.us/a/img10/7055/snqk.jpg
So I went ahead and worked on making the down pipe. Can't believe how easy it was to make a down pipe out of a U bend.
http://imageshack.us/a/img541/2743/rnvq.jpg
I'll be taking my new down pipe to get the end flared with a floating 3 bolt flange at a local muffler shop.

http://imageshack.us/a/img692/811/k4gp.jpg
Cut some intercooler pipe and hose tonight. I have the driver side figured out. I the passenger side I have a reducer 2" to 2.5" coming in the mail. Once I mount my intercooler bracket the intercooler setup will be done.

[PKFIRE]

http://www.youtube.com/watch?v=vdC1ILe68LQ&feature=youtu.be

[2Fast4You]

Nice job, enjoy.

[PKFIRE]

Nice job, enjoy.

Thanks, I have an exhaust to build still and add some gauges. Just glad I got it running at this point.

[rtvickers]

Awesome job Joe. Sounds good. You made fast work of that.

[PKFIRE]

Awesome job Joe. Sounds good. You made fast work of that.

Thanks, I spent a lot time Ebay shopping in the process,lol. Amazing how many little things I needed along the way.

[PKFIRE]

Worked on making a 3" exhaust yesterday. I wish I had some welding skills before I started the project. I had coworker weld up the downpipe and then I gave Adam at S&M a visit to weld on the flex pipe. I may try practicing welding on the left over scrape for the fun of it.

The exhaust has Catco 3" stainless cat, magnaflow chamber muffler. I added a Wideband to it too yesterday. The car is much quieter but has a deep tone to it.

http://imageshack.us/a/img818/9099/4rsf.jpg (http://imageshack.us/photo/my-images/818/4rsf.jpg/)

http://imageshack.us/a/img7/1876/3pb6.jpg (http://imageshack.us/photo/my-images/7/3pb6.jpg/)


http://imageshack.us/a/img837/2525/z2z6.jpg (http://imageshack.us/photo/my-images/837/z2z6.jpg/)


http://imageshack.us/a/img545/1885/np9z.jpg (http://imageshack.us/photo/my-images/545/np9z.jpg/)


http://imageshack.us/a/img21/7635/yd2k.jpg (http://imageshack.us/photo/my-images/21/yd2k.jpg/)


http://imageshack.us/a/img29/3782/a7ze.jpg (http://imageshack.us/photo/my-images/29/a7ze.jpg/)


http://imageshack.us/a/img18/5752/q2wk.jpg (http://imageshack.us/photo/my-images/18/q2wk.jpg/)


http://imageshack.us/a/img593/6579/s9cr.jpg (http://imageshack.us/photo/my-images/593/s9cr.jpg/)

[Marks99gt]

Cool project. Glad you got it going.

[PKFIRE]

http://imageshack.us/a/img600/3530/wx5l.jpg

Found the old G-meter to try out. Last time I did this the best I could get out of the car was a 10.0 to 60mph with the VX3 cam and 2.25" catback exhaust. I'm a bit curious on what it will run in the quarter the way it sits before I up the boost a bit.

So I guess this what I know so far

12.5 (figured out number)seconds 0-60 stock 18.6@73
10.0 seconds 0-60 (g-meter)vx3 cam and 2.25" catback 17.4@79.10
6.08 seconds 0-60(g-meter) vx3 cam, 3" full exhaust, cone filter and td04-13c turbo at .5 bar of boost. Quartermile ???

Yesterday the car went 6.5, 6.7 and brake boosted 6.08 to 60 mph according to this g-meter.

[PKFIRE]

Cool project. Glad you got it going.

Thanks, I had most the parts laying in the garage. I finally just decided to do it,lol.

[PKFIRE]

Well I blew the headgasket and now the head is off it. I sent it over to Performance Engineering today for a surface clean, increased cc bowl and a 3 angle valve grind.

[PKFIRE]

Well finally I got to my head ready for reassembly. Bit of learning experience on being picky about how the final product should turn out. After a few trips to the machine shop for some surface clean up and some work of my own the cam now spin freely in the assembly. I need to check the shim clearance on the cam and once I get that set I can put this head back in.


http://imageshack.us/a/img845/461/pacg.jpg
http://imageshack.us/a/img689/754/lkil.jpg
http://imageshack.us/a/img196/3865/c46n.jpg

[PKFIRE]

3 Angle Valve Grind, Radius exhaust Valves and bowl blend to reduce compression to 8.5

http://imageshack.us/a/img407/8945/7tz7.jpg
http://imageshack.us/a/img594/4092/ftte.jpg
http://imageshack.us/a/img585/9986/cman.jpg
http://imageshack.us/a/img571/2729/vxlp.jpg

40 dollar Boost Controller mounted in the glove box.
http://imageshack.us/a/img822/6509/prt5.jpg
http://imageshack.us/a/img196/518/skm5.jpg
http://imageshack.us/a/img89/7571/lwlj.jpg

[PKFIRE]

Added an adjustable FPR to the vehicle and I will be running the car on the Dyno at S&M next week using the free dyno pulls I won at Quaker Steak at the last Terminator Cruise. I'm thinking 170-180 whp since it on a Mustang Dyno and the turbo in it is rated at 339 cfm.

[PKFIRE]

I noticed I haven't updated in awhile. Since then I have added 15G-TD04HL turbo that got me a 14.0 in the quarter. I was hoping for a high 13 so I've swapped in a 20T-TD04HL turbo with a full 3" Outlet. I have a higher lift and duration camshaft that I'm planning to place into it soon. The car feels pretty quick as it sits on pump gas. Probably even more so then when it turned a 14.0 running 110oct with the 15g.

[draggin50]

Nice work!!

[PKFIRE]

Well I got somethings done to the car in the last month. I broke another Automatic Aw71 transmission and finally decided to install a transmission with the Home Depot shift kit upgrade. I stuck cut bolts between the actuators in the transmission for quicker shifts and eliminated most the slips during shifts that was killing second. I wish I did it earlier since the car now barks 2nd gear pretty easy and goes for 40-50 stupid fast. Accord to my phone's video editor it went 5.1 seconds 0-58 mph with little brake boost. The power comes in strong and it's running 18 psi. I think it should easily turn a 13 now on pump gas. I'll eventually change the cam out and put in some breather barbs so it gets the crankcase pressure out of the motor.

So I can run it as is and put slick on and brake boost it to 15psi or wait until I put my higher lift and duration Turbo Cam in. I'll eventually up the boost more.

[PKFIRE]

Valve body with Home depot Performance shift kit.
http://i.imgur.com/mLBLFhmm.jpg

[PKFIRE]

Well I hit my first goal of getting the car to run a 13 second quartermile and did it with my 15g used turbo. I've decided not stop there and push it a bit harder into the low 13's or 12s for next year.

In the process of trying to get my 20T to boost past 20psi I over spun the turbo because of weak CBV Spring. I took the turbine wheel and compressor wheel to Diesel injection service for balance. I ended up finding a place out in Oregon where it seems all the Volvo performance shops exist who had a TD04HL Bearing housing already machined out for a 58mm compressor wheel. Standard housings can only accept a 56mm wheel.

