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Rydell
Tuesday 1st November 2011, 17:54
Hi there.

As I am now getting to the stage where I am going to need advice and help with all things 854 T5, i thought I would start a thread to chart the progress of what I assure you, will be a slow burn race car preparation thread.

If I can get the car in some sort of order, and out for the last race of next season I will be extatic!!!

So, where do I start?
Having competed in sprints and hillclimbs for around 5 seasons in a Clio 172 Cup, I had to give up due to the recession and a distinct lack of funds. Jump forwards 2 years and I was attending the end of season sprint event held by NSCC at Thoresby, just outside Ollerton, Notts.
I was talking to some of my old friends while watching the action, and talk turned to whether I would do any motorsport again?
I said yes, but this time I would like to do something a little different!!!!
At the time I had a picture on my phone of an 850 estate touring car rep, which I showed to my friends. There were a few raised eyebrows, but the general consensus was that it would be a good idea.
So, on returning home, I fired up the lap top and behold, an 854 T5 in white on Ebay for £600!!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/KGrHqIOKocE43NOzp3BONRVCrGJw0_12.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/KGrHqQOKiYE4bHWdboBONRVKNeGQ0_12.jpg

A deal was struck and the Volvo made its way straight into the workshop, where it is going to spend the next few months undergoing its transformation into a 1995 BTCC replica.
The first job was to remove around 200kgs of interior trim etc.
I then started to remove chunks of the wiring loom that was no longer going to be required.
As per the works cars, we also removed the various cross members from the floor pan which we would not be needing.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0645.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0652.jpg

The hand brake tower has now been modified and will be re welded at the rear of the tunnel out of the way. The gear lever platform has also been removed and will be re made to allow the gear lever to be mounted further back and a little higher than standard. These mods are all a result of me being 6’ 3” and sitting quite far back in the car!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0646.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0647.jpg

All the sound deadening pads have also been removed from the floor pan to help reduce weight further.
We then borrowed a seat from another competitor so we could weld in some 30mm box section for the seat rails in the right position. While adjusting the seating position, it became clear that the steering wheel was going to have to move. The adjustment bracket has been modified to allow more of a drop and slightly longer reach, and with the new steering wheel and boss in place is just right.
At the moment the car just keeps getting taller and taller as we remove more and more weight!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0651.jpg

Compared with it its original condition:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/KGrHqYOKjE4jv-TYYkBONRVJ7-7w0_12.jpg

This weeks tinkering has resulted in:
Bonnet pins fitted to bonnet and boot lid.
The boot lids inner skin has been cut down.
Door inner skins have been trimmed back.
Switch panel has been fabricated for battery cut off and starter button etc.
All battery wiring has been re-directed into the car. The battery will sit in a box in the passenger footwell.
I have also sent some rollcage specs off to a pipe bender to get a quote for the main hoop and front legs of the cage I have designed. Once the quote is back and I have enough money, the cage can start to go in and the interior will then be painted and we can move on to the engine bay!
More pics and updates will follow. I now have to try and get her running again. Following advice given in another thread, I may have to reinstate the transponder ring so the car will start again.
I’m going to need lots of advice on getting the car to handle and releasing more power from the engine etc, so stay tuned!

JT
Tuesday 1st November 2011, 18:26
oh the memories come flooding back!! lol

just shout as an when you need some help, the guys on here are "second to none"!
I might be able to help, but I wouldn't bank on it!! lol

keep up the great work.
JT

Jamest5r
Tuesday 1st November 2011, 19:54
Getting quite common these race car's lol, wish i had the space/cash to do it, any reason no-one is going for the 855?.

JT
Tuesday 1st November 2011, 19:56
one word!

aero.........:)

AndysR
Tuesday 1st November 2011, 19:59
Welcome to the fold, sounds like a nice interesting project. Keep us updated with your developments.

Jim S70R
Tuesday 1st November 2011, 20:03
Very nice, welcome to the club and keep up the great work.

antz
Tuesday 1st November 2011, 20:15
looking forward to seeing this unfold...

Rydell
Tuesday 1st November 2011, 22:25
Only reason I didnt do an 855 was there wasnt one available at the right money at the time! 855 was definitely the inspiration for this project. My previous experience of Volvos are an 855 T5 CD and and 855R.

Volvostorm
Tuesday 1st November 2011, 22:41
Cool! Another replica, we will have to all meet up up one day :)

Its starting to look really good.

M-R-P
Tuesday 1st November 2011, 23:12
Really liking the look of this project. The Flying Moose and Claymore will agree with you about getting the bonnet pins in early ;) Welcome to the loonybin and please keep us posted on the project. :welcome:

Volvostorm
Tuesday 1st November 2011, 23:15
Really liking the look of this project. The Flying Moose and Claymore will agree with you about getting the bonnet pins in early ;) Welcome to the loonybin and please keep us posted on the project. :welcome:

Yeah! Got mine to fit too!

t5_monkey
Wednesday 2nd November 2011, 09:25
awesome project keep the thread updated with lots of photos please!

The Flying Moose
Wednesday 2nd November 2011, 12:33
Nice project, love the Replica BTCC cars... especially roadworthy ones. Anyone who doesnt give them a second glance must be insane!

martybelfastt5
Wednesday 2nd November 2011, 16:58
nice these are getting popular lol,,,,,surprise pedro hasnt thanked you for them grinder shots lol

Rydell
Wednesday 2nd November 2011, 20:04
Rickard runs once more.

