240GLT T5 conversion

[antz]

Well guys I thought Id better start a thread about my new 245 and plans.

I bought it off eBay a few weeks back and had a 5 hour road trip down to Ipswich to collect it followed by its first modified car cruise the same night.

Shes a 1988 GLT with the 2.3 engine and horrible automatic gearbox. Only done 127k from new. The last owner had her a year and covered 15k miles so I know shes reliable. (She went to Le mans in June!). He also spent quite a lot on her including adding Kilen 40mm lowering springs and Monroe gas shocks.

My plans are to rip the whole 2.3 engine and automatic gearbox out and drop in a 850 T5 engine just for some fun! Im not sure on modifications yet but Ive already got a 960 sump, oil pickup pipe and engine mounts on the way from Tomcat and Ive bought a S60R turbo manifold for it too. Ill also be looking out for a 16T turbo at some point then some IPD sway bars, polybush it right through, add some upper and lower strut braces with an adjustable panhard rod.

Here it is the day I bought it as she came off ebay:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01304.jpg

First job was to add my Nardi Torino steering wheel which I bought from a scrapyard for £3.60. YEP £3.60!
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01357.jpg

Then I removed the roofrack because quite frankly, the wind noise was horrible and it weighed a tonne.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01323.jpg

Then off came the spotlights as they werent my thing, headlight wipers as I dont like them and I changed the indicators to some clear ones from the USA with a compliment of some V40 side repeaters.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01358.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01359.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01360.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01316.jpg

Then onto the towbar and electrics. I decided to ditch the towbar as I wont need it and its just dead weight. A few hours heaving and swearing then an almighty scream at the wiring which was a sea of scotch locks and random wires and I was left with this. I need to brace up the plastic rear valance as the tow bar had twisted it though.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01317.jpg


My next step is to get the old girl up my unit when I get the keys next weekend and then get on with removing the engine and prepping for the T5 conversion whilst also keeping my eyes peeled for a 960 M90 gearbox which I need for it.

It wont be a quick conversion cos im paying off some debts and trying to do this all myself learning as I go along or roping in whoever I can to help out in exchange for favours and beer tokens. :)

[cherry1809]

I love 240's. If I had the balls I'd do a full on B230 245 16v turbo on BBS 17's... Keep us posted.

[Tomcat]

Gotta say that just from the jobs you've done so far you've taken years off it, oh...the sump and stuff got removed today so I've just got to wrap them up for you and they're ready to go.

[antz]

Gotta say that just from the jobs you've done so far you've taken years off it, oh...the sump and stuff got removed today so I've just got to wrap them up for you and they're ready to go.

Thanks mate! Let me know how much I owe you for postage!

The only thing on the exterior I would possibly change now would be some rear lights from PFS that are red, white, white, red to get rid of the orange but thats not on my immediate list.

[t5 pete]

looking good if theres anything i can do just give me a shout

[antz]

looking good if theres anything i can do just give me a shout

Thanks Pete! Ill definately need to rack your brains at some point! I cant really do a lot until I get the keys to my unit next weekend.

[The Flying Moose]

Looking good so far, I think its definately going to be a "learning experience".

I have only ever seen one other conversion done to a 240 which was in PPC and it looked fantastic.

Best of all can you imagine the look on drivers faces as an F reg Volvo comes screaming past.

[T5frankie]

i have always thought of owning a t5 245 awesome mate can't wait to see how it turns out

[t5_monkey]

I wanna do something similar with a crazy 2.3 turbo upgrade :)

I hear that the T5 is a bit big and heavy for the 240? still... will be totally awesome when you get it done.

[antz]

I wanna do something similar with a crazy 2.3 turbo upgrade :)

I hear that the T5 is a bit big and heavy for the 240? still... will be totally awesome when you get it done.

Cant be any worse than the 2.3 N/A cast iron red block engine thats already in it! The quickest thing about it is the fuel gauge. Plus according to curb weights online a 240 Estate only weights 9kg more than a 850 T5 estate.

TFM you dont happen to have a copy of that PPC mag I could grab a photocopy of or buy off you for reference do you?

Thanks for the comments guys. Its really spurring me on to get my arse into gear. Money is the main issue though (as with everything) so Im buying bits as and when I can afford them and recruiting as much slave labour (friends) as I can during the build!

[The Flying Moose]

Cant be any worse than the 2.3 N/A cast iron red block engine thats already in it! The quickest thing about it is the fuel gauge. Plus according to curb weights online a 240 Estate only weights 9kg more than a 850 T5 estate.

TFM you dont happen to have a copy of that PPC mag I could grab a photocopy of or buy off you for reference do you?

Thanks for the comments guys. Its really spurring me on to get my arse into gear. Money is the main issue though (as with everything) so Im buying bits as and when I can afford them and recruiting as much slave labour (friends) as I can during the build!

Ill dig it out and grab some pictures for you mate. No problem sending photocopies either. Ill see if a photo is legible first though.

[antz]

Thanks dude! If you have the date of the issue ill try and get one off ebay or something too =)

Just claimed dibs on an engine and ECU from Smithness which I need to pickup sometime and Im planning a major scrapyard run this weekend for whatever else I can get that will help me such as a wiring loom!

[WOODY T5]

No probs mate it's yours hope u enjoyed the little run in me car?

[The Flying Moose]

Thanks dude! If you have the date of the issue ill try and get one off ebay or something too =)

Just claimed dibs on an engine and ECU from Smithness which I need to pickup sometime and Im planning a major scrapyard run this weekend for whatever else I can get that will help me such as a wiring loom!

I have just been on the phone to smithness, he did mention you.

Just taken a few pictures of the mag once I found it. Demeber 2010 issue. If they are not legible ill take some more tomorrow during daylight.

Just seen your not too far from my playground either. Will have to catch up sometime soon.

What did you think of smithness's car? Does clinging on for dear life ring a bell? According to him you were!!!

http://i1115.photobucket.com/albums/k549/EMLYNT5/P7250024.jpg

http://i1115.photobucket.com/albums/k549/EMLYNT5/P7250025.jpg

http://i1115.photobucket.com/albums/k549/EMLYNT5/P7250026.jpg

http://i1115.photobucket.com/albums/k549/EMLYNT5/P7250028.jpg

[antz]

No probs mate it's yours hope u enjoyed the little run in me car?


I have just been on the phone to smithness, he did mention you.

Just seen your not too far from my playground either. Will have to catch up sometime soon.

What did you think of smithness's car? Does clinging on for dear life ring a bell? According to him you were!!!

I loved the ride out in your T5! Its got me thinking about 19T turbos, MBC's, bigger injectors and MORE POWER!!!!

Yeah sure thing we will have to catch up! Always good to meet more Volvo lovers than all the haters who take the piss constantly. Thanks for the pics of the mag! Im going to try and get myself a copy if I can find one :)

I learnt a long time ago if you are going to cling on for dear life then fold your arms and grip the seatbelt as hard as you can! That way you dont look so much of a fool as your grasp wildly for something solid going AHHHHHHHHH!!!!!

Its one hell of a machine and goes like a flipping rocket! Definately a whites of the eyes moment! My T4 feels slow now :( :hilarious

[antz]

Well today I dragged a couple of mates with nothing better to do over to U-Pull-It near York to try adn get some parts for this project.

First up was an engine bay loom which althought it was still there, some tit had cut right a big chunk of it whilst trying to remove some uselessly boring piece of ABS kit although we can repair that.

So after 3 hours we managed to extract a full engine bay loom complete with fuse box that we can strip down, throw bits away from and splice into the 240s loom.

I had no idea how heavy and massive the loom would be!

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01373.jpg

I also got a couple of interior switch blanks for the 240 and a spare T5 engine cover for re-painting.

Also yesterday I received the keys to my new industrial unit which is now home to Porject 240 so a great amount of time has been spent removing all the old **** the previous occupant left, dying of shock at the wiring of the place which Ive complained about and demanded be fixed as its too dangerous to use the power at the moment and I bought an engine hoist.

[t5 stealth]

just a thought.........................
your getting a 960 sump for your t5 engine ?



960 is a 6 cyl engine,t5 is a 5 cyl engine.
the sump may be 1 cylinder too long ?

correct me if im wrong ? :)

[antz]

just a thought.........................
your getting a 960 sump for your t5 engine ?



960 is a 6 cyl engine,t5 is a 5 cyl engine.
the sump may be 1 cylinder too long ?

correct me if im wrong ? :)

You arent wrong! But the sump is the only one suited to a whiteblock for a RWD application so what you need to do is cut a cylinders worth out and re-weld it like this:

http://lh4.ggpht.com/_7EUAij74Ycw/Sa3s_HVqHNI/AAAAAAAATOM/FADtTbRR2qg/s400/7.JPG

[t5 stealth]

now it makes sense lol................cheers

[p fandango]

just out of interest, why is the original T-5 sump no good, is there a crossmember it fouls on or something?

[antz]

just out of interest, why is the original T-5 sump no good, is there a crossmember it fouls on or something?

I dont know to be honest. All the guides say when converting to RWD to use the 960 sump and cut a cylinders worth out and the pickup pipe. I assume its the wrong shape and fouls the crossmember or possibly causes oil flow problems. I imagine T5Pete will know more on this subject cos he is further on with the conversion than I am.

On a side note today I managed to source a 850 T5 rad, s70 t5 inlet manifold, 850 t5 water pump return pipe, 850 haynes manual and a ECU housing and lid all through this site. TOP WORK GUYS!

[t5 pete]

The sump fouls the cross member so that's why u have to use the 960 as there the correct shape just too long

[antz]

Right well things have been pretty slow in the camp whilst I collected bits, moved into my new workshop and got it all cleaned out, painted, powered up, leak free and such. Its not 100% yet but good enough to start playing cars in!

This update is mroe of a LOOK AT WHAT IVE GOT rather than what Ive done but Ill get there! Collecting things is part of the process.

First big step was to get the bonnet off and drain the water out of the system. LET THE GAMES BEGIN!
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01408.jpg

Today I received a nice big pile of parts from Niles which included a T5 Radiator, T5 Water pump return pipe which Ill have to mash together with a 960 one from Tomcat, a S70 inlet manifold and a ECU box.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01419.jpg

My Genuine Volvo upper strut to bulkhead braces have arrived back from the powder coaters but I forgot to get a picture of them.

Then on a side note I went to VW Festival yesterday at Harewood House and inspired by the "Dub" scene I got a couple of stickers from the show purely because one made me giggle and the other might come in handy!
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01420.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01407.jpg

Then today I started removing all the crap that sits on the bulkhead so I could get to the foam and rip all that off. Its no wodner that 240 bulkheads rot out when they are covered in foam and rubber which traps all sorts of crap like this:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01424.jpg

And finally whilst wandering round Halfords the other day I saw these on sale in the old stock pile. Pair of Brand new Sparco 3 point harnesses for £60! They are notmally £60 a piece! (dog not included)
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01416.jpg

Im hoping to get the engine out this week as my dads mate is itching to get started on this. He has offered to do all my wiring which is good of him.

[t5 pete]

its coming all together

[The Flying Moose]

Looking good Antz. The sparco's were definately a bargain.

Next step...engine out! lol

[antz]

I tried to get some work done today but with my T4 going in for an MOT a day early it kind of ruined my plans BUT....the garage lent me a loan car which came in the shape of a 1987 Volvo 240 GLT Saloon! WHAT A COINCIDENCE!

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0001.jpg

My mate did me this sticker the other day for a laugh:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0003.jpg

I started clearing out the engine bay for the engine removal and sorting the wires. Its a bit of a spaghetti junction and labelling everything up with photos so I know what goes where and what it does. In that I forgot to get some pictures.