20T turbo
http://i963.photobucket.com/albums/ae119/pkfire240/2014%20December%20Pictures%201022_zpsrcwrrdxj.jpg (http://s963.photobucket.com/user/pkfire240/media/2014%20December%20Pictures%201022_zpsrcwrrdxj.jpg. html)

http://i963.photobucket.com/albums/ae119/pkfire240/1001152240_zps4qagnlfh.jpg (http://s963.photobucket.com/user/pkfire240/media/1001152240_zps4qagnlfh.jpg.html)

Standard Bearing Housing
http://i963.photobucket.com/albums/ae119/pkfire240/1001152242_zpsutcsqve4.jpg (http://s963.photobucket.com/user/pkfire240/media/1001152242_zpsutcsqve4.jpg.html)

20T Bearing Housing
http://i963.photobucket.com/albums/ae119/pkfire240/1001152241_zpsxv77yrsn.jpg (http://s963.photobucket.com/user/pkfire240/media/1001152241_zpsxv77yrsn.jpg.html)

I'll put it back together this week. I'm not planning on installing it for a bit because the car is quite fun the way it sits for now.
My wish list for next year..
I will need to replace the GTP 36 lb injectors with larger 52lb injectors, put lighter front wheels on, drop some weight in the car and possibly adding a locker next year. I may also add a 3" cutout before the cat to free up some horsepower.

What I have on order
17psi Garrett Wastegate to replace the 4psi Wastegate currently being used. That should get rid of the turbine pressure opening the puck too soon.

[86gt40]

Coolest thread I've read in a long while.

[PKFIRE]

After running Sunday the car went 0-60 in 5.2 seconds. Based on the time slip.

[PKFIRE]

I went ahead and rebuilt the 20T turbo tonight. I learned that someone messed up designing or machining the turbine shaft as it pushed a thrust collar right into a thrust bearing it shouldn't ever bind to. So the turbo was locked up when I went to tighten it. I now know why there was step put into the original thrust washer to account for this. I'm really not sure if this common practice when building a turbo but it makes it a pain trying to put it back together. I'm kinda disappointed but it's not the first time I seen parts adjusted to fit.

http://i963.photobucket.com/albums/ae119/pkfire240/10151521241_zpswekxzfjl.jpg (http://s963.photobucket.com/user/pkfire240/media/10151521241_zpswekxzfjl.jpg.html)

http://i963.photobucket.com/albums/ae119/pkfire240/10151522281_zpsjj4ivlya.jpg (http://s963.photobucket.com/user/pkfire240/media/10151522281_zpsjj4ivlya.jpg.html)

[PKFIRE]

I'm in the process of getting the car ready for next year. I found a guy who tunes these cars through burning chips. He's helping me right now find a plan on what to get to support my goal of a 12 second 1/4 mile. Currently I found and purchased a V6 Volvo MAF that is 30 percent bigger than the one that I'm running that works with my stock computer. I will have to get larger injectors and the tuner will help me fine tune my airfuel with it. This also removes the fuel cut which is nice since the car after 20 psi just likes to cutout at part throttle. I will be running about 25psi through this engine. I'll see if the 1/4 million mile redblock holds together. If not I'll just pick up a used redblock and put some H beam rods into it and try again.

I have 55lb injectors on order, time to make some more horsepower.

[PKFIRE]

I'm collecting more parts, I've decided to convert the car to E85. Found a chip burner in Arkansas and he is going to burn me a ignition chip and a fuel chip. I had to purchase a chipable EZK ignition box. Apparently the one I'm getting has the fastest processor. The car is becoming a mess of various parts.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1445895335171111871060_zpsap3qkwij.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1445895335171111871060_zpsap3qkwij.jpg.html)

E85 parts list complete.

[PKFIRE]

Fuel, Computer, New Air filter, Spark Box and Injectors are installed. I just need to fill up with E85. I'll see how the 15G turbo is before I put the 20T back in.

[draggin50]

Gotta love new parts!!! That thing is gonna be fun I bet!

[facemelter71]

What will you be doing with the 15T turbo?

I might be in the market for a 15T, if it is the angled exhaust housing.

Also, one more thing.
If you need anything from Volvo parts, get ahold of Britt. She took my place at the parts counter. She will take care of you. Just let her know Stacks sent you.

[PKFIRE]

Gotta love new parts!!! That thing is gonna be fun I bet!

I hope so, I'm going to start It today for the first time with E85.


What will you be doing with the 15T turbo?

I might be in the market for a 15T, if it is the angled exhaust housing.

Also, one more thing.
If you need anything from Volvo parts, get ahold of Britt. She took my place at the parts counter. She will take care of you. Just let her know Stacks sent you.

Oh kewl, where did you run off to? Its a 15g btw. I sold the conical flange housing it had. I'm going to keep it for now. I actually have enough parts to build most of another +T.

[PKFIRE]

http://youtu.be/9ZzlZl62Uuc
It's alive!

[facemelter71]

I ended up accepting a new job at GE.

[PKFIRE]

I have a new chip sitting at my house for fuel. The first tune is running a bit lean. I'm hoping this time corrects the fuel enrichment at cold starts. The E85 tune was taking forever to cold start.

[PKFIRE]

Well after 3 chips and still running lean I decided to get larger injectors and the tuner sent me this nifty device called a ostrich 2.0. I downloaded the software and place his bin file into it. After looking it looks like this device will work with multiple obd 1 cars and there is a bit of info on jetronic tuning on the internet. I think it's time for me to read into it.

[PKFIRE]

Plenty of fuel to new 7000 rpm redline, old was 6000. I have the software now and can program myself. Still working with the tuner to get my E85 starting issues resolved. I've asked for a burner for Christmas so I can change chips myself. I can't believe the stock computer has so much adjustability. So far found you can raise the limiter up to 14432 rpm, can adjust cranking fuel per temperture, this is injector pulsewidth and duration. You can adjust fuel cut and modify MAF and fuel tables. Different year computers also have different circuits which new ones tend to have more adjustability.

[PKFIRE]

During my learning curve with tuning I found out that the my replacement 951 ECU does not have the circuit for the cold start injector. Though the 563 Computer that I took from the junkyard does. The only issue is that the 953 computer does allow for cold start cranking adjustments and the 563 does not other than with the cold start injector that my car was equipped with. Well after reading there was a ECU 937 that both has the cold start circuit and the cranking fuel adjustment. I located one and will become my main fuel ecu. I know these numbers don't mean much to anyone but Volvo made so many different versions of the same LH2.4 ECU and they all have some sort of weird difference in the program. Luckily there have been people who found or figured out most the differences and stuck it online. This should help me get this car to start under 30F on E85.

[draggin50]

Sounds like your learning a lot along the way. Why did they have to make things so difficult I wonder?

I just want to see it make some passes!

[PKFIRE]

I'm not sure why but I bet it had something to do with emissions. Newer Volvo's got EGRs and eliminated the cold start injector. That's my guess.

[PKFIRE]

Yeah, I'm looking forward to taking it to the track. Last track day I couldn't figure out why I was limited with fuel but I know why now and fuel cut has been eliminated. It should be quicker by just allowing me to up the boost more.

[PKFIRE]

It's interesting how you change some parameters tuning and how the car response. E85 isn't too friendly under 50-60F start ups. You have to dump exponentially more fuel the colder it gets compared to gasoline. Kinda frustrating since once I have time it gets warm outside again,lol.