Re-connected the transponder ring and taped the key to it. Car fired 3rd time of asking on its new starter button!! Woohoo!

The order for the roll cage main hoop and front legs is going in tomorrow. Should be ready in 1-2 weeks. Then fabrication can start on the rest of the climbing frame!

Must admit, the cage in Rickard is not as extensive as Johnny T's, biut is copied from the 1996 850 that is currently for sale in Holland. Anyone got £67,000 they dont want????

Rydell
Saturday 5th November 2011, 21:24
Ok, update time.
Got to the workshop at 8.45 this morning and left tonight at 5.00pm. Managed to tidy up quite a few loose ends and get the interior ready for the impending roll cage.
Here is my bin liner of spare wiring taken from the Volvo.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0693.jpg

As mentioned previously, I have lightened a few panels etc. Here is the boot lid:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0691.jpg

Doors

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0695.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0700.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0701.jpg

Rear bumper and brackets:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0707.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0706.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0709.jpg


Dash

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0702.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0698.jpg

I’ve even taken the saw and grinder to the steering column:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0744.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0743.jpg

Bonnet and boot pins installed ready:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0710.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0711.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0714.jpg

Rydell
Saturday 5th November 2011, 21:25
Back to today’s progress. First job was to remove the starter panel I have just got working and the dash. The dash will be going off to be flocked in the next few weeks. Just need to get the cage front legs in place so we can cut the dash to fit around it before it goes away.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0696.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0697.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0698.jpg

Dash out. Now time to tidy up the last of the wiring. Whats left of it anyway!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0717.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0716.jpg

I’ve been using copex to tidy up the wiring as I go:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0719.jpg

Also re fitted the immobiliser module to the column which was the route of the starting problems I had last week.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0718.jpg

Now all the wiring has been tied up and the dash is out of the way, I could start removing seam sealer from the sills where the cage feet will be welded and generally tidy up spot welds that had been drilled and other bits and pieces.
The last of the sound deadening from inside the car being chipped away:

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0722.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0727.jpg

Once it had all been knocked off, I cleaned up the panel with some gun wash

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0726.jpg

Removing the seam sealer with a strip and clean wheel

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0725.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0724.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0723.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0733.jpg

Rydell
Saturday 5th November 2011, 21:26
Then, having given the floor pan a good vacuum and a panel wipe down, I prepped the modified hand brake tower ready for welding into its new position.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0728.jpg

In its new position I have had to re-route the cables, which has worked quite well

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0741.jpg

Also gave the seat mounts a bit of a clean up with the strip and clean wheel

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0736.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0735.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0734.jpg

Something I have found is that since cutting the inner skin from the boot lid, there is a lot of flex when you pull the boot lid shut. Once it is locked in place, its fine. We decided that a bit of a tack weld in the corner of the boot would help

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0739.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0738.jpg

One of the last bits to give up its hold on the shell was the rear seat pivot brackets. These are pretty heavy duty and the spot weld cutter wasn’t doing it. Bought out the grinder and they soon gave in

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0737.jpg

While im waiting for the cage to be fabricated, I will need to tidy up the wiring in the boot.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0692.jpg

Talking of the cage, here are some pics of the template I made using 20mm plastic conduit and a bending spring! One of Stuarts customers thought it looked a bit thin for a roll cage!!!!!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0687.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0705.jpg

Here are some pics of the cage as I hope it will look

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/Volvo-850-Sedan-Benzine-Wit-022--9926463-Medium.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/Volvo-850-Sedan-Benzine-Wit-021--9926461-Medium.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/Volvo-850-Sedan-Benzine-Wit-020--9926459-Medium.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/Volvo-850-Sedan-Benzine-Wit-023--9926467-Medium.jpg

Rydell
Saturday 5th November 2011, 21:26
I have taken delivery of the 3mm steel that the feet of the cage and the base plates will be fabricated from. Can’t wait to try cutting this up!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0748.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0745.jpg

So far so good!

AndysR
Saturday 5th November 2011, 21:26
Blimey, you have been busy...

Rydell
Saturday 5th November 2011, 21:34
Blimey, you have been busy...

Mans got to have a hobby! I try and make the most of the time I get to play.

Rydell
Saturday 5th November 2011, 21:36
Anybody know of any major pit falls when dropping the engine out on the subframe. Want t o drop the lot out in one go so I can get around the engine and prep the engine bay. Also looking for uprated/solid bushed for the subframe, which will be seam welded.

AndysR
Saturday 5th November 2011, 21:39
Mans got to have a hobby! I try and make the most of the time I get to play.

What a fantastic way to spend your spare time. I am insanely jealous.

I also love the fact that, despite it's age, there appears to be absolutely no rust and to add I bet it's not been treated like a fragile piece of china over the years either, coming to Volvo from a Ford background you really do appreciate how much thought and time has gone into the design and construction of a Volvo when compared to most other cars.

Jamest5r
Saturday 5th November 2011, 21:53
Blimey, you have been busy...

Your not bloody wrong very good going make's my suspension and alternator change look like i was sitting around drinking beer all day :)


Anybody know of any major pit falls when dropping the engine out on the subframe. Want t o drop the lot out in one go so I can get around the engine and prep the engine bay. Also looking for uprated/solid bushed for the subframe, which will be seam welded.

Dropping the sub-frame for a man of your obvious talent's will be easy lol, on tip i could suggest is do the steering from under the dash not by the sub-frame makes it so much easier to put back in.