In the mean time Ive had a pair of half leather Recaros in the loft which I removed from a Rover 820 Turbo a few months back. Paid £36 for the pair from a scrapyard! Decided to roughly drop one in the driver position of the 245 cos the standard ones have a slight twist to the middle and the same lumbar support or a wooden stool.

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0007.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0004.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0005.jpg

and a harness thrown on too:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0006.jpg

Thats another job on the list then. I really like the Recaros in there so as well as the engine and suspension Ive gotta somehow fabricate some runners for these bad boys to go in the car. And fix the rip on the drivers bolster (i used the passenger seat in the photos).

[Volvostorm]

Love the Werther's sticker :D I can't say don't cover it in stickers, look at mine!

Its coming along nicely too

[antz]

Love the Werther's sticker :D I can't say don't cover it in stickers, look at mine!

Its coming along nicely too

Im done with the stickers! I just wanted a few to make the greenhouse windows less boring!

Hopefully get some more time on the engine bay tomorrow.

[Dangerous Dave]

Looking good mate!

I followed the 740 T5 conversion thread on turbobricks a few years back...
http://forums.turbobricks.com/showthread.php?t=132921

[The Flying Moose]

Have to admit I too am a fan of the Werthers sticker.

Where abouts can one be purchased???

[antz]

Have to admit I too am a fan of the Werthers sticker.

Where abouts can one be purchased???

My mate did it specially. If you want one, let me know what colour and I can speak to him and get a price for you?

[antz]

right well today we actually did some proper work! shock horror!!!

Over the last few days Ive done a few jobs to the old 245. First job was to remove the electric window switches which are plain black and impossible to find in the dark. A tip off on the internet was that 940 illuminated window switches were a direct plug and play replacement so down the scrapyard I found some. Literally popped the originals out, new ones in, plugged them in and TADA INSTANT ILLUMINATION!

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01430.jpg

Also fitted a proper radio surround in place of the horrible chipboard one someone had bodged in:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01431.jpg

And my dads mate glen helped out tonight with some engine removal and wiring. We ran out of light in the unit as we simply dont have enough striplights yet but we got everything cleared out the way so this weekend we can attack it and get the lump out.

old man in check and glen in blue!
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01441.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01439.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01442.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01438.jpg

[The Flying Moose]

Looking good antz, keep up the good work. Nice to see your dads motor looking glorious next to the 240!

[antz]

Looking good antz, keep up the good work. Nice to see your dads motor looking glorious next to the 240!

Aye he is just keeping it there whilst he sorts out a few things on it and sells his 4x4! Last night he was underneath scraping the muck out the wheel arches and giving it a good waxoyl! Then he atatcked the exhaust and the back 4 inches of tail pipe well off! WHOOPS!

Hoping to get the engine out of the 240 this weekend, picking up a m90 gearbox on wednesday, hopefully get the engine off Dean as soon as I can too. In the meantime Ive got plenty to do with cleaning the engine bay up, fitting my seats and some rust prevention behind the rear bumper!

[M-R-P]

Superb work there, Won't be long now... The T-5 lump will actually fit won't it? ;)

[antz]

Superb work there, Won't be long now... The T-5 lump will actually fit won't it? ;)

They do fit! The onyl real problem is the dizzy cap as it wants to occupy the same space as the bulkhead. Now I can either recess the bulkhead to create enough room OR go for a standalone system which gets rid of the ECU and empties a wallet very quickly.

I think T5Pete is going for the standalone system but Im going to recess the bulkhead as its cheaper and the Volvo system isnt bad really. It makes it mroe of a plug and play job too rather than faffing with custom mapping.

[M-R-P]

Good choice, the job looks hard enuff without making it harder. Funnily enough, earlier I was dropping some lifting brackets to a haulage yard out in the a*sehole of the new forest and what did I see being HIAB'd off a lorry and onto a scrapheap...? a white 245, looked like it had been sat in a ditch for a while!

[antz]

still not got the engine out! Stupid Volvo seem to enjoy making every bolt 9ft long and hiding it behind 10 other items under the car, each with a 9ft long bolt. Spent ages today trying to get it out but in the end, hunger struck so tools were downed.

Did manage to get the front seats out though and the exhaust disconnected.

Going to get the full day on it tomorrow to get the engine out as its all undone and start adapting the Volvo seat runners for the Recaros.

[antz]

FINALLY THE ENGINE IN OUT!!!!!

Got the engine and box out today finally. They really didnt want to leave their home but after undoing a thousand bolts all 9ft long followed by lots of hammering, shaking, hitting, more hammering, swearing and pulling the lot came out!

Also got the full exhaust system off as Im hoping to use a custom 3" stainless system.

So if you know anyone that wants a 2.3GLT engine or auto box for the same, get them to make me an offer otherwise itll be going for scrap

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0032.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0028.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0034.jpg

And as Im fitting Recaros I cant run heated seats. Luckily some spare 240 dash switch blanks I had fitted perfectly over the holes left by the switches.

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0035.jpg

[cherry1809]

Looking good! :)

[antz]

Well Ive had a busy few days collecting parts!

Last Wednesday I went down to pick up my long awaited gearbox. I finally managed to get hold of a Whiteblock M90 manual gearbox and propshaft from a 960.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01454.jpg

Heres a few bits I picked up from The Flying Moose a while back but never got round to photographing. 16T turbo and White injectors.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01455.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01456.jpg

Also swapped the original crappy washer jets on the 240 for some V40 Phase 2 ones that spray a mist instead of a piss poor jet.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01453.jpg

Then by pure luck I managed to find a badly listed Rover 820 Turbo Vitesse frll interior listed on eBay which happened to include the front Recaro seats. A quick bid later and I went to Doncaster today to pick them up for a pricely sum of £40. The drivers side if knackered so its going to become a seat in the unit but the passenger is good so Ill use that as the passenger in the 245 and my previous Passenger seat as the drivers seat as thats a good one too.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0039.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0040.jpg

And I painted myself up a nice engine cover a few weeks ago whilst I was bored:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0026.jpg

[The Flying Moose]

Look good Antz, keep us posted. Will be nice to see it all coming together.

[antz]

Thanks dude! Its a a bit annoying all my updates are just of stuff Ive collected so far but the more I get now the more I dont have to buy later!

Last night my mate also brought me a genuine German Volvo dealership numberplate surround that he got from a German V40 in the scrapyard. It needs a couple of lugs fixing that hold the plate on so I might make some up and plastic weld them on or glue them..not sure yet but itll add a nice touch of euro class to the tailgate :)

Coincidentally Ive just de-activated my Facebook account so I can get on with working on it as Facebook is just a waste of time that was taking up far too much of my life. Im possibly going to push the old girl out tonight and attack the engine bay with some industrial strength floor cleaner to get it all nice.

Ive also been thinking about how to mount the seats on the Volvo runners. Ive got a mock up in my mind of how Im going to do it, its just building the adaptor plates to fit the seats and the runners.

[WOODY T5]

looks like its all coming together now just need an engine now mate ;-)

[antz]

Tonights lovely job was to try and get the engine bay as clean as possible whilst there was no engine in there so I could climb in and move around.

Que a whole lot of de-greaser, some elbow grease, a hose pipe and more water on myself than the car and we got from this:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01459.jpg

to this:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01461.jpg

and after a final wipe down we ended up with this!
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01463.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01464.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01465.jpg

[M-R-P]

Says a lot for these cars when they clean up so well after all this time. Good job mate. :)

[antz]

Says a lot for these cars when they clean up so well after all this time. Good job mate. :)

Im really impressed with how solid she is for a 23 year old car!

The only rust on it is 3inch patch on sill in the drivers door shut as its peppered into a hole.

Theres a couple of surface patches which Ive just dabbed with some kurust and hammerited over. job done!

[biggbn]

wow what a great project..always wanted something like this...keep up the good work bro

[martybelfastt5]

bay cleaned up a treat pity the t5 lump going to hide most of it lol,,,

[Jim S70R]

Thats come up really well, job well done :B_thumb:

[antz]

The last couple of days have been spent drinking coffee...lots of coffee.

In between the coffee I managed to slap some kurust on the tailgate and give it a coat of hammerite to prevent the tin worm attacking it any more.

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01474.jpg

and I finally got round to cleaning up the left over gunk from the foam and rubber that covered the bulkhead. Here it is now:

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01471.jpg

[antz]

more cleaning on the engine bay. IT NEVER ENDS!!!!!

Also fitted the bonnet rubber strip thingy back in plasce after I did some rust treatment on the lip.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC01479.jpg

Then tested out my genuine volvo upper strutbraces which came all the way from Australia

http://i52.photobucket.com/albums/g36/letpigsfly/DSC01480.jpg

[antz]

we have engine!!!!!

Got the engine from Dean on Tuesday night, its done 220k but itll be an ideal tester engine for fitting, mods and if it goes bang then its no great loss for what it cost me.

First job was to start taking off the old bottom engine mount which went in the bin, took off the front cover cos I like the look of seeing the timing pulleys :) and generally get to know a T5 engine by poking it, wire brushing it, wondering how Im going to get it in the bay etc etc.

Also raised it up and dropped the oil out afterwards and as usual I dropped the sump bung AND socket in the oil....muppet!
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0041.jpg

I also managed to source a manual pedalbox which has arrived but my free Sparco pedals wont fit due to the mount screws so I'm going to buy the same sort I had on my old 245 which were ace and fit them instead.

I'm off to the scrapyard on Saturday to try and find a fuel rail and such bits and bobs Im missing.

[The Flying Moose]

Very nice, its the lump from Fridge Movers car which did a 13.9 on the strip.

I have a couple of fuel rails mate if you need one, come to think of it nearly a whole car!

[the young mechanic]

going to be a good car that

[antz]

Very nice, its the lump from Fridge Movers car which did a 13.9 on the strip.

I have a couple of fuel rails mate if you need one, come to think of it nearly a whole car!

Cheers dude! No doubt you have everything I need, I'm running extremely low on cash though after buying the gearbox, all those bits from you and an engine hoist all in the last month. :(

Good to know some history on the engine, Dean did say it was pushing some large power before it was removed from the car! Ive got the ECU to go with it but Im not sure what im doing about ignition and engine management yet so I dont know if Ill be using it. Itll be an ideal tester unit for chopping the sump, fitting and setting everything up and if it runs sweet in the end its a bonus but if it tries to eat itself its no big loss.

[graemewelch]

great project. i might be able to help you with the sump. well can weld it for you but you,d need to cut it

[antz]

great project. i might be able to help you with the sump. well can weld it for you but you,d need to cut it

Thanks mate but Im going to whip it over to Ralloy who do all the alloy fabricating for rally cars near York. Hopefully they can fit it into their schedule :)

[antz]

Well it may seem like progress is slow but I am working my arse off on this. Just the updates dont show it.

The other day I spent 3 hours making brackets for the Recaro seats. First off I stripped the Volvo runners down as much as I could to this:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01494.jpg

And created some brackets like this:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01495.jpg

After bolting it in I discovered a problem, Im too low, too close and too far to the left which is a problem so Im going to use these mounts as the passenger side and have a re-think on how to mount the drivers so Im actually comfortable.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01498.jpg

Also I finally ordered my nice new Pressed numberplates from eBay which were a bargain at £26 for the pair. They come with all the UK complient numbers, are standard font and I didnt have to send off all my documents for them either. Ordered them Sunday and theya rrived today!
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01496.jpg

Slotted nicely into my genuine German Volvo numberplate surround my mate got me from the scrapyard.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01497.jpg

Ive also been in discussion about some engine mounts, a nice man in Germany has offered to make me some so I dont need to weld them which is a bonus.