[draggin50]

Mine does the same on E85. Below 50 it runs like crap until it gets some heat in it.

[PKFIRE]

I drove it to work this morning and it was running rich at part throttle cruise when it was warming up. It sputtered at part throttle until it was about at full temp. I guess I have to keep adjusting the warm up enrich until it smoothes out. Wish I had a load dyno,haha.

[PKFIRE]

https://m.youtube.com/watch?v=UCJOYPK8DDs
Figured out my misfire issue, bad plug wires. Starting to get somewhere now with the cold start and driveablity. Can't wait to remove this turbo.

[draggin50]

Seems like its making a good bit of boost! That's crazy!

[PKFIRE]

I want it to hold 25psi. The 15g won't do it. I do like how fast it gets into boost with the smaller turbo. I'm just happy the motor is holding together because the rotating parts are still naturally aspirated Volvo stuff with a ton of miles on it.

[draggin50]

That's crazy! Hard to believe it will take it really. Its good to hear though.

Should make for a real fun car. Nobody will ever expect it that's for sure!

[PKFIRE]

I wonder if I should stick with the B230 motor or someday swap it. I've seen people make good power out of these. The car started fine this morning but for brief few seconds it went lean after cranking and then went to warm-up enrichment which allowed it to idle fine. There has to be a way to adjust this.

[PKFIRE]

I got it all figured out fuel wise. The car started this morning at 18F. Now if I can only get the ignition system working perfectly.

[PKFIRE]

Before I drive to work tomorrow I'm going to try to start the Volvo in 6 degree weather. If it starts I'm done with the cold start issue. I got the car running well and the misfire was caused by a poor connection on the first injector and a bad spark plug wire. Rock Auto has a great replacement plan. I just put in my order number answered 4 simple questions and they sent me a new set of spark plug wires. Now I just have to remove my Autolite 64 for my BPR6ES NGK's and I'll be good to go engine wise.

[draggin50]

That should be the deciding factor! I know its cold enough already!

[PKFIRE]

Started right up! Time to get a chip burned and call it a day.

[draggin50]

That's good to hear! Sounds like progress is being made! Can't wait to see it in person!

[PKFIRE]

I changed to my NGK plugs tonight and no misfire at highboost. The stock coil is pretty strong and the stockish pumps are supporting 250-300hp at probably 60-70lb rail pressure on 7.8 AF. Kinda surprized since they only needed to support 114 NA hp on gasoline.

[PKFIRE]

Well onto transmission number 5. I'm replacing the cooling lines and putting two coolers in. I found a place that rebuilds torque converters and my new stall will be set at 3000. The transmission I pulled is geared lower than the ones I've previously used. Hoping for a better 1/4 this year.

[draggin50]

Hope this one works out better for ya. I cant wait to see this car in person making passes. Sure its gonna turn some heads!

[2Fast4You]

Good story, can't wait to see what this thing is capable of.

[PKFIRE]

I'm hoping 12s but I'm pretty happy with 13s. It's a far cry from how it use to be. It would be nice if I would just put my money into the Mustang but definitely a learing experience.

[rtvickers]

Looks like you're making good progress Joe. Keep up the good work. There might be a 2.3 whipple available this year. I know a guy that's thinking of switching to TVS or a 2.9. He having trouble making up his mind. Lol

[PKFIRE]

Looks like you're making good progress Joe. Keep up the good work. There might be a 2.3 whipple available this year. I know a that's thinking of switching to TVS or a 2.9. He having trouble making up his mind. Lol
Is this guy you??? I'm all for 2.3 TVS, I just like a car that gets into the power band quicker.

I dropped the transmission core off at You Pull and Pay with my truck (Volvo)yesterday and beat the heck out of my broken transmission for fun. Now it's in the garage getting new brakes. I had a vibrating front right caliper that I needed to fix and found out the guide pins for the pads had a deep grove on the outter most side. It was hanging up a bit. Just strange. I found a place for both transmission coolers and I'll get to work mounting them and replacing the front brakes this week. I should have the new torque converter this week also.

[rtvickers]

Maybe. He has to do something. Don't want to get beat by a Volvo.

[PKFIRE]

Maybe. He has to do something. Don't want to get beat by a Volvo.

Haha, not going to happen. Anyway you thought about upping the boost on the Whipple 2.3 and switching to E85?

[rtvickers]

Haha, not going to happen. Anyway you thought about upping the boost on the Whipple 2.3 and switching to E85?

Yeah I am still debating if it's worth switching to a tvs on e85 or going e85 with the whipple. I was thinking about a 2.9 but it's a little out of my price range. I'm probably going to upgrade the fuel system. Lethal's budget system. Either way I still can't keep up with the Volvo sedan.

[draggin50]

Id try the E85 with the Whipple. Its already on.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0208162148a_zpswwcv6nvq.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0208162148a_zpswwcv6nvq.jpg.html)

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0208162051a_zpsrxmzvhhb.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0208162051a_zpsrxmzvhhb.jpg.html)
3250 Stall torque converter and filter kit
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0208162051b_zpsjxveppmp.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0208162051b_zpsjxveppmp.jpg.html)
fittings and hoses for the transmission. AN5 fitting seem not to be the norm since there isn't many choices. I just bumped it up from AN5 to AN6 for more of selection of fittings to get.
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0215162237_zpsk65guemn.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0215162237_zpsk65guemn.jpg.html)

The two transmission coolers fit even with the added fan. I bought a light bar relay kit to run the fan which was cheep. I'm just going to have fan run when the car is on the on position and not worry about adding a thermoswitch. I think it will help it run cooler anyway. I still have to mount it correctly but luckily I can mount it to the intercooler fairly easily.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0215162151_zpskdzyir2d.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0215162151_zpskdzyir2d.jpg.html)

I'm in the process of replacing the warped front rotors and brake pads. I got one side on tonight.

[PKFIRE]

I've installed the transmission with the new coolers. I just need to add transmission fluid and the intake back on and it should be ready to drive.

[PKFIRE]

Finally on the road. I ended up finding a water pump leak when I was done with the transmission. It's sealed up and I'm enjoying the higher stall. It's no V8 but It comes off the line much quicker.

[COOP]

Finally on the road. I ended up finding a water pump leak when I was done with the transmission. It's sealed up and I'm enjoying the higher stall. It's no V8 but It comes off the line much quicker.

Awesome progress! Interested to hear what it will run
It may not be a v8, but I bet I can out run some!

[draggin50]

I cant wait to hear how it does either! I like seeing the oddballs that run real good put a frown on some ones face when they get gapped!

[PKFIRE]

I installed a 17lb Wastegate in place of my stock 4lb tonight. It would spike to 25lbs and drop boost to 16psi. I hope this keeps Wastegate flap from opening and give me more boost up top.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0418161855_zpsji2qcp7m.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0418161855_zpsji2qcp7m.jpg.html)

Here's the 17lb Garrett Wastegate I found on ebay for 30 dollars. I can't physically move the arm with my hands. The 4lb one was easy to.

[PKFIRE]

Awesome progress! Interested to hear what it will run
It may not be a v8, but I bet I can out run some!
Thanks! I'm just thinking if I blow this motor up if I should stick with the red block Volvo engine and put forged rods in it or goto a v8 swap. This seem to the unusual side because I get a lot of people wondering what I did to it around here and it's just an old tired Volvo motor. I kinda want to run mostly junkyard Volvo parts.