Jim S70R
Saturday 5th November 2011, 22:09
You certainly have made good use of the day, I'm lovely the attention to detail your putting in this car. Great work!!

Itching to see the next update.

JT
Saturday 5th November 2011, 22:09
Anybody know of any major pit falls when dropping the engine out on the subframe. Want t o drop the lot out in one go so I can get around the engine and prep the engine bay. Also looking for uprated/solid bushed for the subframe, which will be seam welded.

I have been searching for the same bushes, I think you (we...lol) are gonna have to get them made.


Blimey, you have been busy...

at this rate, your be ready for the start of the season, Forget the last race!:)


Your not bloody wrong very good going make's my suspension and alternator change look like i was sitting around drinking beer all day :)

nothing wrong with a good beer mate!
quite agree, sooooo much easier done on the inside,especially having put mine back on today.


about time this thread was promoted to the projects section !!:B_thumb:

Tomcat
Saturday 5th November 2011, 23:04
Agreed, moved to 'Projects section'.

T4Rick
Saturday 5th November 2011, 23:47
That was a good read mate lol.how much do you rekon the car weights now

Rydell
Sunday 6th November 2011, 08:54
That was a good read mate lol.how much do you rekon the car weights now

I'm hoping for around 1200 - 1250kgs and around 300 - 350bhp? Also hoping I can get the car to sit low enough on the suspension kits that are available.

T4Rick
Sunday 6th November 2011, 10:33
I'm hoping for around 1200 - 1250kgs and around 300 - 350bhp? Also hoping I can get the car to sit low enough on the suspension kits that are available.

Sounds good mate i will be watching this thread

Rydell
Sunday 6th November 2011, 20:19
Order now placed for the cage hoops and material. The guy making them will be sending me a cad drawing of my design for sign off and will then make them up as soon as the material arrives at his workshop.

That will create quite a lot of work I think!

JT
Sunday 6th November 2011, 20:28
you going to fit the cage yourself??

Rydell
Monday 7th November 2011, 20:08
Yes, once the main hoops are bent, everything else is a straight tube which we will measure, cut and profile ourselves before welding them in.

Cant wait to get started.

JT
Monday 7th November 2011, 20:13
blimey, good luck with that

I'm sure you are but...
you are aware of the new roll cage regulations???


not sure if this is any use to you?

http://www.msauk.org/uploadedfiles/msa_forms/bluebooks/11/152-190%20Competitor%20Safety.pdf

Cubes
Monday 7th November 2011, 22:18
Loving this thread!

Rydell
Tuesday 8th November 2011, 11:03
blimey, good luck with that

I'm sure you are but...
you are aware of the new roll cage regulations???


not sure if this is any use to you?

http://www.msauk.org/uploadedfiles/msa_forms/bluebooks/11/152-190%20Competitor%20Safety.pdf

We have been referring the the 2011 blue book and have spoken to scutineers at the last round of the CSCC series to make sure we are doing it right.

Rydell
Tuesday 8th November 2011, 11:04
Here is the cad drawing of the front leg of the roll cage. Material should be in stock on Monday so cage bits should be ready Wednesday next week. Can’t wait.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/Frontleg.png

JT
Tuesday 8th November 2011, 11:09
Sounds like you have everything under control
I think the biggest revision was the front leg from the roof to the footwell
Is only allowed1 bend at the bottom of the wind screen.
There was a massive failure of the cage on a car with 2bends!
Look forward to see progress on weds then! Lol

Rydell
Wednesday 9th November 2011, 10:10
Sounds like you have everything under control
I think the biggest revision was the front leg from the roof to the footwell
Is only allowed1 bend at the bottom of the wind screen.
There was a massive failure of the cage on a car with 2bends!
Look forward to see progress on weds then! Lol

Dead right. My co-builder on this is co-ordinator for the tin tops series at Classic Sports Car Club and said that Peugeot 205's ran a cage with more than 2 bends and they were all pulled up on it at scrutineering. Ours has a bend at the dash and one at the top of the screen.

Rydell
Wednesday 9th November 2011, 20:02
Just purchased this vital bit of kit. The tube notcher is used to profile the end of each roll cage tube so it fits perfectly onto another tube.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/BtyYldw2kKGrHqQH-CgEvpZvB8fHBL9Z0uWUsg_14.jpg

Here it is in action. Takes a maximum of 51mm tube (2in) which is lucky, as my cage will be made out of 50mm CDS tube. Will be interesting to see how long the hole saws last after a few cuts. I can feel a bit of trial and error coming on.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/BtyYnzmkKGrHqEH-DsEvpZ7q4SvBL9Z01dM_12.jpg

p fandango
Wednesday 9th November 2011, 20:08
if found these hole cutters LINK (http://www.screwfix.com/c/tools/erbauer-bi-metal-holesaw/cat830308) to be good, but i'm not cutting CDS tubing lol. Nice bit of kit tho that notcher

JT
Thursday 10th November 2011, 18:14
Just purchased this vital bit of kit. The tube notcher is used to profile the end of each roll cage tube so it fits perfectly onto another tube.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/BtyYldw2kKGrHqQH-CgEvpZvB8fHBL9Z0uWUsg_14.jpg

Here it is in action. Takes a maximum of 51mm tube (2in) which is lucky, as my cage will be made out of 50mm CDS tube. Will be interesting to see how long the hole saws last after a few cuts. I can feel a bit of trial and error coming on.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/BtyYnzmkKGrHqEH-DsEvpZ7q4SvBL9Z01dM_12.jpg

proper bit of kit that!:)

at work I have always found Starret cutters to be the best.
http://www.starrett.co.uk/shop/holesaws/

Rydell
Thursday 10th November 2011, 18:24
Just received the drawings for the main hoop of the cage. 6 days and counting now!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/MainHoop.png

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/MainHoop2.png

Should receive the tube notcher at the workshop tomorrow as well.
The next job though is to finalise the position of the gear stick and weld in the new mounts etc. Might have a bit of a play with the notcher when making the gear stick mount. More pictures will follow over the weekend as I am at the workshop again on Saturday.