[JT]

making engine mounts??

tell me more:)

[antz]

making engine mounts??

tell me more:)

A guy over on turbobricks has done this conversion and he developed his own engine mounts that utilise the standard mountings in the crossmember which look like the below. He has offered to make me a pair and ship them to me for a nice sum of money :)

https://lh3.googleusercontent.com/-CcnBsHQJ0DM/Tlxm4kNQ5eI/AAAAAAAAGEE/yL6ajPwQLxA/s512/DSC_0370.jpg
https://lh3.googleusercontent.com/-GxtECUJ4_RU/Tlxmxing65I/AAAAAAAAGEA/mi2-wnD9PnE/s720/DSC_0371.jpg
Just to note, the mounts aren't sitting level in this pic. They only need an extra hole drilled in the xmember.
https://lh5.googleusercontent.com/-5FK64mP3344/Tl7ZKCieRcI/AAAAAAAAGEQ/pI7x7cYuuw4/s720/DSC_0004.jpg

Then Ill need a 240 M46 gearbox crossmember to adapt to look like this:
https://lh3.googleusercontent.com/-R1aWnn6Yk9k/TeWrex3qMfI/AAAAAAAAFWI/otfMhfiCEh4/s720/DSC_0028.jpg
https://lh4.googleusercontent.com/-CtU5wFIgLOk/TegaOeGSWAI/AAAAAAAAFWs/5a4JNq-XHT4/s720/DSC_0031.jpg

[JT]

very smart!!!!

not quite what i had in mind! lol:)

[p fandango]

not quite what i had in mind! lol:)
the "240" in the title is a bit of a give-away it won't fit your 850, you really would be lost without Sam doing everything on your car wouldn't you lol

[JT]

your not the olny 1 who can use a grinder!!:wink:

[LiamT4]

the "240" in the title is a bit of a give-away it won't fit your 850, you really would be lost without Sam doing everything on your car wouldn't you lol

:lol:
I could do with one of those to do stuff on my car!

[antz]

Well progress has slowed since I quit my job so Ill no longer be able to buy nice bits until I get another job but on the bright side I do have the time to do some jobs that dont require money!

Todays job was to sort out some of the horrible under dash wiring and cutting out what has no purpose except to look ugly. Im no car electrician but when a big wad of wires falls down wrapped up in electric tape you cant help but think WTF!?

So I managed to chop out all this which was taped together in a ball and "hidden". I also cut out a stupid "fake immobiliser" the previous owner had wired in to a little light that blinked when a toggle switch was active. This doesnt look like much but there was about 10ft of wire here.

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0042.jpg

Theres more wiring to do but Ill look at that when it comes to graft in the T5 loom.

Also with my car being a stupid automatic I had to swap the pedal box which took 2 hours just to remove. You need the hands of a child and the flexibility of a high class hooker to get to the bolts.

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0043.jpg

New pedal box loosely bolted in then i gave up as I couldnt bear another 2 hours lying in the footwell (note a random wire hangs down. stupid things)
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0045.jpg

Some people may cringe at the fact Im putting Sparco rally pedals on but the original rubbers were knackered, I had a set left from my old 240 like the ones below and the massive accelerator feels like a go-kart pedal! I still need to drill the accelerator pedal though.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC00505.jpg

[martybelfastt5]

thats gonna be some fun!!!

[antz]

well engine mounts on order and the roofrack has been sold to help fund things :)

[M-R-P]

Liking the project so far... keep us posted mate - lotsa pics please :)

[T4Rick]

Thats some nice work mate i will be following this thread

[antz]

well Im trying to do what I can whilst I wait for my engine amounts to arrive and various bits from Tomcat. Until that happens theres not a great deal I can do within the engine department.

Today though I managed to re-fit my 240GLT badge that my mate kindly re-stickied up for me. (the Le Mans badge was on the car when i bought it along with a ticket stub from Lemans 2011 so Im leaving it there)

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0047.jpg

And a nice bargain find in the scrapyard today was a pair of VDO gauges from an Audi something-or-other. Ill probably use the oil pressure to replace the RMD oil pressure gauge in the car at the moment and itll go well with the VDO boost gauge when I finally buy it.

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01527.jpg

Also managed to get some more wiring chopped out, theres so much useless stuff grafted into the loom its unreal, half of it doesnt work, its hooked up anymore or has no purpose so is still being hacked out anyway.

[antz]

well I spent a couple of hours on the car today and as usual.....nothing looks different

Well I managed to get the passenger recaro fitted up so I now know its all ok. Now I have to take the damn thing back out and all apart to repaint the mounts before final fitting. Also chopped up the side plastic bits on the seat for the drivers seat. Next I need to make those mounts too.

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0053.jpg

I also attacked more of the wiring which is a never ending mass of horrors and I havent even got round to fitting the T5 loom yet!

Getting low on jobs now until my mounts and parts arrive from Tomcat.

Oh and a quick shot of my steering wheel which I got from a scrapyard for £3.60 :)

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0051.jpg

[antz]

well Ive been sourcing more parts the last couple of days and might have found a gearbox crossmember, my new engine mounts are being made at the machine shop and ive got my recaro seat brackets being sprayed in my garage so Im keeping busy doing what jobs I can.

Other than that Ive got my accelerator pedal back on with my sparco pedals. Love them or hate them the original ribbers were knackered and I got the Sparco pedals for free!
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01537.jpg

Yesterday I removed the old washer bottle because I broke the lid off and theres no need for it to be that big. Im going to invest in a smaller twin pump washer bottle that takes up less room and obviously weighs less. The only main problem is the headlight loom hides under the original washer bottle and with it not there the loom is about 1ft too long! Ill chop it down and shorten it at a later date to tidy things up.

Lots of muck underneath:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0060.jpg

cleaned up:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0064.jpg

header tank after a few runs in the dishwasher
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01535.jpg

battery tray removed and some surface rust underneath which ill treat and paint:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01536.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01538.jpg

[antz]

Well I managed to get some rust treatment on the battery tray the other day and refit the big plastic top after neatening up the original plastic cast marks because im a OCD SOB!
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01551.jpg

Also shortened the loom that goes to the headlight as it was too long after i removed the washer bottle. I cut roughly 6inches out of it and resoldered it back together, shortening the headlight wiper wires and tucking them back into the loom at the same time as I dont need them. The remaining two wires are for my washer bottle when I source a small twin pump one and Ive now re-attached the earth wire thats hanging loose in the picture.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01550.jpg


And I took a trip to Ray Chapman Volvo at Malton on Friday and ordered a butt load of seals, o-rings and gaskets for the M90 box and engine. Not a cheap trip I tell ya! Everythings coming direct from Sweden for that so should be here later in the week.

[M-R-P]

Looking real clean mate, Are you gonna polish/paint the block before fitting?

[antz]

Looking real clean mate, Are you gonna polish/paint the block before fitting?

Nope haha. I did think about it but to be honest I dont want the car to be a minty fresh show car, I want it to be clean but useable. Im cleaning the bay whilst everythings out for ease but im not going OTT on it. I gave the gearbox a wire brush down to get the oil off it and the engine a quick go to tidy it up but thats it. I dont want to worry about if it gets wet, taking it on track days, drift days, to the nurburgring and such events. Plus I want it to be my summer daily when its done so it will get mucky.

When I did my Escort mk2 I went through the whole car using stainless washer and bolts, cleaning and spraying every bracket and making it mint, which it is but its a bitch to keep clean and I feel I have to keep the standard up every time I wash it.

Heres the Escort
http://i52.photobucket.com/albums/g36/letpigsfly/DSC00290.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC00291.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/Escort1.jpg

[Volvostorm]

Nice mk2, I still miss mine :(

[M-R-P]

Nope haha. I did think about it but to be honest I dont want the car to be a minty fresh show car, I want it to be clean but useable. Im cleaning the bay whilst everythings out for ease but im not going OTT on it. I gave the gearbox a wire brush down to get the oil off it and the engine a quick go to tidy it up but thats it. I dont want to worry about if it gets wet, taking it on track days, drift days, to the nurburgring and such events. Plus I want it to be my summer daily when its done so it will get mucky.

When I did my Escort mk2 I went through the whole car using stainless washer and bolts, cleaning and spraying every bracket and making it mint, which it is but its a bitch to keep clean and I feel I have to keep the standard up every time I wash it.

Heres the Escort
http://i52.photobucket.com/albums/g36/letpigsfly/DSC00290.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC00291.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/Escort1.jpg

Stunning mate. My mum had a mark 2 ghia. I had a new engine just before she got it. After accidentally drifting it round 2 ramps in a multi-storey, it started to sink in - the words "MEXICO" we found on some of the paperwork...

[Jim S70R]

That mk2 is lovely and very mint!!

[AndysR]

Nice work, mk2 Escort looks lovely and well worth the effort you've put into it.

[antz]

Stunning mate. My mum had a mark 2 ghia. I had a new engine just before she got it. After accidentally drifting it round 2 ramps in a multi-storey, it started to sink in - the words "MEXICO" we found on some of the paperwork...

Funny you mention that, I was awarded a section 59 by the police yesterday for flicking it out if a roundabout.

Thanks for the comments on both cars everyone, I'm trying my best. I've just got my old job back and when iget paid ill start looking at the suspension whilst i wait for the engine parts to arrive.

[antz]

new bottom arm arrived from Partsforvolvos today! Shame I cant fit it until I can find £300 to buy a polybush kit for the whole car so I'm not doing jobs twice..

[antz]

Well yesterday I picked up a huge bag of bits from Volvo that included engine mount rubbers, various o-rings, seals & oil for the gearbox but sadly didnt include the inlet manifold gasket or gearbox mounting rubber I ordered so Ill have to get back onto them tomorrow.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0067.jpg

Then today I decided whilst Im stuck waiting for engine parts I cant continue with that side of things, Im stuck waiting for money to buy suspension parts so I cant do that.....ill attack the bodywork instead.

Off with the rear bumper trim revealed this...not looking good:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01593.jpg

Off came the rear bumper and I was presented with crusty bits. Oh dear:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01594.jpg

Cleaned up the bodywork so I could assess things and its looking like the whole lip and lower valance under it is going to have to be cut out and have new sections welded in. Not the most ideal situation but Ive seen old Ford Escorts with worse rot repaired so all is not lost. I just need to find a welder who can come and do it in my workshop as I cant transport the car anywhere and I cant weld for **** so doing it myself is out of the question.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01595.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01596.jpg

No wonder the rear has gone rusty on the car as the bumper brackets have a nice thick layer of rock hard salt built up.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01599.jpg

When its all welded Ill give this area some damn good rust protection to stop this happening in the future.

[Niles]

Great job. keep it up!!!

[Jim S70R]

AtLeast you know about it and are attacking it before it gets any worse, looking forward to the next update.

[graemewelch]

if i had a mig welder id come and do it for ya. love to see projects like this. keep up the good work

[antz]

thanks mate. Ive had a lad on the VOC forum offer to do it for petrol money which is good of him so hopefully itll be welded up soon!