I cant wait to hear how it does either! I like seeing the oddballs that run real good put a frown on some ones face when they get gapped!
The more I read I keep finding more junk yard performance parts. There is a 1994 Volvo 940 NA that has a G80 locker with a 4.10 rear end at you pull and pay. I have a open diff with 3.73. I'm really tempted to run there and get it.

[draggin50]

This car is going to be neat to watch!

At least you have a variety of junk yard parts that can be made to work. Im sure the 4.10 with locker would help out if the gear isn't to steep. Whats in it now?

[PKFIRE]

3.73, I'm running a 23 in tire in place of my 24.2"stock tire size. The Transmission I installed is geared lower than the last one and I increased my rev limiter to 7000 from 6000. The cam I converted to should pull good to 7k. The old one fell flat after 5500.

1st. Was 2.45. Now 2.83
2nd. Was 1.45 now 1.49
3rd. 1.00
4th. Was .69 now .73

[PKFIRE]

It worked, 20 psi 1st 23 psi second and 25 psi 3rd. Before it would drop to 16psi. I'm bit nervous though since I never ran this boost in higher rev range.

[draggin50]

I bet it feels like a different car now!

[PKFIRE]

It does, the turbo is way past it's efficiency range. I'm going to run it Friday if Edgewater is open.

[draggin50]

Ill be stuck at work so I wont be able to come down and watch. One of these days, Ill make it down though. Id love to see it run. Make sure someone gets some video!

[PKFIRE]

Bummer, I found someone to video tape.

[PKFIRE]

We got rained out, I'll try going a again soon.

[PKFIRE]

https://www.youtube.com/watch?v=9KLONvz32l4&feature=youtu.be

Quick dry run with the slicks onto the highway before I took them off today. I could only brake boost to 5 psi before they lit up. I had to get it to 15psi before but they were fully warm. I can't wait to get a clean run with these tires sticky.

[redfirepearlgt]

Well that sucks. The youtube link is posted private.

[PKFIRE]

Well that sucks. The youtube link is posted private.

I got it set to unlisted now. Just a short clip to 70 or so.

[draggin50]

Sounds pretty cool! Seems to pick up speed quick!

[PKFIRE]

This is the fastest it's ever been. It has a slight mis-fire/stumble sometimes I'm not sure what it is yet. I think with a prepped track it would turn at least low 13 now the way it sits but I don't know yet.

[draggin50]

That would be cool! Gonna hurt some feelings with the old Volvo!!!

[redfirepearlgt]

Never thought I'd see a volvo Speedo climb that fast. That is really impressive. Low thirteens would hang a lot of unsuspecting heads. Anyone seeing it even attempt to keep up like that would be bound to be impressed as well.

[PKFIRE]

I'll be happy if it grabs a 12 with this setup but I would need a harder launch to get it. I really hope it runs better than a 13.8. I need to stop driving It because I keep flooring the thing and laughing.

[draggin50]

That's what its for! Enjoy that thing!!!

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/P1010001_zpsqcrwcbza.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/P1010001_zpsqcrwcbza.jpg.html)

G80 locker in my future! Finally I'll have another pulling wheel!

[draggin50]

Your probably gonna need it making that much more boost and power.

[PKFIRE]

The slicks hold well heated but when I brake boost I can cause the car to move forward even standing on the brakes even with the open diff. I just know people can run well on street tires with a locker. Anyway one wheel burn outs aren't as kewl.

[PKFIRE]

2.0 60' 13.7, I still have a bit go. I lost my alternator my last run and barely made it home. I miss tristate, you can make 20 passes no problem and make changes.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/art0027_img018_zpsh63z7ijq.gif (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/art0027_img018_zpsh63z7ijq.gif.html)

So the G80 locker has a centrifical arm that doesn't allow it to lock above 25mph. I'm half tempted to remove material to higher the speed which it disengages. Also the tone ring is in the diff and my Speedometer is set for 12 per revolution. The tone ring has 48 points per revolution. Need to cut that down to 12 or 30 mph will show 120, haha.

[draggin50]

Haha the picture kinda freaked me out there for a minute! Wasn't expecting it to move!

Any way to swap rings?

What about removing the arm completely? I guess removing weight to raise the speed would work just as well though.

[PKFIRE]

Elaborate on rings. Are you talking about ring and pinion?

As for the arm somehow it locks into the mechanism that locks the shaft together. There is a set of clutches also that after 100 rpm difference it causes both wheels to spin at the same time.

[draggin50]

Tone ring is what I was curious about. Can they be swapped? All else fails, remove 36 teeth spaced evenly.

I think weight removal is about your only option then on the arm.

[PKFIRE]

I think people have before but it requires welding. I could also get a Speedo out of a 92-93 abs Volvo 240 and It would work since It is set up for 48 tone ring. Everyone wants a arm and a leg for one. I can just leave 12 strips and space out as evenly as possible. At the rate of rotation I don't think if one of the 12 not space evenly will be too noticeable.

[PKFIRE]

I took out my alternator yesterday and took a trip to AutoZone tonight. They confirmed the alternator was dead. Luckily over a decade ago I replaced it with one with lifetime warrenty there. I'll be getting a new one tomorrow. Free is always good. I think I'll swap turbos while the car is apart.

[draggin50]

Gotta love the Autozone lifetime warranty! I keep a spare clutch kit for a old 5.0 laying around and haven't bought one in maybe 15 years.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0520162329_zpskxtvb2sx.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0520162329_zpskxtvb2sx.jpg.html)

My wife had a girls night that means I had some free time after the kids went to bed. So after I put a new belt on the washer which was a PITA I installed the 20T I rebuilt. I hope it holds together this time.

[PKFIRE]

After two failed attempts to get the alternator working I finally got it. I had terminal issues but that's solved now. The 20T isn't smoking which is a good sign. I'm going to finish plastic dipping the wheels next.

[draggin50]

Good to hear! Cant wait to hear how it does with the new turbo.

[PKFIRE]

Before
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0529160940_zpsbk5dwnpa.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0529160940_zpsbk5dwnpa.jpg.html)

After
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0529161059a_zpspooytkth.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0529161059a_zpspooytkth.jpg.html)

[draggin50]

Those turned out nice. Looks good on the car.

[PKFIRE]

Thanks! Here's the before and after. This is the original look of the wheels before the finish went bad and I repainted them silver. The new color is gun metal. I'm hoping it last awhile and won't show brake dust as much.http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/Screenshot_2016-05-30-03-19-362_zpsyuimgolu.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/Screenshot_2016-05-30-03-19-362_zpsyuimgolu.jpg.html)

[2Fast4You]

Now it's time to get that LImited Slip Differential in there and let it rock...

[PKFIRE]

I'm looking forward to installing. I'm just hoping the Speedometer works right after. I still drive the car to work and around sometimes. It will be nice to be able launch the car on street tires.

[PKFIRE]

I've been messing with my Wastegate. The 1st day I took the car out I got 14psi out of it. I tightened and I was at 18psi. I tightened it some more yesterday and now I'm at 22. I was bit scared to get on it today. I wanted make sure I got the car home in one piece until I saw an Audi S5 take an entrance ramp fast. I decided to also without thinking but 22 is probably ok. The new turbo doesn't spool as fast but it pulls harder up in the rev range. I'm hoping to get it to hold 25 psi. I'm hoping the motor will hold too.