Rydell
Sunday 13th November 2011, 10:56
Another busy day on the Volvo.
Got some welding done today until the gas ran out!
Handbrake tower now re located to the back of the tunnel, out of the way!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/001.jpg

Next item to receive attention was the gear lever. As the Volvo has a cable shift, we have been able to move the gear stick back and up for a more comfortable position. This involved plating the tunnel with some 3mm steel to add strength and give a flat platform. I then fabricated 4 posts from 20mm tube and welded captive nuts into the top. And just to finish off, and add some strength fore and aft, I used the tube notcher to make 2 braces between the towers (needed to have a practice).

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/005.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/022.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/021.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/028.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/027.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/037.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/044.jpg

Next up was to add some strength back into the rear of the floor where the back seat used to be. This plate will also serve as the base for 2 cross braces from the main hoop down to the floor to help absorb any side impacts!

First thing was to flatten the buldge in the floor. This was done by slicing through the hump in a T shape and then flattened using a hammer and dolly.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/002.jpg

This is the under side of the floor, where the exhaust center box used to sit.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/008.jpg

3mm plate cut and bent to shape with a huge hammer.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/024.jpg

And seam welded into place.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/025.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/032.jpg

The holes left when removing the rear seat squab were also plug welded and then ground flat.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/042.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/041.jpg

Rydell
Sunday 13th November 2011, 10:57
At this point, the argon ran out on the MIG welder, so play was halted until Monday morning when BOC open again. I did get some more blanking plates made up so they are ready for then.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/030.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/034.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/033.jpg

As this was all done, I then started to take the front of the car apart, ready for when we drop the engine out. All did some prep work for bracing the strut tops back on to the bulk head. This involved moving some of the wiring loom, ABS pump and brake servo assembly.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/018.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/019.jpg

On removing the front wings, I found the first bit of rust on the car! Looks like I will be needing a new O/S wing from the breakers.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/009.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/010.jpg

That said, the rest of the structure was looking solid.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/013.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/012.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/011.jpg

With the front bumper now off the car, which was a job and a half, I did a bit of weight removal in the same way as with the rear. The front beam isn’t nearly as substantial as the rear.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/038.jpg

A huge chunk of polystyrene was removed which weighed more than you’d image.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/040.jpg

And the lower half of the bumper/spoiler is just a plastic skin that clips onto the upper.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/039.jpg

Also spotted another major bodge on the front suspension. The springs have obviously been cut and then, to hold them in place, they have been welded onto the bottom spring platform!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/015.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/014.jpg

Rydell
Sunday 13th November 2011, 10:58
Not a major problem, as this lot will be binned in favour of some KW coilovers.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/100_1012-1.jpg

And, no, these aren’t mine. This is a picture of what I am looking at, but will come a lot later in the project.
Next steps are……….

Roll cage hoop and front legs should be ready on Monday, so I just need to get down to Solihull and pick them up. I then anticipate at least a month or so of weekends to get everything into place, plated , notched and cut, before all being seam welded up. I am also going to be adding more strength to the floor with some channels and flitch panels to the seat base. The channels will also for the platform for the fire extinguisher.

There will be a lot of trial and error I am sure, but this will see the interior fabrication finished and it can then be painted. Hopefully over the Christmas period!

JT
Sunday 13th November 2011, 18:10
so many memories.......lol

keep going mate, long way to go:)

Rydell
Sunday 20th November 2011, 19:01
Right, rollcage installement.
Picked the rollcage tubing up on Wednesday and delivered it to the workshop. Spent an hour with Stuart trying the main hoop and front legs for size, then had to go to work!
Windscreen has now been removed to allow access for welding etc.
Got a text on Friday morning from Stu to say he had got the rear hoop in and boxed the feet of it. Later that day, the front legs went in as well! I thought this was going to take both of us and a lot of time. Obviously not.
Then spent Saturday morning measuring and cutting additional tubes to form the rest of the rollacge.
Stuart then went in this morning and did even more welding and I went in later and cut some more tube. Anyway, enough waffle, here are the pictures.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0840.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0841.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0844.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0848.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0842.jpg


The front of the cage has been bolted to the rear as we cannot get a continuous weld around the tube. The same will be true of the windscreen tube along the top of the screen. All plates, cage feet and joints have to be seam welded.


http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0843.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0847.jpg

An additional brace for side impact resistance!


http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0846.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0856.jpg

Here is the tube notcher earning its keep. My trusty old black and decker drill provides the power, although it does struggle a bit sometimes.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0851.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0850.jpg

This is the finished article. One of the diagonal braces for the rear cage. The excess was ground off the side that the cutter didn’t quite catch.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0852.jpg

Here is the rear bracing taking shape.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0854.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0855.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0853.jpg

And finally, the door bars taking shape. Not decided which way to go with these yet.