[antz]

Well Ive spoke with a lad on the VOC forum and Im hoping he can do the welding on the car. Im awaiting his input for what metal I need so I can get it and a date that he can come up to do the work :)

On my side Ive had an email saying my new custom made engine mounts are at the engineers shop in Sweden being cut out with a fancy waterjet. When they arrive they should look something like this and utilise the original crossmember and needing no chassis welding at all. (For the top Ill be using 960 engine mounts and 240 rubbers)
http://i52.photobucket.com/albums/g36/letpigsfly/DSC_0032.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC_0031.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC_0364.jpg
https://lh5.googleusercontent.com/-5FK64mP3344/Tl7ZKCieRcI/AAAAAAAAGEQ/pI7x7cYuuw4/s720/DSC_0004.jpg

I also got a big parcel today which included a used clutch master cylinder, slave cylinder and some pipework to finish the Auto to manual conversion off and M46/M47 crossmember.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01600.jpg

The plan is to adapt the crossmember to take a 960 gearbox mount which is currently on back order from Volvo (god dangit!) and it should mount the M90 to the car liks this:
https://lh3.googleusercontent.com/-R1aWnn6Yk9k/TeWrex3qMfI/AAAAAAAAFWI/otfMhfiCEh4/s720/DSC_0028.jpg
https://lh4.googleusercontent.com/-CtU5wFIgLOk/TegaOeGSWAI/AAAAAAAAFWs/5a4JNq-XHT4/s720/DSC_0031.jpg

On a side note whilst Im talking gearboxes, the M90 isnt a direct fit into a 240 but its pretty damn close. The tail shaft the shifter sits on is actually too long so will need to be shortened by roughly 100mm as Ive been informed but Ill verify this at a later date:
http://img9.imageshack.us/img9/2435/p9123814.jpg

After that, the M90 gaiter cover needs to be tickled with a hammer to mount into the original 240 tunnel mounts which should look like this when done:
http://img402.imageshack.us/img402/2774/p9123816.jpg

Again Ill check all this at a later date but its that simple and gives you all a good idea of how easy it is to mount a M90 into a 240.

Now back on topic.....
As well as receiving parcels I managed to get the rear bumper mountings off the car with some swearing and tugging. Now its all ready to be attacked with the grinder and welder at some point in the near future with any luck.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01601.jpg

And whilst I was bored I took the top part of the shifter off the M90 box. After swearing for ages I got the shift boot off so i can get a new one made in leather to match the interior, then off came the original crappy foam gearknob after some more swearing and many screwdrivers. I then cut roughly 1.5inches off the top of the shift lever so I could test fit my MOMO gearknob Ive had kicking around for a few years. It looks good I think and should create a slightly shorter shift with the lever being shorter. Ill fit this properly once the gearbox is in the car but at least its all adapted ready for when I need it.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01602.jpg

[M-R-P]

Every little helps mate, Glad to see it all coming together. ;)

[antz]

Well the last couple of days have been spent checking the car for rust and starting on some rust proofing.

First problem was the rear wheels didnt want to come off so a few good smacks with a hammer and a long 2 by 4 of wood got them moving. Next off came the rear mudflaps (3 bolts and both plastic clips snapped grrrr) which enabled me to get a better look at the rear arches. The rear arches were so full of muck I got 3 shovel fulls of soil off the garage floor afterwards.

Oh look shiny new Monroe shocks! The previous owner fitted them just before I bought the car:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0071.jpg

They arent perfect with some paint flaking off and a few brown bits but no horrors, very nice actually.

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0074.jpg

After a coating of some kurust.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0075.jpg

And the other side which has a little nasty bit that Ive given some kurust then Ill just hammerite it as it cant be seen.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0076.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0077.jpg

Im unsure of how to protect the arches now. On my old GL I sanded the lips back and hammerited them but it was silver car so didnt really stand out. To be honest Im tempted to do it again as its only the inner lip I do to protect them from the elements.

And one picture of it floating away ARRRGH!!

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0073.jpg

The lower plastic valance is all bent and looks crap. Im not sure what do do about that, part of me says leave it but part of me is saying to hack it off at the exhaust outlet and the other side where the hole is and have no middle in it but Im not sure if they will look worse.

Oh and heres a pic of the only other rust on the car. The driver sill where its peppered into many small holes The rest of the sills are mint.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0069.jpg

[antz]

Well as mentioned above yesterday was spent lying on my back in the scrapyard fighting with a very rusty 245GLT estate trying to remove its plastic rear valance to replace the bent on on my 245.

Had to cut the brackets off the car in the end and grind the bolts out at home, luckily my car was easier to do. I only had to grind two bolts off and since the old valance was off in the bin I didnt worry about damaging it.

Old Vs New:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01606.jpg

Then with the old one off it let me assess the rear "buttcheeks" of the car better which are really good thankfullY.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01607.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01609.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01608.jpg

Slight bit of rot on the passenger side but theres no holes thankfully. A good rust treatment and, seam sealer and thick coat of paint should stop this going any further. Most of the dark patch is just kurust so it looks worse than it is:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01613.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01612.jpg

Ive also been cleaning up a few other items and stopped by Volvo for some trim clips on the rear bumper. £1.40 per trim clip and theres 15 along the back of the car! :swoon:

[antz]

Well today I had two very nice chaps come up and attack my car with various grinders and hot objects in an attempt to repair the rust on the rear panel......and a fabulous job they did!

Thanks to Steve_And_His_244 and John_h over on VOC.

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0099.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0100.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0101.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0102.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0103.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0104.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0105.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0110.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0111.jpg

It still needs grinding down, rust proofing, seam sealing and spraying which Ill do tomorrow evening.

Heres my rear panel!
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0109.jpg

And a final shot from the back seat at the dash in bits. Im going to have to get my steering wheel re-trimmed since i spilt something on it thats eaten the leather. DOH! It was quite worn anyway.

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0108.jpg

[Jim S70R]

Looking very good, she'll be a minter before you know it.

[graemewelch]

i might be wrong but i think that should be fully welded.

[martybelfastt5]

looking good nice to see fellow members mucking in,,

[antz]

Thanks guys. Its certainly much stronger than Volvo ever made it now! Just currently tidying it up and making it all pretty....plus I dug some sound proofing out and decied "thisll come off easy". 3 hours later im 1/4 through. ARGH!

[M-R-P]

Keep up the good work dude. Will keep you informed about the bits I promised ya ;)

[antz]

well things are progressing slowly so heres another update of what Ive managed to do..

Ive been prepping the back end a bit more. Got the outside all seam seaered up and a quick blast of primer to cover the bare metals:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01637.jpg

The blob of grot in the tailgate shut which Ste welded has been cavity waxed from the inside and whilst I decide how to properly fill it Ive given it a blast of seam sealer just to cover it. Not pretty but better than bare metal.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01635.jpg

And finally a good old injection of dinitrol 3125 cavity wax into everywhere i could find on the rear end has been done. I havent finished yet but ive got it into all the creases, crevises and nooks to help stop the rot. It looks like its seeping poo but it does dry with a nice waxy protective layer......unlike poo which dries hard.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01636.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01638.jpg

Then I got these lovely shocks off Steve and his mighty 244. Koni reds!
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0117.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0118.jpg

My 960 sump arrived which needs shortening for the T5 lump. Bit off a ballache but do-able. I also have a water pump connection pipe which i might need to apadt into a t5 one to make it clear the engine mounts, my 960 upper mounts to bolt to my custom made lower ones and a 3" throttle body
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0119.jpg

and a final word of warning.....when you find soft sound deadening, dont pick at it because you end up with this.....the soft bit all removed and the solid bit to now scrape off with a heat gun then a whole boot to repray. ERROR! Too late now though and sound deadening does with a tonne though. Stage 1 weight reduction?
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0120.jpg

[M-R-P]

You start something and often think "I shouldn't have gone for this one, oh f**k it!"

Mine was shortly after I said "yeah, I'll have the volvo"!:)

[antz]

You start something and often think "I shouldn't have gone for this one, oh f**k it!"

Mine was shortly after I said "yeah, I'll have the volvo"!:)

Yep! The sound deadening was soft and tacky so when i dug the scraper in it came off really easy.....for a while and then it got hard and now its a bigger to get off. chipping away 3mm at a time with a scraper then ill have to get some white spirit on it tog et the gunk off and spray the boot.

least its udner the boot floor hatch where no one sees it anyway!

[Shadow]

those rear shocks look the same at the ones i have on the 480. do you know how to adjust them? iv still got the instructions that came with mine if you need them.

[antz]

those rear shocks look the same at the ones i have on the 480. do you know how to adjust them? iv still got the instructions that came with mine if you need them.

Oh yes please mate! I have no idea how to adjust them.

[Shadow]

well this is embarrassing can't seem to find them now sorry. but i can still remember how to adjust them.
you have to pull the dust shield down off the bottom of the shock. now with that off you should see a small brass button where the rod goes into the lower part of the shock.
you have to fully compress the shock and press the button at the same time. now with it still compressed and the button in you have to turn the top mounting whilst holding the lower mount still and you will feel it click (there is only 3 positions soft med and hard)
once you set it just let go of the button and the top mount and let the shock fully extend and that it set.

the hardest setting is full clockwise.

hope that make sense. its a lot easier that it sounds il keep looking for the instructions tho.

[antz]

Cheers fella! I would never of guessed how to do it like that :)

[antz]

Well Ive been spending a lot of time on this and there doesnt seem to be too much progress considering my time spent on it!

Well after picking off all the soundproofing with a hairdryer and scraper than a wipe with white spirit I was left with a big grey area.

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0122.jpg

Add in primer:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0127.jpg

Some Volvo 189 Polar White:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0128.jpg

Laquer:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0129.jpg

I was left with a spray line at the back because I cant feather in for poo. Im not too bothered as its just a spray line and once the boots all back in the only person to ever see it will be me if I ever open that comparment.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0130.jpg

There were a few bits in the paint as I was using a blanket to cover the seats from the spray and when I removed the blanket loads of bitys fell off into my nice fresh lacquer. DOH! Itll be alright though.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0131.jpg

The welded area that was waxed has been sprayed over too so its protected. Next time Im at the garage Ill give it another waxing over the top for double protection.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0132.jpg

Slapped some bridging filler on the rear lip. It aint pretty butI I was struggling to make it do what I wanted
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0123.jpg

Athe amount of dust that gathers in the garage is amazing. This is only 3 months of buildup!
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0126.jpg

Also in the background of things Ive mocked up my drivers side seat mounting and my new mounts are all packed up and on their way from Sweden or Germany or wherever the guy is....somewhere like that anyway.

[antz]

Well heres the update Ive put many hours into working on and yet again, i look back at the photos and think NOTHINGS CHANGED!

Anyway I got my seat back from the re-trimmers and he has doen a wonderful job again. I used DAWSONS UPHOLSTERY in Malton N.Yorksire and he does a really great job.

What I did was sacrifice a good spare passenger seat I had so the bolster could be used to replace the worn one on my drivers seat, I cant even tell that my Recaro has even been repaired let alone had a full bolster grafted in. This cost me £120 which I think is very reasonable.

Before and after preview of the same seat. In this photo you cant really see the damage to the drivers seat but the tear had split the seam in such a way you couldnt just stitch it up. Also the leather was worn and rippled.
http://i52.photobucket.com/albums/g36/letpigsfly/recarorepair.jpg

Repaired seat against the donor seat to see what was used:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01670.jpg

Completely un-noticeable stitching has been replicated to look factory.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01669.jpg

As well as getting the seat back I made up the brackets so it fitted on the original Volvo runners. Fo this I used my other spare drivers seat as the guinea pig to throw round in the garage and muck about with. This wasnt easy but it was my first go at making brackets on my own and my dads mate who is a qualified engineer actually said they were damn good, let alone for a first attempt and they fit perfectly in the car BONUS! Ive designed the brackets with the L shape so when you sit on the seat it puts pressure on the bracket and re-routes that pressure back up against the base of the seat to stop the mount bending over time or with a sudden impact (E.G A crash). They just need spraying now.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01671.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01672.jpg

And on a negative side i accidentally touched my steering wheel with something in my hand and it ate the leather so I took it to be trimmed and the cost was more than a new wheels as its gotta be hand stitched. So Im going to do it myself when I get some leather.