[draggin50]

Probably getting close to finding out the limits of the little engine! I bet it's fun though!

[PKFIRE]

23 psi 1st gear and 24 psi 2nd gear tonight. Not sure where 3rd gear will be at. I want to turn it up more but I think I need to make some passes first before I destroy the thing. Who knows maybe it will be just fine with a bit more boost.

[draggin50]

Haha only one way to find out!!

[NXcoupe]

Cool project! You ever watch videos of the gold brick on youtube? That thing was flying. I'd like to see your car make a pass. I think your project is pretty cool.

[PKFIRE]

Thanks! The motor just keeps chugging. I've beat on this thing since 1997 and ran it low on oil plenty of times in its life. The motor keeps surprising me,lol. I really need to get another bottom end just incase. I do want to run 13.2 or better with this block before I replace it though.

Yeah, he made into the 9s this year over 140 mph with a dohc 2.3 liter redblock and a th400 transmission.

[PKFIRE]

Ok it's to 25 psi now. I had to add another clamp to hold another vac hose to the intake. Once it popped off it took away my fun. Well there's always tomorrow. I wish I had time Friday to run it.

[PKFIRE]

COMPRESSOR SPECS:T04S housing flow: 61 lbs/min 781cfm .70 A/R housing 60 TRIM wheel TURBINE SPECS:T3 .63 A/R housing HIGH FLOW 76 TRIM stg 3 wheel

I have an opportunity to run this Garrett turbo, I'm not sure if it's worth it because my head flows so low. I'm not 100% sure. I could probably run this on my cobra and be more than happy.

[PKFIRE]

I pulled about 200lbs out of the car. I knew the seats were heavy but 45 lbs for a single bucket seat is a ton. I wish I could take out the driver seat. I may have to put weight back in if the one rear tire starts spinning. I do have lighter front wheels but I should replace the tires before I race with them.

[NXcoupe]

Wow that's heavy. Mustang seats are similar tho. They are very heavy. I bought an LX hatch yesterday to get the engine out of it for mine. I'm going to toss bearings and maybe rings in it for the time being. I think it will take 20 psi eventually without an issue. I will need 60 lb injectors at that point tho.

[PKFIRE]

Blowing smoke rings and spraying antifreeze on my first pass. I think I blew the head gasket. I'll post as soon as I find out.

[redfirepearlgt]

Sorry to hear that Joe, was looking to see it make a low 13 pass. I saw the white smoke coming out of the exhaust and wondered if it lost something. Hope you can get it back together cheap enough.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0624162245a_zpswcaqmhq8.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0624162245a_zpswcaqmhq8.jpg.html)

I talked to my wife last night and realized I have two new head gaskets sitting in my garage and enough upper gaskets for a top end rebuild. This maybe a cheep fix.

[PKFIRE]

Tore the head off today. It was just a blown head gasket. I'll put it back together this week. I'll post pictures later.

[PKFIRE]

I pulled the spark plugs one by one front to back and after pulling the second one I was surprised how clean they were. I was getting bit nervous that maybe I did lock the motor up but the last plug was cover in antifreeze and the spark plug opening started draining antifreeze out of it. That was at 11am today.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0626161121_zpsjd4km90j.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0626161121_zpsjd4km90j.jpg.html)

So after a buddy helped push my car in the garage I pulled the head off. Took about 30 minutes. I found the bad gasket. I'll just replace it probably this week. My 1/8 Mile speed went up 3 mph but that's probably the same time this happen because I think it went on top of second. My brother said timing usually pops head gaskets. I'm wondering if this is my issue and I need to take some timing out of it.
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0626161353a_zpsvavd0z3g.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0626161353a_zpsvavd0z3g.jpg.html)
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0626161403_zpswluaibs2.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0626161403_zpswluaibs2.jpg.html)

[redfirepearlgt]

good news Joe. Glad it was that easy for ya. Hope to see that thing go 12's soon.

[PKFIRE]

good news Joe. Glad it was that easy for ya. Hope to see that thing go 12's soon.

Thanks Chad, I'm going to fix it and probably try again in August or September. I've been wanting to put a stereo system back into it. I keep putting it off to get it faster. I really just want to just drive it and I spend so much time tinkering with it I really should focus on exercising and watching tv a bit more, haha.

[NXcoupe]

Do you have a wideband on it? Wonder if you are running out of fuel, going lean? Pull 2 degrees out if you can.

[redfirepearlgt]

Thanks Chad, I'm going to fix it and probably try again in August or September. I've been wanting to put a stereo system back into it. I keep putting it off to get it faster. I really just want to just drive it and I spend so much time tinkering with it I really should focus on exercising and watching tv a bit more, haha.

I thought watching tv was exercizing. :confused:

[PKFIRE]

Haha, tv is the only thing missing from my desk body workout!

I started checking the motor further today. I found that none of my rods are bent. The stroke is right at 80mm which is stock. I cleaned my head and inspected it further. It has pitting around where the firing ring is. I'm going to have it resurfaced and I contacted the person who burnt me a ekz timing chip. I asked him to take a couple degrees out. Mid 13s isn't bad for a older car that ran 18s. I'm going to keep it here for now and maybe in future do a v8 swap.

[draggin50]

Remember a guy from here years back that went by Mailman? Had a 5.0 Volvo swap. Super cool guy and turned out some nice old cars.

[PKFIRE]

Remember a guy from here years back that went by Mailman? Had a 5.0 Volvo swap. Super cool guy and turned out some nice old cars.

I do remember him and I've talked to him in the infancy of my project. I really like how older 5.0s sound. I'll probably end up going LS 5.3 since they are a dime a dozen and built pretty strong.

[PKFIRE]

Do you have a wideband on it? Wonder if you are running out of fuel, going lean? Pull 2 degrees out if you can.

Yes, I was running 8.33:1 when it happened according to my aem wideband. I'm going to have 2 degrees taken out on my next tune.

[draggin50]

I do remember him and I've talked to him in the infancy of my project. I really like how older 5.0s sound. I'll probably end up going LS 5.3 since they are a dime a dozen and built pretty strong.

Its been a while since I seen or heard from him. Really good guy.

Its hard to beat the LS for the price and the power they make and will hold.

[PKFIRE]

You can find them in junk yard all day long and a shipped running one isn't too bad in price either. If I could lift an entire motor it would be only 54.99 July 17th at Pull and Pay.

[PKFIRE]

The head is at the machine shop for a little bath, valve check and resurface. They said they can put larger valves in but I must restrain myself. A junkyard is motor is cheaper to buy than some more cfms.

[draggin50]

You can find them in junk yard all day long and a shipped running one isn't too bad in price either. If I could lift an entire motor it would be only 54.99 July 17th at Pull and Pay.

That would be nice if you could carry one out!

[PKFIRE]

530 lbs motor, I wonder what the steriod cost to value ratio would be?

[draggin50]

Can 2 people carry it out?

[PKFIRE]

Maybe, I'll have to look into it.

[PKFIRE]

Looks like 2 people would be 54.99 x 2 plus core charge.