Rydell
Sunday 20th November 2011, 19:01
http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0857.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0858.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0861.jpg


Where possible, the cage tubes have also been welded directly to the shell. There will also be additional gussets fabricated to tie the cage into the shell and to reinforce certain junctions between tubes. (Hoping James RScos has made a tool for this)

Tomcat
Sunday 20th November 2011, 19:30
Don't door bars normaly go the other way around?...ie. lower at the front than the back?, that way getting in and out is easier..

JT
Sunday 20th November 2011, 20:04
here are the regs on cages TC

and if you understand any of it, can you explain it to me??

http://www.msauk.org/uploadedfiles/msa_forms/bluebooks/10/160-195%20Competitor%20Safety.pdf? lol

Rydell
Sunday 20th November 2011, 22:24
Don't door bars normaly go the other way around?...ie. lower at the front than the back?, that way getting in and out is easier..

The 1996 works car has them higher at the front than the back. Johnny T has the full cross for door bars and Im undecided.

As long as you can get out in 7 seconds, and the door bars dont obscure more than a 3rd of the door aperture, then pretty much anything goes.

JT
Sunday 20th November 2011, 22:48
I only went for the crossover bars as my cage goes through the bulkhead to the suspension mounts at the front. otherwise mine would have just had the single bar higher at the back,lower at the front.
but as you say....personal choice
I think if you need to get out asap and the door wont open, the cage makes no difference.

looking great mate,keep up the great work:)

Rydell
Sunday 20th November 2011, 22:59
Going to brace the front struts to the bulkhead, purely because if the front takes a big knock and is connected to the cage, it could twist the cage which would involve loads of work to put right on top of whatever repairs the bodywork might need!

As you say, personal choice.

JT
Sunday 20th November 2011, 23:13
thats a good idea.
having just had mine put on the jig, the guys said the front chassis legs are so strong on these cars the dont really bend,but in the event of a front impact the whole leg goes inwards.which is quite a major job to replace anyway.it goes all the way under the floor plan.

anyway, whatever you decide, I'm sure will be fine and fingers crossed you never need it!!!

:)

Jim S70R
Monday 21st November 2011, 00:36
The cage has come together really nicely, welding looks good as well.

AndysR
Tuesday 22nd November 2011, 00:42
Very neat work, you've clearly welded before and your attention to detail is commendable. Looking forward to your future updates

Rydell
Sunday 27th November 2011, 18:32
Right, rollcage is just about finished now, along with various other strengthening bits and plating that was required.

Just need to make the windscreen bar and weld in the eye bolt plates for the harness, then the interior will be ready for paint.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0865.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0864.jpg

Door bar position changed from original design.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0866.jpg

Decided on a last little strengthener for the door bar to front leg.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0867.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0870.jpg

Stuart doing more welding

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0877.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0876.jpg

Strut bracing cut and ready to go.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0869.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0868.jpg

Steering column brace.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0886.jpg

Heater inlet blanked off.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0879.jpg

Gear lever mount finished.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0887.jpg

Windscreen pillar strengtheners front and back of screen pillar.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0873.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0881.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0882.jpg

Rydell
Sunday 27th November 2011, 18:33
Fire extinguisher mounts, doubling as floor strengthening.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0871.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0872.jpg

Starting to look like a race car now!

AndysR
Sunday 27th November 2011, 18:43
Fire extinguisher mounts, doubling as floor strengthening.

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0871.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/DSCF0872.jpg

Starting to look like a race car now!

Excellent work :)

Rydell
Wednesday 7th December 2011, 16:50
The roll cage is now finished!

Next job is to prep the inside for paint. Gun metal grey is the colour Ive chosen. Should be done just before Xmas.

The next job will be to drop the engine and front suspension out and prep all of that. More pics to follow as soon as I get to the workshop.

Leeds_finest
Wednesday 7th December 2011, 20:26
Awesome project - I myself have a VW Polo that i've been modifying for about 2 yrs now and the hardest part is documenting all the progress :(

Top work :)

Rydell
Wednesday 14th December 2011, 19:09
Been working away this week and been generally busy with the whole “run up to Christmas” thing, so was very pleasantly surprised when these two pictures dropped into the inbox of my phone.

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/intpant.png

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/intpaint2.png

My good friend Stuart has finished the prep of the Volvo’s interior and spent a good 5 hours masking and painting it gun metal grey.

I am hoping to get over to the workshop tomorrow to get some more detailed pictures and see it in the metal.

More to come soon.

t5steve
Wednesday 14th December 2011, 22:31
looking very good...........keep up the high standards you have put in place throughout this build as it will pay huge dividends in the finished car............looking forward to next installment

Rydell
Sunday 18th December 2011, 16:35
As promised, here some pictures of the interior in gun metal grey. I got to spend some time refitting various bits including:
Wiring run down the sill tops in copex.
Handbrake
Dash, trial fitting
Harness eye bolts
Will have to wait and see if santa brings any more goodies to move it on now!

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0913.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0914.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0915.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0908.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0909.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0902.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0905.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0896.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0899.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0907-1.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/DSCF0916.jpg

Jim S70R
Sunday 18th December 2011, 21:28
That looks awesome, I bet you can't wait to get this out on track once it's complete.

JT
Sunday 18th December 2011, 22:18
yep, I have to agree, looking great!

I assume your gonna wrap the dash?
(I cant remember the tech name for the finish?? lol)

JT

t5steve
Sunday 18th December 2011, 23:32
yep, I have to agree, looking great!