Wheel and damage to leather:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01651.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01653.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01654.jpg

After stripping it ready for new leather:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01655.jpg

Old leather laid out to be a template for the enw leather when I order it:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01656.jpg

And on a side note, my boot is now fully sprayed but Ive decided to give the weld lines on the inside a quick dab of seam sealer and a quick blow over for further protection.

Also my engine mounts are en-route from Kansas USA to my house and at the time of typing this they are sat in UK Customs where I expect to get a letter saying I owe them £9m import duty and £13.50 admin charge for the letter to tell me I owe them £9m.

[M-R-P]

Ya been a busy bunny dude, the seats and wheel look dam good.
Watching...

[antz]

Well today I have an update Ive been very excited about all week.

NEW WHEELS!

Today I had a quick trip down to Birmingham (3 hours each way) to go pick up these bad boys from Smithy to go on the 245 or 255 as I shall now refer to it since the 4 stands for 4 cylinders and mins has 5 etc etc...

Anyway Im rambling....Here are my new Galaxies! Smithy had them refurbed in a special colour called Chrome Black so its not silver, its not black, its not chrome....its all 3 mixed but they look lovely to me.

Only two tiny chips on two seperate wheels but otherwise mint with 4 Avon ZV5 tyres.

Cant wait to get the 255 rolling on them but until its done they will be going into storage to protect them and keep the tyres nice.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC01691.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01692.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01695.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01697.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01696.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01693.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01694.jpg

Also in other news my Koni's are primered up and waiting some paint, front numberplate has been taped ready for fitting as had the rear arch bottom plastics and the outside rear where it was welded has been tetrosealed ready for stone chipping and final painting. I just need to go to Halfords to stock up on stone chip, paint & primer now!

[M-R-P]

Awesome wheels! I want ;)

[Volvostorm]

Its going to look great on those wheels! :D

[smithy]

Well today I have an update Ive been very excited about all week.

NEW WHEELS!

Today I had a quick trip down to Birmingham (3 hours each way) to go pick up these bad boys from Smithy to go on the 245 or 255 as I shall now refer to it since the 4 stands for 4 cylinders and mins has 5 etc etc...

Anyway Im rambling....Here are my new Galaxies! Smithy had them refurbed in a special colour called Chrome Black so its not silver, its not black, its not chrome....its all 3 mixed but they look lovely to me.

Only two tiny chips on two seperate wheels but otherwise mint with 4 Avon ZV5 tyres.

Cant wait to get the 255 rolling on them but until its done they will be going into storage to protect them and keep the tyres nice.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC01691.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01692.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01695.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01697.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01696.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01693.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01694.jpg

Also in other news my Koni's are primered up and waiting some paint, front numberplate has been taped ready for fitting as had the rear arch bottom plastics and the outside rear where it was welded has been tetrosealed ready for stone chipping and final painting. I just need to go to Halfords to stock up on stone chip, paint & primer now!

get abit of touchup paint for those 2 chips mate that will sort that mate and yes they will look nice on your car like they did on mine

[antz]

Yeah Ill get some touch up on those chips when I can. Thanks for selling me them Im well happy!

Going to do a test fit on the car when Im next up there to give me some motiviation :)

[smithy]

Yeah Ill get some touch up on those chips when I can. Thanks for selling me them Im well happy!

Going to do a test fit on the car when Im next up there to give me some motiviation :)

no probs glad you are happy but problem is i have no rims now lol

[t5 pete]

What u gunner get Carl

[T5frankie]

What u gunner get Carl

i know some like these

http://www.aronline.co.uk/images/devtagora_15.jpg

or these

http://t3.gstatic.com/images?q=tbn:ANd9GcTTGl9VKOmAyhy2hMFfpUiMRmN57cXGE E9sfLGVa1t1QKw0AOXu

[antz]

He told me he was buying a set of these haha:

http://www.fakewheels.com/images/bear.jpg

[T5frankie]

He told me he was buying a set of these haha:

http://www.fakewheels.com/images/bear.jpg

good one lol

[smithy]

He told me he was buying a set of these haha:

http://www.fakewheels.com/images/bear.jpg

i like those but know sorry

[smithy]

but if i could get the pic on here of the 940 with the wheels i putting on it on but im rubbish with computers .please can someone put the pic up on another thread or this one .the pic is the same colour as mine i sent a couple of members the pics with some ideas of my car.

[The Flying Moose]

Nice wheels Antz, smithy is going to regret selling those I think.

Good to see your making good progress too. Keep it up mate.

[Jamest5r]

Nice Antz, you can forward me the "finder's fee" when ever you like :)

[antz]

Nice Antz, you can forward me the "finder's fee" when ever you like :)

Ill buy you a burger at a meet/RWYB day when the cars finished! :)

two updates in two days!

Tonight I gave the rear end a sand down and a second slapping of bridging filler to cover the bits I missed the first time. This fillering lark is harder than first thought so it might be time to call on my retired boy racer friend who has lots of experience of filler after hitting many speedbumps in his old kitted Fiesta.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01698.jpg

Picture of tetrosealed underside
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01699.jpg

First coat of stone chip applied
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01701.jpg

And fitted the front numberplate to give me a sense that things are progressing and putting thigns back on the car makes it seem that little bit more complete rather than taking more bits off. I do like the look of pressed numberplates!
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01700.jpg

On a side note my rear shocks are in the paint process but its reacted so ill have to strip them again and my engine mounts have been cleared by customs UK after a £17 tax charge and £9 for parcelforces privilage. gits!

[The Flying Moose]

Avoid those pressed plates Antz, not worth the points and fine mate ;)

***Cough*** speaks the old hand of law.

[antz]

Avoid those pressed plates Antz, not worth the points and fine mate ;)

***Cough*** speaks the old hand of law.

But they are reflective in the legal UK font with correct spacing and have the little ID number in the bottom corner so surely they cant do anything?

[The Flying Moose]

But they are reflective in the legal UK font with correct spacing and have the little ID number in the bottom corner so surely they cant do anything?

I would beg to differ my dear friend. Here is an extract from the PNLD which states the requirements for UK Registrations:


PART 1
VEHICLES REGISTERED AND NEW REGISTRATION PLATES FITTED ON OR AFTER 1ST SEPTEMBER 2001 (MANDATORY SPECIFICATION)
1. The plate must be made of retroreflecting material which, as regards its construction, colour and other qualities, complies with the requirements of—
(a)the British Standard specification for retroreflecting number plates published on 15 January 1998 under number BS AU 145d(1),
or
(b)any other relevant standard or specification recognised for use in an EEA State and which, when in use, offers a performance equivalent to that offered by a plate complying with the British Standard specification,and which, in either case, is marked with the number (or such other information as is necessary to permit identification) of that standard or specification.
2. Where the registration mark is displayed on the front of the vehicle, it must have black characters on a white background.
3. Where the registration mark is displayed on the back of the vehicle, it must have black characters on a yellow background.

As Im sure you are thinking... what is the problem? Well...

“ The plate must be MADE OF retroreflecting material “

Steel is not a retroreflecting material.

There is suggestion on the internet that some unscrupulous sellers of show plates could offer to mark the plates to BS standard however they do so knowing that it is the driver who will have to answer the questions at the road side and pay the fine.

Plates have a fixed font style and size. Retroreflective means the plate should reflect light back to its source with a minimum scattering of light which is met by using the vinyl reflective material on the backing of the plate similar to the backing of road signs and the livery on the sides of emergency vehicles which cannot be met by simply painting a metal plate orange or white.

The standards for plates is to allow clear reading of plates and clear photography of plates by roadside cameras and automatic number plate recognition cameras and if your plate fails to meet the standard and you get stopped by police then you are open to prosecution.

Just my four pence worth :)

[antz]

that was too much for me to read but I got the jist!

I think Ill risk it for a biscut for the time being haha. :) itll be my own fault if i get rumbled

[t5 pete]

Never had a problem with them come the mot time and there easier to read than standard plate I suppose it depends on how you read the bit you have put up and how much a nob in the suit wants to be.

[The Flying Moose]

Never had a problem with them come the mot time and there easier to read than standard plate I suppose it depends on how you read the bit you have put up and how much a nob in the suit wants to be.

I think most aspects of the law are open to interpretation, this goes without saying.

Personally for the sake of a registration plate, I dont see why its worth taking the risk?

In many cases from past experience it provides the reason to "tug" the car and can open many a can of beans.

[t5 pete]

i cannot see any risk, if there from a reptuable number plate company stating they are UK legal I honnestly cannot see a company advertising them to be legal if they are not as it leaves them liable also the mot station would be aware of this and wouldnt have passed them if they weren't legal would they.

[JUDGENINJA]

There is one get out clause with this section of the regulations. If questioned, it was fitted pre 2001 as the regulations only cover vehicles or plates fitted/registered after the date.

The regulations can not be enforced well on older cars.....unless of course you were to place your build history on a website frequented by the local bobbies....:;)

[antz]

OK well on Friday night I had my mate come over and lay down some filler on the rear of the tailgate to start shaping it but it was too cold and took forever to go off so we went for a coffee and never finished it. It still needs rubbing down so Ill get that done when I can drag him over.

Seat brackets are currently in primer and awaiting some paint. Rear shocks are all painted and ready to go on the car at some point to replace the Monroe Load Levellers (which will be for sale). Front mudflaps have been re-fitted.

The rear end has had 3 coats of stone chip on the outside and the inside seams got a coat of seam sealer to lock the cavity wax in and help protect things further. Bad news is Ill have to touch up the spraying in my boot but no huge problem.

and....rather than do some more work I decided to give myself a motivation boost. This involved two Galaxies as seen earlier and I dropped the T5 lump into the bay just to see what things would look like. Its only sat on the crossmember cos its still got the wrong sump on and I havent fitted my mounts yet. Thats a job for the weekend. (ride height is obviously a bit higher as well due to the missing gearbox and most of the engine bay!)

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01712.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01716.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01715.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01720.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01713.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01717.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC01719.jpg

[M-R-P]

Hmm, getting there mate. Keep up the good work ;)

[antz]

Thanks mate! I need to get the rear end sanded down and sprayed so I can get it back together but in this cold the filler is taking ages to dry. Also need to get my engine mounts fitted but I forget the drill everytime I go to the workshop and need some longer bolts to get the engine on the engine stand so i can get the old sump off....bolts which i dont own.

Yes im full of excuses!

[silverswedemachine]

Looking good mate, starting to feel alittle jealous now ive seen it with the engine nearly in place...

[antz]

Looking good mate, starting to feel alittle jealous now ive seen it with the engine nearly in place...

Dont get too excited! Its only sat in there on the crossmember. My sump needs to be finished being shortened, then I need to fit the upper and lower engine mounts. Until then the engine cant go in. Then the gearbox cant go in until the selector is shortened by 65mm, the gearbox crossmember is adapted which cant be done until I get a gearbox mounting rubber. Once thats done I need the clutch and flywheel before it can all be slotted together.

Then theres the clutch cylinders to hook up and finish the auto to manual conversion.

Oh did I mention wiring, mocking up of rad intercooler etc, custom propshaft, and find/buy all the other 900,000 parts Im missing!

[martybelfastt5]

them wheels are perfect love them!

[johnners]

Not bad going Antz, and Galaxies look spot on! Dunno when this mate of yours will get chance to come over again yet though ;)

[antz]

Not bad going Antz, and Galaxies look spot on! Dunno when this mate of yours will get chance to come over again yet though ;)

Well if he deosnt hurry up Ill increase the bombardment of V50 links that I keep sending him :D

[96T5Andy]

Looking good can't wait to see it operational!