[PKFIRE]

Took the Cam out and sent it to get resurfaced and checked.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0628161900_zpskjn4mfhy.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0628161900_zpskjn4mfhy.jpg.html)

I got it back today.
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0701161611_zpsvhhfax6t.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0701161611_zpsvhhfax6t.jpg.html)
I ended up putting the cam back in and getting the Brick on ramps. I'll install the new head gasket soon. If all goes well then I'll pay 10 dollars for a new chip to get burnt with 2 less degrees of timing.
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0701162208_zpszimso8gk.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0701162208_zpszimso8gk.jpg.html)

[draggin50]

I wish I had your motivation!!!

[PKFIRE]

I wish I had your motivation!!!

Haha! I just find a block of time and yell at myself to get off the couch. This doesn't always work. I thought I'd go running today. I failed miserably.

[PKFIRE]

I put the head back on, mounted the intake and exhaust manifold. Then did the timing. I'll finish it up when I get new v belts and plugs from Rock Auto. I hope to have it running by the end of the week.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0704160926_zpsudmz9hxs.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0704160926_zpsudmz9hxs.jpg.html)

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0704161422_zps5cimpdlv.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0704161422_zps5cimpdlv.jpg.html)

[PKFIRE]

I got it running tonight. I did a compression test from front to back cylinders. 105, 118, 133 & 135 cold. I shot some oil in first cylinder and it went to 116. I'll just drive it and probably grab another short block for it.

[2Fast4You]

Good to hear some progress is being made Joe.

[PKFIRE]

Good to hear some progress is being made Joe.

I wanted it running over the weekend but between a late postal arrival and then needing a new valve cover gasket because the one I was going to reuse fell apart before I even tried putting it on pushed it back a few more days. I need to adjust the idle and I should be good to drive it.

[draggin50]

Which Volvo head was they swapping onto the Ford 2.3?

[PKFIRE]

http://m.ebay.com/itm/Volvo-B234f-CONVERTED-Ford-2-3-Turbo-16v-SVO-XR4Ti-2300-/160519943726

It flows a ton more Cfm. It takes a pretty modified 8v volvo head to come close and the head I'm using now only flows half as much. Thinking about building a ford 2.3?

[2Fast4You]

How is the limited slip diff install going?

[PKFIRE]

How is the limited slip diff install going?

No where at the moment. The car really isn't running well. Once I figure out I'll probably start working on it.

[NXcoupe]

I'm wondering if you bent a rod like I did? I had a cylinder that was low as well, but the head gasket wasn't damaged at all. I can't wait to get the engine out and apart to see what failed. Ever thought about putting a dohc engine in yours with the turbo?

[PKFIRE]

I'm wondering if you bent a rod like I did? I had a cylinder that was low as well, but the head gasket wasn't damaged at all. I can't wait to get the engine out and apart to see what failed. Ever thought about putting a dohc engine in yours with the turbo?

I measured the piston stroke with calipers and the measurement was right at 3.14" or 80 millimeters on all cylinders. I didn't remeasure my valve shim clearance. I wonder if the valves are not closing all the way. I'll check that this weekend. As for dohc motor I have thought about it. The Money involved in doing it is fairly expensive. I'd probably part my car and go lsx, 5.0 or 350 and it would be cheaper.

[PKFIRE]

It has low vacuum at idle and goes up if I give it gas. I either got the timing wrong, gasket leak, incorrect valve setting or the rings are not sealing well. I'll check for leaks with a pressure tester tomorrow and check valve clearance sometime soon.

[PKFIRE]

I'm going to probably put new rings in it. I'm planning on going to save up for a whipple, tvs or KB for the Cobra. In the mean while I'm going to start selling some parts off this I don't need and whatever else I got for one. I'll just keep this Volvo a 13 second car for now.

[redfirepearlgt]

I'm going to probably put new rings in it. I'm planning on going to save up for a whipple, tvs or KB for the Cobra. In the mean while I'm going to start selling some parts off this I don't need and whatever else I got for one. I'll just keep this Volvo a 13 second car for now.

Still quicker than a lot of GT 4.6 2V's with bolt ons and some 3 valves.

[PKFIRE]

Still quicker than a lot of GT 4.6 2V's with bolt ons and some 3 valves.

It just as fast as I hoped. Heck maybe after some rings It maybe faster. Still is a fun project without the worries of huge $$ signs if something goes terribly wrong. I'm going to put building this 4 cylinder on back burner though.

[draggin50]

Its still cool to see this car run as good as it has! Impressive for sure!

[PKFIRE]

Its still cool to see this car run as good as it has! Impressive for sure!

I'll still run it. I'm at a point where the build is getting more costly than I intended for it. It's still fun to get the locals confused that a old brick can run pretty decent with mostly oem parts.

[NXcoupe]

This is one of my favorite projects. I need to tear my donor engine down this weekend. Going to have Oreilly's get some rings and bearings in for me, then do the hone and carwash block clean, then assemble it. I'd like to do springs and valve job, etc, on the head, but we will see how that goes. This engine ran and did not smoke a bit, so hoping it will be a good runner and last a long time until I can build a forged shortblock with ported head.

[PKFIRE]

I really enjoy you're project also. I'm sure I'll get itch again to do something different to the car. Having a desk job makes me want to work with my hands when I get home somedays. The Cobra I would never put EBay and junkyard stuff in it. More of a great bolt on car that I want to keep pristine for years to come. I now and again think about going 2011+ Mustang or a new RT challenger but I don't think it would make me any happier.

[NXcoupe]

I like reading your project as well. Gives me hope that mine will run a decent et when I do get it to the point that I can race it. Right now the bellcrank clutch linkage is crap and delays the release of the clutch from all the stuff flexing. I want to go to a turbo coupe hydraulic setup using the Mcleod master and TC slave cylinder. I think that will speed the release and allow me to shift it the way I want to. Any progress on yours?

[PKFIRE]

I haven't made too much progress since I strained my shoulder I keep reinjuring. Luckily a MRI shows I didn't tear anything.

The progress I did make is that it not pulling too much vacuum to stay running at base idle. There is a bunch of blow by now but it's not smoking. The compression was low on two cylinders. I'll either install new rings in it or if my buddies brother-in-law sells me a Volvo motor that his grandfather rebuilt before he passed away for the right price I may just do that. I'm hoping it's the same motor because I haven't gotten that confirmed yet.

[PKFIRE]

I'm back at it again! My shoulder is getting better finally. I'm tearing out the bottom end and probably getting it bored and honed. The bore Diameter is spot on according to my bore gauge but there is step/groove at the area where the rings stop at right at full upstroke. It would be good to get this cleaned. I wonder if I could just run a ball hone and get it smoothed out. I've only honed one motor and plus one cylinder before this. I didn't have to do much work on those motors because the bores we're in decent shape. Maybe any of you guys can chime in before I decide to take it to a machine shop next week.
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0827161634_zpsghhc7x5y.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0827161634_zpsghhc7x5y.jpg.html)

Just checking if my engine lift was big enough to reach.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0829162213_zps1vndbi9g.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0829162213_zps1vndbi9g.jpg.html)

[draggin50]

Ring ridge cutter would take care of it. Probably a little easier and quicker too.

http://www.ebay.com/itm/like/331913467705?lpid=82&chn=ps&ul_noapp=true

[PKFIRE]

I just found out autozone has one in their borrow a tool program. Thanks for the info! As far as I can tell it's all I can see wrong with bore. I'll see more once I get the pistons out.