I assume your gonna wrap the dash?
(I cant remember the tech name for the finish?? lol)

JT

i think you mean flock the dash?
looking good ..love the colour....very nice

JT
Tuesday 20th December 2011, 20:50
i think you mean flock the dash?
looking good ..love the colour....very nice

yea thats it!! :slap:

that will give it that proper works team look!!:)

Rydell
Sunday 25th December 2011, 12:55
Just checked through my pictures of the 1996 car doesnt have a flocked dash! Thats £75-£100 saved towards my fire extinguisher then!!

Rydell
Thursday 5th January 2012, 18:31
Hi Guys.

As dome of you may know, I am currently in the middle of preparing my 854 T5 for circuit racing.

When it comes to turbo charged engines, however, I am a complete novice and am finding it difficult to get to grips with all the acronyms flying around the forum like PCV, RIP, MBC etc etc.

I really need some advice on what I need to get more reliable power out of the T5.

My shopping list at the moment is:

Bigger intercooler with appropriate ducting in aluminium to maintain boost pressure.

Cold air intake.

New/uprated head gasket.

Inspect bottom end and possibly replace main shells and replace main bolts with ARP?

Uprate all bushes with proflex equivalent.

Cat free exhaust system from turbo back.

A manual boost controller, whatever one is and however it works!

Oil cooler.

I think that is everything, but I welcome any and all advice. I'm looking for around 280-300 bhp at the flywheel initially.

Look forward to any help.

JT
Thursday 5th January 2012, 19:00
Hi mate,
all I did was: A K&N induction kit,3" turbo back exhaust, a 16T turbo and a Turbo Tuner ecu and got these results:

http://i1198.photobucket.com/albums/aa454/johnnytempest/DSC01120.jpg

http://www.turbo-tuner.co.uk/

http://www.jt-tuning.se/shop/default.aspx?lng=ENG&cur=EUR

http://www.demon-tweeks.co.uk/performance/induction-kits/car/volvo/850-t5/kn-filters-57i-performance-induction-kit

JT

Volvostorm
Thursday 5th January 2012, 20:55
Cool, some nice figures, for not many mods :)

p fandango
Thursday 5th January 2012, 21:01
Cool, some nice figures, for not many mods :)
yep, Sam really knows what he's doing lol

Volvostorm
Thursday 5th January 2012, 21:29
yep, Sam really knows what he's doing lol

Does he want to try a car with a lots of mods!? ;)

Rydell
Friday 13th January 2012, 19:52
Hi mate,
all I did was: A K&N induction kit,3" turbo back exhaust, a 16T turbo and a Turbo Tuner ecu and got these results:

http://i1198.photobucket.com/albums/aa454/johnnytempest/DSC01120.jpg

http://www.turbo-tuner.co.uk/

http://www.jt-tuning.se/shop/default.aspx?lng=ENG&cur=EUR

http://www.demon-tweeks.co.uk/performance/induction-kits/car/volvo/850-t5/kn-filters-57i-performance-induction-kit

JT


So you haven't rebuilt the bottom end or changed the head gasket or anything then? How many miles does your engine have on it?

JT
Friday 13th January 2012, 20:05
So you haven't rebuilt the bottom end or changed the head gasket or anything then? How many miles does your engine have on it?

at that point I had not changed a thing.
101k on the clock,completly standard

but.........
http://i1198.photobucket.com/albums/aa454/johnnytempest/conrods.jpg

but possibly a bad turbo rebuild is the cause of this,not the power I was putting through it??

I'm sure someone will argue that point.

Rydell
Sunday 15th January 2012, 10:22
So did you replace with uprated rods or standard rods?

JT
Sunday 15th January 2012, 10:31
I've got forged rods going in.

Not sure of the figures, but I have 300bhp in my head as max on standard rods, but I think boost levels play a part in there somewhere too???

With any luck, someone who knows what they are talking about will post here soon and be a bit more specific! Lol

claymore
Sunday 15th January 2012, 10:42
I think standard rods can take in excess of 350bhp if the car is mapped properly, but you can bend the rods with around 260bhp with the wrong use of a MBC

Rydell
Sunday 15th January 2012, 10:56
So, to sumarise, uprate or die! Have to confess, at this stage I am really torn between building for more power (expensive) or getting the car up and running and out on circuit to see what it actually does. Would hate to get out there with all that power only to find the car doesn't go round corners very well or wont pull up quickly enough.

Just added up some engine tuning basics and got to £2500 without new rods, ARP bolts, head gasket etc.

claymore
Sunday 15th January 2012, 11:02
Just added up some engine tuning basics and got to £2500 without new rods, ARP bolts, head gasket etc.
How on earth did you get to that price? My car stands me about £1500 in total, that includs the price of the car, the brakes and the suspension.

JT
Sunday 15th January 2012, 11:53
So, to sumarise, uprate or die! Have to confess, at this stage I am really torn between building for more power (expensive) or getting the car up and running and out on circuit to see what it actually does. Would hate to get out there with all that power only to find the car doesn't go round corners very well or wont pull up quickly enough.

That was my idea and think it was the best way forward.
get a sensible amount of power,otherwise you could find yourself getting left behind ( as I did in my second race! lol) and just run the car,get used to it and sort out those gremlins that will show up once your up and running.

looking forward to seeing this finished,do you think it might be done intime for trax???

Rydell
Sunday 15th January 2012, 13:44
When is Trax?