[antz]

Well things are slowly getting there.

My good friend Johnners pulled his finger out of his bum and did the rear filling on the car.

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0151.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0158.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0159.jpg

The engine is now on an engine stand. The old sump is off and after having countless ally welders say it cant be done Ive found a guy who can do it and will start it ASAP.

T5 sump next to 960 sump to see why I cant use the original.
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0161.jpg

Any test fitting of my new engine mounts. They mount via the bottom arm bolt and a new bolt opn the crossmember needs drilling. Simples really.......theoretically.
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0156.jpg

[M-R-P]

Really starting to come together mate.
Recon it'll be ready for the strip next year?

[antz]

Really starting to come together mate.
Recon it'll be ready for the strip next year?

I doubt it mate. I must admit I have thought about seeing if it can be done but then I dont want to rush getting it done and not be happy with it just for the sake of it being done. Also with the possibility of being without a job in April then I have no idea whats going to happen money-wise which is a huge factor in affording everything obviously!

2013 without a doubt though :mischievo

[graemewelch]

if they say it cant be welded its cause they are crap welders. ive lost count of the number of things ive modified like that

[antz]

if they say it cant be welded its cause they are crap welders. ive lost count of the number of things ive modified like that

Exactamundo!

[johnners]

Well if he deosnt hurry up Ill increase the bombardment of V50 links that I keep sending him :D
Stop it you are tempting me enough as is!! Glad I managed to get the filling finished for u though, get it sprayed up and rear end can be built back up and we can get cracked on with something else!

[antz]

Stop it you are tempting me enough as is!! Glad I managed to get the filling finished for u though, get it sprayed up and rear end can be built back up and we can get cracked on with something else!

Well I set myself a rule that I will not do any work on the car on Chritmas day as thats just sad.......I ended up fitting up my seat brackets whilst waiting for dinner so the seats are all ready to bolt in when the time comes.

Will be spraying the rear end tomorrow and stripping the bottom girdle off the block for the sump welding.

[antz]

Well today I managed to get on with the rear end after Johnners did a brilliant work filling it.

So.....trim clip holes drilled and seam sealered:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01721.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01722.jpg


Then primered, sprayed and laquered. Ready for rust proofing where needed and then its all ready to fit back up and get the rear end back in one piece!
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01724.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01725.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01726.jpg

[graemewelch]

are you alsorted now for getting the sump welded.

[antz]

are you alsorted now for getting the sump welded.

Yep all sorted now! Just need the bottom part of the block from a t5 lump to bolt the sump to when its being welded so it doesnt warp.

[antz]

Well with the help of my mate Johnners on Friday we decided to get the back end waxoiled and re-fitted along with a few other silly jobs like drilling out the snapped off mud flap screw ends.

Johnners drilling out the mud flap screws which were an absolute bugger to do! (He has no head in real life)
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0170.jpg

Starting to fit up the rear end with new trim clips, new rear valance as scavenged earlier on with no tow bar hole, and a good waxoil all over to stop it rotting out in the future:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0169.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0168.jpg

And after the long slog here is the back end all rebuilt and ready to go (just a small hole in the drivers rear wheel well to sort out now which will be a piece of piss)
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0174.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0177.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0175.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0176.jpg

At this point I would like to thank Ste Haigh & John Hughes for the welding, Johnners for the marvellous filler work and myself for doing a damn good spray job :)

NOW BACK ON TO THE ENGINE CONVERSION!.......Updates soon.....

[smithy]

very nice thread mate

[antz]

Well heres some work Ive been doing on the rear arches. All bubbles sanded down, rot ground out, kurusted and primed ready for spraying. It was too cold to spray today though.

The arches are surprisingly solid with only a small chunk missing on drivers rear behind the mudflap which I can hide as long as i rustproof it well. Passenger side is really good.

Drivers side Kurusted (pre-primering)
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0180.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0178.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0180.jpg

And for the first time ever I changed a pair of rear shock absorbers (new skill learnt wooooooo!) Off came the Monroe ride-levellers for some more sporty Koni reds which came off Ste Haighs legendary "Thor" and will work better with my plans for the car.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0190.jpg

[M-R-P]

Fine workmanship there mate. Top marks to all involved.

[antz]

Fine workmanship there mate. Top marks to all involved.

Thanks mate! I think everyone I know is learning new skills whilst working on the car and everyone is doing a top job!

Considering I've only ever serviced my own car once I dont think Im doing too bad a job :D

[Jamest5r]

Thanks mate! I think everyone I know is learning new skills whilst working on the car and everyone is doing a top job!

Considering I've only ever serviced my own car once I dont think Im doing too bad a job :D


That is a quality rebuild your doing there :)

What are your plans for it when finished? showing..1/4mile..track :)

[antz]

That is a quality rebuild your doing there :)

What are your plans for it when finished? showing..1/4mile..track :)

Thanks James!

My plans...? All of the above! 1/4 miles, track, showing, summer daily driver, drift what you brung days.....I wanna do it all! All the things I cant/daren't do in my mk2 Escort I want to do in this!

[Jamest5r]

Cool that's what i like to hear :) we have a yearly meet at York Raceway will probably be at the end of May bank holiday this year, reckon you'll make it?.

[antz]

Cool that's what i like to hear :) we have a yearly meet at York Raceway will probably be at the end of May bank holiday this year, reckon you'll make it?.

Doubt it, I dont want to rush it and TBH I cant afford everything I need in once go, especially with my job prospects after April looking bleak at the moment (Im temping in a job thats soon to be non-existant) Might bring the Escort mk2 along to York though for some fun! :)

My target is 2013 to have it done though when Ill definitely be hitting everything I can.

[antz]

Well heres a long overdue update.

First up is my passenger rear arch which I wasnt too happy with as I'd ground off a rust bled and tried to get away with just spraying it. It looked $*&#.

So here it is beforehand:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0210.jpg

After a quick grind back, skim of filler and rub down:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0107.jpg

Primered up:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0115.jpg


Now the weathers too cold Im struggling to get a good day to finish spraying it so Ill pick this up as soon as the weather improves.


As well as this I also bought a Volvo 960 spoiler dirt cheap off eBay which Ive been toying with adapting to fit the 245. It almost fits widthways (2mm too long each side), curves the tailgate perfectly but unfortunately is too low and hangs over the rear window. Im not sure but I dont think it actually hangs low enough to create a gap, its more of just the lip that overhangs. Ignore the metallic blue colour, it will end up matte black so suit the GLT trim it the idea pays off.

At the moment its a bit of a faff around and if it fits and i can do it, all will be well, if i try it and it looks crap or i ruin it then its only a £10 spoiler.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC01800.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01801.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01802.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01804.jpg

On a seperate note, I managed to pick up this nice Blitz R-Spec Boost controller from ebay Japan for £160 delivered (came with instructions, solenoid & all wiring too)
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0110-1.jpg

Ive managed to source a T5 single mass Flywheel from JamesT5R and a full 2.5 bottom end which Ill strip down and use as a solid platform for when I get the sump welded.

[daza-b]

looking good m8

[antz]

Finally an uodate!

I now have a T5 single mass flywheel because the dual mass ones suck.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01863.jpg

Also my K&N arrived which Ive given a clean out and re-oil. Its to fit a Volvo T4 but it should suit the 255 nicely as its a big size.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0132-1.jpg

Boost gauge arrived from USA so Ive decided to ditch my clock (my phone tells the time!) and Ill be going for an accompanyment of oil pressure gauge and boost gauge in the car which looks like this (not hooked up yet)
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01859.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01858.jpg

Im still in the middle of respraying my rear arch because its been too cold. Its just awaiting lacquer now then it can all go back together and thats one more job done.
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01862.jpg


And finally I picked up a 2.5 bottom end from 850Rick a couple of weeks back to strip down as I want the bottom cradle to bolt my 6 cylinder sump to for when its being shortened to stop it warping.

This is where I went old school with bigass tools and brute force to get the block seperated and everything in bits but its finally done.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC01844.jpg

Cradle and crank seperated:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01846.jpg

And finally after much hitting, swearing, hammering, swearing and more hitting I have a bare cradle:
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01861.jpg

And a bare block which Im going to use as a spacer for my engine mounts as its easier to shift round than a full T5 engine
http://i52.photobucket.com/albums/g36/letpigsfly/DSC01860.jpg

[M-R-P]

I like your logic here;)
got my eye on a couple of 240s, don't yet know if i can get my hands on them. If i can, I'll let you know :)

[antz]

I like your logic here;)
got my eye on a couple of 240s, don't yet know if i can get my hands on them. If i can, I'll let you know :)

Theres something about the 240's I love but I dont know what it is because I personally think they arent a good looking car at all haha maybe its just all the memories of my first 245GL I owned from 2006-2009. Ive got so many stories and good memories from when I owned that car I could easily write a book about them all.

Here she is in all her glory back in the good old days! http://www.vpcuk.org/forums/showthread.php?t=37946

[M-R-P]

I cant believe that thread didn't get any comments! I can't remember seeing it. Sweet motor. Still, when the T5 is finished, hopefully, you'll be too busy doing burnouts and doughnuts to miss the old one;)

[antz]

I cant believe that thread didn't get any comments! I can't remember seeing it. Sweet motor. Still, when the T5 is finished, hopefully, you'll be too busy doing burnouts and doughnuts to miss the old one;)

haha I must admit even I was shocked I didnt get a single comment! No 240 love!

To do burnouts and doughnuts Ill have to fork out for a quaife ATB limited slip diff adn thats going to be a huge slice of £800! Still.....its on myshopping list and money is no good in the bank! hahahaha

Cant wait to get this on the road but its not a project I can complete overnight with no other cars previously done in the UK to help me solve problems but Ill get there in the end!

[M-R-P]

Enjoyable project to watch tho. Keep it up mate ;)

[antz]

Well my sump is back from welding!

After goig through a couple of people who said it couldnt be done and wasnt possible I was recommended a local guy who has done an absolutely sterling job on it and it only took 2 days! I will definitely be going back to him for any more fabrication jobs I need doing on the car at a later date.

If anyone wants his details for any general fabrication work on steel, stainless steel, aliminium...you name it he will do it.

Andy Lockwood
Helperthorpe, Malton, North Yorkshire 07896059966 OR 01944738652

Here is a pic of a stock sump against one thats been welded (not mine):
http://lh4.ggpht.com/_7EUAij74Ycw/Sa3s_HVqHNI/AAAAAAAATOM/FADtTbRR2qg/s400/7.JPG

And here is mine all welded up. He cut 91mm out of the sump which is exactly 1 cylinders worth:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0161.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0163.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0164.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0167.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0168-1.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0169-1.jpg

And he shortened the pickup pipe by roughly 90mm so it fits:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0165.jpg

Compared to the original one:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0166.jpg

[graemewelch]

looks like he done a nice job.

[Jamest5r]

Some nice work your having done there :)

[antz]

thanks guys!!!

now the sump is done I get the engine lowered into the bay to mark up my engine mount positions for drilling then once they are drilled and fitted the engine can finally go in the bay.

After that its a case of getting the gearbox crossmember adapted (ill get andy to do that!), getting the gearbox fitted, making everything fit around the engine and to sort out some kind of management system to run which Im yet to look at because its a huge headache.