[draggin50]

Good to hear! I think they all get the same ridge over time.

[PKFIRE]

Pulled the motor yesterday. The motor is pretty dirty. I'll start tearing it down soon.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0904161534c_zpsajydo1v2.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0904161534c_zpsajydo1v2.jpg.html)
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0904161545a_zpsw9siycsk.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0904161545a_zpsw9siycsk.jpg.html)

[PKFIRE]

Taking the assembly apart so far everything looks good other than the cylinder bore looking kinda of glaze other than the typical cross hatch. I think I maybe able to just hone it and put it back together.

[PKFIRE]

This weekend I'm going to finish taking the rotating assembly apart and check the bores to see how out of round they are. I hope they are in spec because std rings are easy to find and much cheaper than oversized.

[PKFIRE]

This upcoming week I'm taking my motor to the machine shop. If the block needs bored I'm going to need to get new pistons. So I'm trying to decide at that point I just get forged pistons and h beam rods. If I do that then that opens the door for future mods. If I just go with new cast pistons I would just leave it where I've gotten it. I guess I will have to decide soon.

[draggin50]

Best bet is to go ahead and do it while its apart. You know that you will continue to do mods and that will give you more options in the long run!! I guess it all depends on what the future holds for it.

[PKFIRE]

Yeah it's the best thing to do. Next step would be better engine management, transmission, exhaust manifold, fuel pump, turbo and more head work or 16valve swap. I could go 5.3 now but then lots of downtime and fabrication but I would have to modify a 5.3 to make it faster than what my car is now. It would be so much easier and faster to just put a tvs in my Cobra and do a basic rebuild on the Volvo. Though I would probably kick myself when I get an itch to go faster in Volvo again if I didn't upgrade the bottom end.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0910161352_zpsyqegzwmb.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0910161352_zpsyqegzwmb.jpg.html)
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0910161353a_zpszueuvcmo.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0910161353a_zpszueuvcmo.jpg.html)

Tore the motor down after lunch.

[PKFIRE]

Pistons are wore out. A Volvo engine builder said that .004 or larger ring groove clearance would cause excessive blow by. 0.004 fit in between all the pistons top grooves. It should be 0.001 to 0.002 clearance.

[redfirepearlgt]

Dumb question. What is that shaft next to the crank in the box?

[draggin50]

Looks like a balance shaft.

[PKFIRE]

Accessory shaft, it drives the oil pump and the distributor.

[redfirepearlgt]

Gotcha.

[PKFIRE]

Tomorrow I'm taking my motor to machine shop. I talked to various performance vendors for this motor. I learned the stock rods are good to 350whp, stock pistons are good to about 500whp and the block is good to about 700whp before it needs modified.

I'm thinking about just h beam rods and new factory pistons. They said that the custom order pistons have better geometry since the rod is longer and the piston rotates in the block more easier. The one thing is those forge pistons are 4-6 weeks out and 600-800 dollars. Stocks around 300 oversized. H beam Rods are about 400 with arp bolts

[draggin50]

That sounds like a good plan though. I cant believe that the stock parts are that good but that's impressive!

[PKFIRE]

There are some 6 second drag cars overseas that run 6 second quarter mile runs with the old 2.3 block.

[PKFIRE]

Ahh, I need a new Block. The block needs bored .030 minimum and the limit is .024 for turbo applications. I guess I'm on the hunt for one now.

[draggin50]

Man that sucks! Is there any stock blocks that will work that are stronger? I know you said the block was good for around 700. Im sure if you get to that point, you would upgrade more than just the block though.

[PKFIRE]

http://www.maxxtuning.eu/customer-cars/tuning-maxxecu/681whp-volvo-945-turbo--johan/

I guess with good head work you can get these sohc's to flow 700 whp. Here's one making 681 whp on E85. I don't know any specifics on what blocks are out there for it. I found a penta boat block that I may buy. I believe they have forge cranks but this will be a bare block. The 1993+ B230s have oil squirters. I never thought about making much more than 350 whp in this car.

[PKFIRE]

I located a few motors. I should be picking one up next week. The guy is ok just giving it to me. He said if I feel like it I could give him a smaller car part. I couldn't follow all the builds but he's building a 700 plus horsepower big block GM Volvo. He has another built small block Ford Volvo also. Pretty cool stuff.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/0924161513_zpsvgihjgkn.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/0924161513_zpsvgihjgkn.jpg.html) I picked this short block up today for 135 dollars in Springfield Ohio from a guy who built a 16 Valve B230 engine for his 240. He decided to buy a 1960s Volvo Amazon and he is parting his build. Lucky for me he cleaned and painted this motor and added a an10 drain tube. I'm going to add stronger rods to it. He even cut reliefs for a 4 valve head into the pistons from a rental jig. I should be getting another motor soon to build on the side. I guess I'm not done building it yet.

[redfirepearlgt]

good deal. will it make a pass this year ?

[PKFIRE]

Possibly, maybe later next month.

[NXcoupe]

It's gonna fly in that playskool romp around! Lol. J/k. I'm jelly, your's is moving along. I haven't touched mine at all. Busy on customer stuff.

[PKFIRE]

Haha! I'm probably going to have an additional motor and transmission some time soon. Maybe I can wedge it into the cozy coupe! I just want to get it back on the road. It will be nice looking at a motor that isn't caked in 26 years worth of grease.

[PKFIRE]

I decided to go ahead and get the stock 13mm rods resized and will get them back next week. Tomorrow I'm dropping the pistons off for rebalance tomorrow. I'll start putting the motor back together next weekend. This weekend I'm going to clean up the bores.

[draggin50]

Your a machine! I wish I had your motivation!

[PKFIRE]

I pulled the rods and pistons out tonight and removed pins from the pistons. So they are ready for tomorrow now. I ordered a ball hone that should get to my house by Sunday. I'm ready to start actually stop tearing things apart and actually start putting things together.

[PKFIRE]

So I pulled the crank and found out the motor I got was a odd ball. I got the newer stronger block with the weaker rods. I'm really happy about this. The guy who sold me the motor was wrong about the block which is fine with me.

[PKFIRE]

I took my first measurement after I reamed one cylinder. 3.783"
std piston range. 3.7795-3.7897.

Let's see how the others turn out tomorrow and after a good hone.

[PKFIRE]

I took the borrow the tool at autozone ridge reamer to good use tonight. I'm going to ball hone this weekend and start putting the motor back together.

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1004162045c_zpsae24yiaz.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1004162045c_zpsae24yiaz.jpg.html)
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1004162107a_zpse8egdfxp.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1004162107a_zpse8egdfxp.jpg.html)
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1004162112a_zpsjzgsawep.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1004162112a_zpsjzgsawep.jpg.html)

[draggin50]

Looking good! You going to use your old rods and are they the stronger of the 2?

[PKFIRE]

Looking good! You going to use your old rods and are they the stronger of the 2?

I decided to use my old 13mm rods. They are good to 350 whp vs 250 whp for the weak 9mm. Right now they are at the machine shop getting resized.