Cant see it being ready this year. Once you start adding up how much all these bits cost, it soon mounts up. Priced up the brake system plumbing yesterday and got to £200 without much trouble. Fire extinguisher is £100, poly windows £150, seat another £400-500! Rich on enthusiasm, poor on budget!

Rydell
Sunday 15th January 2012, 13:47
How on earth did you get to that price? My car stands me about £1500 in total, that includs the price of the car, the brakes and the suspension.

Turbo tuner, Samco hoses, CDA cold air filter, injectors, fuel pump, fuel pressure regulator, 18t turbo, exhaust system, and engine overhaul (plugs, leads, dizzy cap, rotor arm, cambelt, all fluids etc.

JT
Sunday 15th January 2012, 13:59
check out this thread.

http://www.vpcuk.org/forums/showthread.php?t=40195

be great if you get there,give it a blast round silverstone and plenty of guys around who can help with probs or info

and of course a great pic of them side by side!!:B_thumb:

Rydell
Sunday 15th January 2012, 14:43
I will be there.........not so sure about the car. My friend and co-builder wants the car fully tested before he will let me put the livery on it! Still not sure on the engine spec, not to mention a whole heap of money to be spent on things like suspension, wheels, brakes etc. Will be doing everything I can though:smile:

JT
Sunday 15th January 2012, 15:39
i see what he's saying

mine looked like this at the first test:
http://i1198.photobucket.com/albums/aa454/johnnytempest/SDC10816.jpg

we even bolted the suspension on at the track!! lol

Rydell
Monday 16th January 2012, 16:31
Thats the one!

I think a decision has been reached and the car will be remaining relatively standard as far as the enginew spec goes at the minute. That said, I still need a full exhaust, air filter ecu and new hoses etc.

Will be running in invitation for the first season to ensure that we havent built something that will blitz the rest of the field. Also be good to get experience of the race tracks and general set up of the car.

That said, I can still see around £5k changing hands before it is somewhere near!!

Nobody said racing is cheap.

JT
Tuesday 17th January 2012, 21:27
Thats the one!

I think a decision has been reached and the car will be remaining relatively standard as far as the enginew spec goes at the minute. That said, I still need a full exhaust, air filter ecu and new hoses etc.

Will be running in invitation for the first season to ensure that we havent built something that will blitz the rest of the field. Also be good to get experience of the race tracks and general set up of the car.

That said, I can still see around £5k changing hands before it is somewhere near!!

Nobody said racing is cheap.

oh yea!!
do you have any performance bits yet? wheels,tyres,suspension etc?

Rydell
Tuesday 31st January 2012, 19:18
Just finishing off the interior now.

Got seat, harness, poly windows, extinguisher all in.

Just got to make up the new door cards and get the windscreen fitted and the interior is about there.

Next on the shopping list are, wheels, exhaust and engine bits.

Rydell
Tuesday 31st January 2012, 19:22
http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/2811218.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/2811210.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/2811217.jpg

http://i307.photobucket.com/albums/nn315/Tymberland/Volvo%20BTCC/281127.jpg

JT
Tuesday 31st January 2012, 20:57
looking great! :B_thumb:

any idea on your race weight?

AndysR
Tuesday 31st January 2012, 22:31
Still looking fantastic :)

t5steve
Wednesday 1st February 2012, 01:01
good work mate..............keep updates coming.............

Rydell
Friday 3rd February 2012, 20:26
looking great! :B_thumb:

any idea on your race weight?

Not at the moment. Hope to get it weighed once its up and running again.

Maybe 1150kgs???

Jim S70R
Friday 3rd February 2012, 23:27
Looking good....

JT
Friday 3rd February 2012, 23:37
Not at the moment. Hope to get it weighed once its up and running again.

Maybe 1150kgs???

does the series your going into not have a race weight reg?

ie a target weight????

streaky744
Tuesday 7th February 2012, 01:07
great project and good read this thread.

the v70 that i stripped and raced on short curcuits weighed 930kg and i'm guessing your car won't be much heavier so should fly.

as others had mentioned i thought roll cage now had to have a bar front top of front hoop to the door bar where your brace bar is, as well as your brace bar?also from the rear hoop to the outer roof bar? and from someone who has had a drivers door hit i would have gone for a double drivers door bar as well. but your car your choice or is the group you intend to race in restricted on cage sizes?

i've attached a couple of pics to show type of bars i mean and the door bar set up. sadly know its not cheap any of this but your saftey can't have a price on it when it comes to a roll cage

JT
Tuesday 21st February 2012, 18:36
allo mate,
no updates for a while??
I was just wondering what series you will be running in,as I might need to look at other options..........

Rydell
Tuesday 21st February 2012, 21:31
Tell me about it! Been working the past few Saturdays which all help pay for the build but mean I have no time to work on the car. Just got back off holiday too, so hope to get some more done this weekend.

The series I will be racing in is the Future Classics with the Classic Sports Car Club. The first season will be in the invitation class as the co-ordinator wants to see how the car goes to make sure that we dont just blitz the field! The 850 runs right at the end of the period covered by Future Classics (70s, 80's and early 90's upto 93 I think).

No weight limit as far as I know. The guy that is helping me with the build is also a co-ordinator for CSCC (Tintops series) so I keep very well informed through him. Regs etc no doubt are on CSCC web site, so take a look. Two 850's in the pack would look awsome!

JT
Wednesday 22nd February 2012, 19:38
will do
and quite agree 2 on the grid would look great!!!