In the meantime I really need to get saving so I can buy my clutch kit. :(

[M-R-P]

I look at metal fabrication all day long at work and what that fella has done is top notch. Skill like that is hard to find. Out of the 30 or so fabricators I've worked with, only one or two can weld like that.
Watching with interest ;)

[Volvostorm]

The weld on your sump is very nice :)

Bet you can't wait to get on with the project? :)

[antz]

I look at metal fabrication all day long at work and what that fella has done is top notch. Skill like that is hard to find. Out of the 30 or so fabricators I've worked with, only one or two can weld like that.
Watching with interest ;)

Thanks mate. He seems to have a outstanding reputation round here and will do anything you need. I had never heard of him but now I have it seems everyone I speak to is like "oh yeah Andy, he is §§§§ hot at welding". He said it was a new challenge for him but admitted he loved doing it.


The weld on your sump is very nice :)

Bet you can't wait to get on with the project? :)

I cant wait!!! Its been slow going with the bodywork issues which Im still on with and various other problems but now I feel like things have taken a positive step forward and Im getting closer to the finished product.....still a long way to get yet though.

[streaky744]

keep up the good work,

and while hunting around ebay for some trick bits for my race car came across this which i think is quite rare for a 240 and thought of you straight away and would make loads of difference to the drive of your finished project

http://www.ebay.co.uk/itm/volvo-240-axle-volvo-lsd-hot-rod-atlas-axle-rally-L-S-D-volvo-drag-race-/140708207946?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item20c2dcdd4a

[antz]

keep up the good work,

and while hunting around ebay for some trick bits for my race car came across this which i think is quite rare for a 240 and thought of you straight away and would make loads of difference to the drive of your finished project

http://www.ebay.co.uk/itm/volvo-240-axle-volvo-lsd-hot-rod-atlas-axle-rally-L-S-D-volvo-drag-race-/140708207946?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item20c2dcdd4a

Ahhhhh yes Im watching that although I cant find £300 at the moment unless I win the lottery this week :( a LSD is on my list of things to buy but I have a feeling I may end up going for a Quaife ATB or such.

[Shadow]

iv seen a lot of people fit these sumps to the t5 engine but how do you know how much oil is in it? the dipstick is in the middle of the engine on the t5 and thats fine with the standard sump as its the same depth all over but with the new sump the stick will hit the shallow bit of the sump not the deep part at the end.

[antz]

iv seen a lot of people fit these sumps to the t5 engine but how do you know how much oil is in it? the dipstick is in the middle of the engine on the t5 and thats fine with the standard sump as its the same depth all over but with the new sump the stick will hit the shallow bit of the sump not the deep part at the end.

You use a Volvo 960 dipstick and dipstick tube :)

[antz]

Small update tonight:

Managed to get the weather warm enough-ish to give my passenger wheelarch a coat of lacquer to finish that off. Its not perfect but in the past the rear arch has been resprayed badly and all the paint is dull and naff. Ill deal with this in a couple of years when the car is on the road, I might treat it to a full respray but thats in the future.

Sprayed arch:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0173.jpg

Trim on - woo one less piece kicking around in the workshop and one more piece back on the car!
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0176-1.jpg

example of bad respray on the arch previously (not my work). Its not the best but its better than nothing:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0174-1.jpg

And I got the engine turned over for this weekends preperation to fit the 960 upper engine mounts:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0177-1.jpg

Plans for this weekend:
Fit upper 960 engine mounts
Drill & fit lower engine mounts to crossmember
Replace lower drivers side suspension arm at same time as fitting lower engine mounts
Repaint passenger sill where overspray occoured

[antz]

Well today me and my mate made a start on the engine mounts.

First up was my decision to bin the standard PCV system in favour of a remote catch tank which will work better and means I dont have to adapt the engine mounts to fit, just do a bit of jiggery pokery at a later stage.

With the PCV off here is the 960 mount bolted on. Only 3 bolt holes exist here so it should hold fine with one missing:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0185.jpg

And on the other side only two bolt holes are here which is a bit more of a problem. I think I may have to weld a bracket onto the left side of the mount and extend it outwards to the hole on the far left for more support:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0185.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0184.jpg

With that under way I looked at fitting the bottom mounts which bolt into the bottom arm holes on the crossmember and require an aditional hold fitting also.

The passenger side went straight on into the original bottom arm hole and lined up ok. It just needs the other hole drilling when I can:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0190-1.jpg

The drivers side bottom arm was knackered so I have a new bottom arm to go on:....Ive also decided Im going to put a bottom arm on the passenger side for the small cost its going to be:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0188.jpg

Annoyingly I got the old one off before realising the new one doesnt have a bush in it so I need a new bush. This means Im either going to have to bring forward my plan to polybush the car, fork out the £250 for a polybush kit and do it all now OR buy a single bottom arm bush and make do for now until I can afford it but do all the work twice...

decisions.....

In the meantime I ordered these stickers off eBay (not the Turbobricks ones):
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0187.jpg

More to come....please feel free to give solutions/ideas on the bottom arm bush dilema Im having....

[antz]

Well I took the plunge and just order the following parts from PFV:

1 x 200 Series, 75' on, Front Wishbone Rear Bush (2)
1 x 200 Series, 75' on, Front Wishbone Front Bush (2)
1 x 200 Series Lower Suspension Arm Left
1 x 200 Series, Rear Torque Rod Bush Kit (4)
2 x 200 Series, Rear Trailing Arm Front Bush
2 x 200 Series, Rear Trailing Arm Rear Bush

I havent ordered anti-roll bar bushes or Panhard bushes because when I get the money Im going to order a IPD 25MM anti-roll bar kit and a DVS Performance adjustable panhard, both of which include polybushes so theres no point me buying items twice.

[claymore]

It's coming on great bud.

[graemewelch]

ust a thought but why done you fabricate a custom mount for the one that only has two holes that line up

[daza-b]

looking good bud :)

[antz]

ust a thought but why done you fabricate a custom mount for the one that only has two holes that line up

I could do but tbh it'd be more of a ballache making a mount up for that side thatll fit and having it all welded up rather than popping the mount and spare block down to my welder and saying "extend that please" :)

[antz]

Well guys Ive had a break from the car for a few weeks due to just total burnout I think so I took the time to get back into my Fords, dig out the mk2 Escort and go burn some new tyres up.

But I am back on the car now and here are the fruits of tonight.

I discovered that the standard anti-roll bar will hit the sump of the new engine and as such I needed to find the super rare Volvo 260 V6 anti-roll bar. A half-assed post on VOC and 20minutes later I had one....WOW!

The only problem is Ive just ordered a standard 240 IPD roll bar set from the USA (DOH!) So im going to use the rear roll bar and sell the front on when it arrives.

Standard on top and V6 on bottom :
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0223.jpg

fitted:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0229.jpg

New bottom arms with polybushes fitted:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0198.jpg

And the rear wishbone bushes fitted which were an absolute bitch! They are now done though which is good.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0228.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0200.jpg

And thats it.....

Next up is the sort the engine mount spacers and finally get the tester block fitted.

[antz]

Well today the car gained its very first taste of 5 cylinder goodness!

I managed to pick up my engine mount from Volvo. I need to use two of the thicker 240 engine mounts for the new engine (exhaust side?) and Id only ordered one originally so now I have two.

Then my mate popped round with some spare metal he thought might work for the engine mounting spacers after we have braced it all up but for now we were only trying a bare block so we gave it a go.

The whole lot literally just dropped in and bolted up in 10minutes!

As you can see there is the 960 upper engine mounts on the 240 rubbers to my spacers and the bottom mounts which are bolted through the wishbone hole and a second hole in the crossmember Im yet to drill.

Mounting everything up has given me a good view of where I need to drill the 2nd holes for the lower mounts. Also now it all fits in the engine mount spacers can come off and be braced and tidyed up so they arent so crude....but at least they work!

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0230.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0231.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0232.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0233.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0235.jpg

[M-R-P]

Is it a good thing I'm browsing the forum with a 42" screen? I think so :)
Good job there sir, comeing along nicely.

[tattoo101]

hey buddy coming along nicely.. what are you going to use for your intake manifold? are you keeping it standard or build you own?

[antz]

hey buddy coming along nicely.. what are you going to use for your intake manifold? are you keeping it standard or build you own?

Im using an ME7 inlet manifold. Turbo manifold Im going to see if an ME7 manifold fits onto a custom downpipe.

[tattoo101]

will that not put the tb at the back of the engine? im looking around for ideas as i will have the same dilema soon

[Volvostorm]

Coming together well mate :)

[antz]

will that not put the tb at the back of the engine? im looking around for ideas as i will have the same dilema soon

It can be done with the ME7 manifold but I havent looked into sorting a way around it yet. The best thing to do would be to speak to Karl Bucha or Homer on turbobricks.com or even Chesh750R on Turbobricks or VOC.

[p fandango]

It can be done with the ME7 manifold but I havent looked into sorting a way around it yet
http://i791.photobucket.com/albums/yy196/pedro-fandango/Volvo/mine/BT/Turbo%20Manifold%20Exhaust/DSCF0426.jpg

[antz]

Well today me and my mate Glen decided to crack on and get the car back on its wheels so that I can get my 960 in next to it for breaking.

We started out by drilling the crossmember to enable us to fit the lower bolts on the crossmember. Then we fitted the lower mounts permanently in position where we found the bottom arms were foulding the new lower bolt on the engine mounts. So we modified the bottom arms and refitted them, then it was all suspension back on and dropped back onto its wheels for the first time in a good while.

Lower mounts & spacers fitted after being all braced up and powder coated:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0265.jpg

Both mounts fitted:
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0266.jpg

finally it sits on all 4 wheels! WOO!
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0267.jpg

[Volvostorm]

Why are you breaking the 960?

[antz]

Why are you breaking the 960?

A combination of too many cars, too much to fuel it, missed the turbo of my T4, I need the parts for this one and I need the money becuase I bought it on impulse haha.

Well tonights a tiny update since I started making a move on breaking the 960 but a lad on the same small estate of workshops came round for a nosey and gave me this:

Original Nissan Skyline R32 GTR intercooler. Its massive!......and it was free!
http://i52.photobucket.com/albums/g36/letpigsfly/DSC02061.jpg

[M-R-P]

Oooh! Naughty ;)

[Volvostorm]

You can never get better than a freebie :D

[antz]

Well todays update is another small one. My lower body braces arrived from DVS Performance in Australia. Ive used them before and ran quite a few of their suspension upgrades on my previous 240 and they were brilliant quality, affordable, arrived in 7-10 days and Ash who runs DVS is such a nice guy and really helpful.

http://www.dvs.net.au/

At some point Ill be ordering one of their adjustable panhard rods, upper strut to strut bars to accompany the original GT style strut to bulkhead braces and probably get one of the aluminium sump guards. I had one on my old 240 and it was much harder wearing than the flimsy plastic volvo tray.

http://i52.photobucket.com/albums/g36/letpigsfly/DSC02070.jpg

[antz]

Well its been a while since I updated this due to too many projects simply. Ive been busy working on trying to strip my 960 for spares, fix up my Escort mk2 (which has broken again) and my mum friend camr round one day and said "dya wanna buy my car off me?" so I ended up with an MOT failure Peugeot 106 Quiksilver.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0290.jpg

YUK! I hear you cry, but its actually quite a sweet little thing, didnt need much for an MOT and should be a tidy profit maker so Ive been working on that quite a lot to get it ready for an MOT

But less of the French tat...

My turbo manifold arrived which I bolted to the engine, although it seems most of the threads in the engine block have gone as it wont tighten up properly. Ill have to helicoil all that. FUN!....Not.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0287-1.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0288-1.jpg

Then actually some real progress. I managed my first M90 bolted to the T5 block ready for test fitting. My next job is to drop it in the hole, bolt it up, measure up my gearbox crossmember and adapt that, measure the shifter arms for shortening and measure the propshaft length so I can get my prop made......then take it all back out again.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0293.jpg

And a final shot of my very full workshop. One battle ship coming to bits and one slowly having bits put on it.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0294.jpg

[M-R-P]

Aah tuere you are lol.