[PKFIRE]

Next week I'll be getting back my block, rods, piston and crank from the machine shop. I couldn't get the ridge eliminated with hand tools. I'm really ready to get the motor back in. One thing I did a few years ago was reduce my compression from 9.8:1 to 8.5 to 1 by having my head bowl blended. I ended up getting oversized turbo pistons that will take it down to 8 to 1. They discontinued .024" oversized NA pistons for B230 motor so it was my only choice other than expensive forged pistons.

[draggin50]

Good to hear!

Sucks you had to drop compression so much. Im sure you can make it up though with added boost.

[2Fast4You]

Should be even more fun!

[PKFIRE]

Good to hear!

Sucks you had to drop compression so much. Im sure you can make it up though with added boost.

I had a lot of blow by in the original motor. Maybe even with the turbo pistons it will have better compression than it did before.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1102162213_zpsftjoh5du.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1102162213_zpsftjoh5du.jpg.html)

Starting to put the motor back together. Crank, main bearings and piston assembly number one is in now. I'm planning on putting piston 2, 3 and 4 in tomorrow. Hopefully I'll have the bottom end finished this weekend.

[draggin50]

Your on it!!! How does the new pistons look compared to the old? Still a stock cast piston?

[PKFIRE]

The pistons look just like the old ones other than being little more dished. They fit so snug in the bore.Yes they are still stock cast but .024" oversized.

[PKFIRE]

I got 3 of my 4 pistons in. I managed to snap a piston ring on piston 3 during install. I ended up having to buy another oversized piston complete assembly since no one carries them. I should get it early this week and start mounting various parts on the block. Today I repainted the block since when the machine shop cleaned it the ended up removing the paint.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1106161450_zpssdvcsgbc.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1106161450_zpssdvcsgbc.jpg.html)http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1106161741a_zpsoc91wman.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1106161741a_zpsoc91wman.jpg.html)

[draggin50]

Looking good! Sucks you cant just buy a ring set.

[PKFIRE]

Thanks, I think I can get custom ones made. The dealer said it would probably take 3 weeks to get them. I didn't feel like waiting so I decided to just get a piston.

[draggin50]

Don't blame you there! That's crazy!

[PKFIRE]

The bottom end is finally back together. I'll hopefully start installing it into the car this weekend.


http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1109162234b_zpsrkmn6vye.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1109162234b_zpsrkmn6vye.jpg.html)
http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1109162234_zps4m5acx8b.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1109162234_zps4m5acx8b.jpg.html)

[draggin50]

That looks good!

[PKFIRE]

Thanks! I just ordered another flex plate. The current one is missing a tooth. I guess I need to wait another week to drop it in.

[redfirepearlgt]

looks to nice to put in that toaster with wings. Well done. How about a glass hood?

[PKFIRE]

Haha Chad! Thanks. Glass hood??? No hood and saran wrap is much lighter and cheaper!

[NXcoupe]

Looks sweet!

[NXcoupe]

I took my first measurement after I reamed one cylinder. 3.783"
std piston range. 3.7795-3.7897.

Let's see how the others turn out tomorrow and after a good hone.
Wait, so the range is .0102"? Thats huge! Most are .002" range. Maybe .003. Ten thou is a lot.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/Screenshot_2016-10-10-07-00-44_zpspoaok0ip.png (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/Screenshot_2016-10-10-07-00-44_zpspoaok0ip.png.html)

Check out bore standard. There is a bunch of wiggle room.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1111162232_zpsek4kck4d.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1111162232_zpsek4kck4d.jpg.html)

Steamed cleaned my engine compartment tonight. It's not perfectly clean but it is 100x better than the greasy mess it once was.

[NXcoupe]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/Screenshot_2016-10-10-07-00-44_zpspoaok0ip.png (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/Screenshot_2016-10-10-07-00-44_zpspoaok0ip.png.html)

Check out bore standard. There is a bunch of wiggle room.

I hear ya, but read the next group to the right. It's.0004" spread. I believe that .0102" spread is a misprint possibly.

[PKFIRE]

Nice catch! Above there is a 96.00 to 96.03 mm spread which is 3.7795" to 3.8070" or .0012" spread.

[draggin50]

The piston clearance is a lot bigger too compared to the AC125A. Wonder why that is?

[PKFIRE]

I'm not entirely sure but I wonder does the diameter of the piston play a role in it?

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/Mobile%20Uploads/1114162156_zpsefetz707.jpg (http://s963.photobucket.com/user/pkfire240/media/Mobile%20Uploads/1114162156_zpsefetz707.jpg.html)

I had a short window before fiber to put on the new flex plate and lower the motor into engine compartment. I'll need to raise the transmission to line up the motor. Tomorrow I hope to have it mounted.

[NXcoupe]

Good job!

[PKFIRE]

Getting closer, mounted the crossmember, finished bolting up the transmission and put the head on today.

http://i963.photobucket.com/albums/ae119/pkfire240/1125161612b_zpsktzwsg4x.jpg (http://s963.photobucket.com/user/pkfire240/media/1125161612b_zpsktzwsg4x.jpg.html)

[draggin50]

Making quick progress! I cant even get in the garage let alone work on something!

[redfirepearlgt]

^^^ WHOA!!! HOLD ON THERE!! You have a garage the size of three of my houses. I've seen the photos. There's no way you filled that thing already. NO WAY!

[draggin50]

^^^ WHOA!!! HOLD ON THERE!! You have a garage the size of three of my houses. I've seen the photos. There's no way you filled that thing already. NO WAY!

Haha my boy has took over the back half and has it full. I meant I was to busy or to lazy!!

[PKFIRE]

I always heard if you buy a bigger house you end up filling it up. I guess the same thing happens with a huge garage.

[draggin50]

That's the truth! 30x69 garage, 24x10 lean too, and 12x16 shed and its all full! I don't know how I got it to fit in a 24x30 garage and the shed before.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/1126161549_zpsycbottol.jpg (http://s963.photobucket.com/user/pkfire240/media/1126161549_zpsycbottol.jpg.html)

I spent part of the day cleaning all the caked on grease on the intake. Glad that is over.

[PKFIRE]

I made some more progress last night. I hope to have it running this weekend.
http://i963.photobucket.com/albums/ae119/pkfire240/1129162333a_zpsfebj1xpb.jpg (http://s963.photobucket.com/user/pkfire240/media/1129162333a_zpsfebj1xpb.jpg.html)

[draggin50]

Moving along nice! Looks pretty good!

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/1203161708b_zpslmgkxsjw.jpg (http://s963.photobucket.com/user/pkfire240/media/1203161708b_zpslmgkxsjw.jpg.html)

Got the turbo and timing belt on today. I would like to get the rest done tomorrow but I'm not sure if I have time. It will be soon though.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/1205162152_zps4jlc3pdg.jpg (http://s963.photobucket.com/user/pkfire240/media/1205162152_zps4jlc3pdg.jpg.html)

One more day of working on it I should be ready to start. I should have it running by the weekend.

[PKFIRE]

http://i963.photobucket.com/albums/ae119/pkfire240/1207162150_zpscldkm6ov.jpg (http://s963.photobucket.com/user/pkfire240/media/1207162150_zpscldkm6ov.jpg.html)

It's finally back together. I'll try starting it later this week.

[redfirepearlgt]

Looks good. Sure are a lot of hoses on that thing.