Nice to see you're still working on the conversion, and selling the pug ;)

[antz]

Aah tuere you are lol.

Nice to see you're still working on the conversion, and selling the pug ;)

Im still here! The conversion wont stop, Ive been doing little bits here and there, just nothing big enough to really update on and a lot of my time has gone into the Pug as thats hopefully going to pay of a chunk of my debt. Once thats gone I can spend all my money on aaprts :)

[the young mechanic]

comeing on slow but good

[y2blade]

Following with interest :cool:

[antz]

Well not really an update on the white one but a bit update on the 960 which is giving its life for the 245.

Finally got the engine and box out. What a horrible job, I never want to go near a 960 again after that job. Although I do now have the dipstick tube, various connectors, starter motor bracket and PAS pump as well as a spare sump, throttle body, engine mounts and M90.

Big thanks to my dada here, without him, I wouldnt of been able to do it although we are now both wearing a fine collection of scuffs, scrapes, cuts and plasters

Battling with the stupid 6cyl:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0297.jpg

http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0299.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0298.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0300.jpg

The 960 is going for scrap this weekend and then I can crack on with the 245 again!

[M-R-P]

Big old lump that 6 pot. Nice to see youre still about dude. Keep it up.

[antz]

Well I had a ncie new steering wheel arrive from Japan today. Those of you with an eagle eye will notice it looks exactly like my scrapyard find £3.60 Nardi Torino wheel as it is the same model! Im having trouble getting my first one re-trimmed and this caem up dirt cheap on ebay in Japan so I bought it.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC02146.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC02147.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC02148.jpg

Now my next worry is...how the heck do I get this:
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC02149.jpg

Into here (Ive removed the front lights to stop them getting broken)
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC02150.jpg

Answers on a post card.....Going back up with my dad later this week as I cant lift, tilt and lower an enigne all by myself at the same time. haha

[tattoo101]

looking good buddy.

[antz]

Well tonight me and my trusty mate Johnners popped up the workshop to pick up a tin of stone chip on the way home and then whilst we were there we fixed some bulbs on my V40...then thought "I know lefts undo the M90 and engine since theres two of us" and then we thought "lets see how this is going to fit" before we go home.......guess what happened...

A 2 minute stop by for some stone chip resulted in the following:

http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0311.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0314.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0315.jpg

Engine fits fine and has plenty of clearance of the crossmember on my mounts and with the radiator in place theres still bags of room! Radiator is the original 240 GLT Auto one which Ill most likely need to upgrade/swap out for a bigger one but for now itll do.
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0312.jpg
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0313.jpg

The turbo looks like it may be a bit tight on the steering column but I cant check that until I swap the studs round as I need to mount the turbo upside down to how it is in the T5.

Sadly the R32 Skyline intercooler is WWWAAAAAYYYYY to big to fit anywhere in the car so thats back to the drawing board. I was told Sierra Cosworth RS500 intercooler should fit. Johnners disapproving thumbs down says it all...
http://i52.photobucket.com/albums/g36/letpigsfly/IMAG0316.jpg

Next job.....get the front of the car in the air and offer up the M90 to enable measuring for the gearbox crossmember and measurements for shifter arm shortening.

[antz]

So last night I decided to crack on and get the holes drilled in the bulkhead plate for the clutch master cylinder that Ive been putting off doing since October.

Top and bottom holes drilled fine but stupidly I made a **** up and didnt drill the middle hole evenly so now its going to be a right pain to enlarge evenly.

Live and learn...
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0326.jpg
Scratch was already there....not my clumsy doing!
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0327.jpg

Then tonight I recruited an army of helpers (Dad and Glen) who gave me a hand getting the M90 bolted to the engine. Its going to be a right §§§§§§ to do up all the bolts so for now its just held in on 4. Its enabled us to look at the gearbox crossmember though.

M90 behind view with M47 crossmember bolted up for a coat of looking at. How do we make this work...
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0328.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0331.jpg

Like this: These are pictures of Homers crossmember over on Turbobricks. He made my engine mounts and after looking carefully at the position of my gearbox, we just need to copy this. Measure twice cut once obviously.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC_0025.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC_0028.jpg

And here is the difference between the back of the box and the gearlever hole. Ill have to measure this distance up and compare it to the length of the gear lever arms, mock them up and get them shortened as necesserily. Bein ally they will need to go to my specialist welder Andy Lockwood who did the sump.
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0330.jpg

Excuse my poor pictures. Light is bad in the workshop and the camera on my phone is junk. I normally take my camera with me but I forgot the last couple of days.

[M-R-P]

Nice to see progress mate. I have a couple of rotary cutters that fit into a cordless drill that may help with trimming holes and removing burrs... ;)

[Volvostorm]

Coming together nicely mate :)

[antz]

Nice to see progress mate. I have a couple of rotary cutters that fit into a cordless drill that may help with trimming holes and removing burrs... ;)

Thats what Im thinking of. Ill have a look in the shops this weekend and get some bought. I find tools like that always come in handy at some point or another in the future :)

Watch this space for more updates soon!.....hopefully.

[antz]

Well today in my usual fashion I recruited another army of helpers.....massive thanks to my mate Glen and Steve and his 244 from the VOC for their help today.

We managed to get the M47 crossmember bolted up, then adapted to take a 960 gearbox mount and all bolted up again.

This means for the first time ever I have a Volvo 240 with a T5 engine and box bolted into the car on their own mounts with no blocks of wood or trolley jacks holding it up!

We followed Homers pictures from Turbobricks and copied this design exactly. This makes things really simple utilising the standard crossmember mounts on the back edge with the front ones only needing some minor modification to the rubbers to get a few mm sideways movemnt for the bolt holes to line up. Still looks factory too.
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC_0025.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/DSC_0028.jpg


And fitted up it looks like this...excuse the bad pictures again
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0333.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0334.jpg

Not much clearance here for a dizzy. Defo a standalone job.
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0335.jpg

Then we drilled the bulkhead out and fitted the clutch cylinder! Its nearly there from its auto to manual conversion.
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0336.jpg

Stay tuned for more kids...

[johnners]

Great progress dude :)

[antz]

Well over the last couple of nights Ive got a few jobs done.

Bolted up the clutch cylinder and attached the clutch pedal. Auto to manual conversion is almost done!
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0338.jpg

Then reconnected all the dash pipes, fitted centre console back and refitted the under dash carpet. Itll probably have to come out when I re-wire the car but for now it tidys things up and makes sure I dont lose too many bits:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0339.jpg

Before anyone mentions the tacky sparco pedals...I had them on my first 240 and didnt have any pedal rubbers for these pedals so they were fitted as a memory of the old car :) and im too cheap to buy pedal rubbers

Gear lever arms test fitted to see how much they need shortening by. I forgot to measure this but according to photos Ive seen I think they will need shortening roughly the length of the gear lever hole itself.:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0347.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0348.jpg
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0349.jpg

More to follow in a few days...

[the young mechanic]

pretty good

[antz]

So today we set about adapting the turbo to fit.

One a T5 the turbo exits through the drivers side of the car so if I fitted the turbo in standard form it would mean the exhaust exits the front and this is no good. So....I have to run the turbo upside down to make it exit correctly.

This presents another problem as the turbo manifold is studded on the top and the turbo is studded on the bottom, so I had to drill out the studs on the turbo so I can nut and bolt it.

After a while of trying to get the studs out (one snapped) we managed to drill the cast housing out so it looked like this:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0356.jpg

turbo slotted on!:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0352.jpg

Im using a 16T for now just to keep things easy. Rather fit it all up and get it running, then think about upgrades:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0353.jpg

And shot from underneath:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0355.jpg

As you can see, the exhaust will foul the steering column so ill have to whip that off and refit it upside down to give more clearance. Ive heard this cam be done so ill soon find out!

[antz]

small update today.

Got a package yesterday from Partsforvolvos. The IPD anti roll bar kit I got on special order to IPD through PFV has arrived!

Its the full 25mm fornt and rear kit with polybushes and bracket. Very swish!

But sadly, I cant use the front bar as I need to use a 260 V6 bar....something I didnt know at the time of ordering but I can still use the rear bar and get a 24mm 260 bar from Whiteline.

Ill be listing the IPD front bar on ebay later tonight as ita a great upgrade on its own without the rear bar.

http://i81.photobucket.com/albums/j205/letpigs63fly/DSC02246.jpg

[antz]

Another small update.....Motivation is lacking and cashflow is low so Im starting to flag with doing jobs :(

Ive managed to source a front uprated ARB I can use. I just need to buy it...more details on that another day.

Bolted up my IPD rear ARB today. Itll have to come off again when I polybush the rear of the car but I cant be bothered to fight with that at the moment and its not detrimental to the build so its a job for another day.

Original GLT bar Vs IPD bar:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0362.jpg

And fitted up! Dead easy job but would of been much quicker with 2 people rather than trying to hold the bar, insert the bolt, adjust the shock absorber and put the nut on the end all in one go.
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0364.jpg

More another day...

[partsforvolvos.com]

I cant quite believe the difference in size between old and new !! omg.

that has to make a considerable improvement for sure...........

[tattoo101]

haha i was just about to ask you about this, as ive just took my engine out and realised the turbo is the wrong way round for rwd. im a little behind you on my project, so when i get stuck i just come here lol cheers dude :)



So today we set about adapting the turbo to fit.

One a T5 the turbo exits through the drivers side of the car so if I fitted the turbo in standard form it would mean the exhaust exits the front and this is no good. So....I have to run the turbo upside down to make it exit correctly.

This presents another problem as the turbo manifold is studded on the top and the turbo is studded on the bottom, so I had to drill out the studs on the turbo so I can nut and bolt it.

After a while of trying to get the studs out (one snapped) we managed to drill the cast housing out so it looked like this:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0356.jpg

turbo slotted on!:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0352.jpg

Im using a 16T for now just to keep things easy. Rather fit it all up and get it running, then think about upgrades:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0353.jpg

And shot from underneath:
http://i81.photobucket.com/albums/j205/letpigs63fly/IMAG0355.jpg

As you can see, the exhaust will foul the steering column so ill have to whip that off and refit it upside down to give more clearance. Ive heard this cam be done so ill soon find out!

[jmc]

Great project. Keeping an eye on this for my RWD conversion. Looking at your pics has helped me with figuring out engine mounts :B_thumb:



Not much clearance here for a dizzy. Defo a standalone job.


Any info on the standalone? Going to have to do the same with mine as I have the same issue with dizzy clearance.

[WillT5]

Really looking forward to your progress update mate, look like alot of hard work but it will be so worth it.

Thanks for sharing

Will,

[rockheadrumble]

Looking good mate, looking forward to seeing it when its finished.

[kfc]

Have been folloeing with much interest, looks a sterling job so far mate.

[streaky744]

did this ever get finished or come to a grinding halt for some reason?

be interested in buying it to finish it if its just sat doing nothing

[M-R-P]

I think it's still ongoing, however, I think he's been busy with other things recently.

[antz]

did this ever get finished or come to a grinding halt for some reason?

be interested in buying it to finish it if its just sat doing nothing


I think it's still ongoing, however, I think he's been busy with other things recently.

Still ongoing and never really ground to a halt. Ive had a few smaller projects in the meantime and I stopped posting on here a long time ago. Ive only popped back on today to redirect people to the current progress thread over on VOC.

http://www.volvoforums.org.uk/showthread.php?t=135987

See you all on the other side.