JT
Wednesday 22nd February 2012, 21:35
I'm liking the 40 minute races, but not sure about the pitstops??

you can just imagine me pulling up into a box,getting out,changing the wheels,having a sandwich, then getting back in, putting the harness on and driving off!!
the race would be all over!!! lmao!!

I might be better suited to the special saloons!:)

woody
Wednesday 22nd February 2012, 21:53
Brilliant effort, loving the progress!

Rydell
Monday 27th February 2012, 14:16
Its been a while I know, but managed to get down to the workshop on Saturday after I finished work.
Got a few more jobs finished off inside the car:

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0355.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0356.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0357.jpg

This is where the cables for the cut off switch and extinguisher go through the bulk head. I have moved these out of the way as the new windscreen is going in today.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0358.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0359.jpg

Aluminium foot rest and clutch foot rest now fitted

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0360.jpg

Just need to get some M8 allen bolts to put the seat in place.

Then turned my attention to the engine bay. Got the inner wings cleaned up a bit and put the ecu and wiring loom back in place.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0361.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0362.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0363.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0364.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0365.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0366.jpg

Then I got all excited and put the headlight panel back on and even offered up a front wing! I have cut out the middle section of the headlight panel, hoping to increase air flow.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0367.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0368.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0369.jpg

Almost looks like a Volvo again. Next steps are to get the bits and pieces for the engine bay, including, intercooler, oil cooler, boost hoses, air filter and then give the engine a service and get it up and running again to see what we have to start with.

Rydell
Monday 27th February 2012, 21:16
Quick update for tonight. Windscreen is now fitted!
Forgot that I had also recently purchased some V70R front caliper carriers. Got them cleaned up and painted over the weekend too.

http://i1187.photobucket.com/albums/z383/Rydell850/V70RCarriers.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/V70RCarriers2.jpg

Rydell
Sunday 4th March 2012, 11:06
Got a day off work this week as a job I was meant to be start was delayed! Got myself straight down to the workshop via B&Q.
Purchased some white hamerite, a set of cheap paint brushes and a couple of drill attachments for removing some of the rust scabs under the arches.
Windscreen now fitted by the local Auto windscreens branch. Top Job.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0373.jpg

Note the state of the bonnet, more later!

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0374.jpg

Quickly whipped off the front strut so as to gain full access to the front o/s arch.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0377.jpg

Here are the befores:

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0376.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0378.jpg

And the after:

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0379.jpg

Here is the n/s arch with a few more pics of the preparation involved prior to painting:

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0386.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0388.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0389.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0390.jpg

And the afters:

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0391.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0392.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0393.jpg

Rydell
Sunday 4th March 2012, 11:07
The rears also got the same treatment:

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0394.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0395.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0398.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0402.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0403.jpg

Now the screen is in, I could finalise the position of the extinguisher and cut off switch pull cables.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0404.jpg

Just got to trim the cut off cable to length and then attach it to the switch in the centre console.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0405.jpg

Here are the 2 cables for the extinguisher in place. One from the scuttle and one from the center consoile.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0406.jpg

Lap timer mounted on Velcro for ease of removal.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0407.jpg

Seat now bolted in with 8.8 cap head allen bolts. Harness is in place, so couldn’t resist strapping myself in to see how it felt!

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0412.jpg

As the end of the day loomed, I thought I would give the car a quick wipe down to remove some of the dust it is hiding under. The bonnet had a number of coffee cup rings on it which wouldn’t budge without a bit of G3 compound. Then gave the bonnet a once over with some G10 and here is the result.

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0410.jpg

Here is the car as I left it this week. Note the holes in the bumper which are there to allow quick access to the bolts for removal should we have an incident!

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0415.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/IMG_0416.jpg

Thanks for reading.

kyboy
Sunday 4th March 2012, 18:21
looking good mate, you know what they say "just add lightness"

Jim S70R
Sunday 4th March 2012, 20:46
I do like the work your doing and have done to this car, can't wait to see the finished result.

JT
Sunday 4th March 2012, 20:58
good work!

you are putting my prep to shame! lol
are you sure you really want to put this in harms way when its finished?? lol

Jim S70R
Sunday 4th March 2012, 21:16
good work!

you are putting my prep to shame! lol
are you sure you really want to put this in harms way when its finished?? lol

Don't worry JT I still think yours is great too ;)

JT
Sunday 4th March 2012, 21:26
ahhh thanks mate! lol

did u see the vid?:)

Jim S70R
Sunday 4th March 2012, 21:34
ahhh thanks mate! lol

did u see the vid?:)

No what vid??

JT
Sunday 4th March 2012, 21:37
on my thread mate

soon we will have two cars racing together!! cant wait!:)

Jim S70R
Sunday 4th March 2012, 21:38
on my thread mate

soon we will have two cars racing together!! cant wait!:)

I'll have alook :)

Rydell
Saturday 31st March 2012, 14:46
A few bits have arrived this week for the car. Just had time to drop my new wheels over to the workshop this morning and snap a few quick pics.

http://i1187.photobucket.com/albums/z383/Rydell850/31320125.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/31320124.png

Also got my Powerflex bush kit in the post. This includes:
Wishbone bushes, top engine mount and lower front engine mount. I have also been advised to get some solid aluminium mounts made for the anti-roll bar and adjustable drop links to suit. These will come into play when the coilovers go on.

http://i1187.photobucket.com/albums/z383/Rydell850/31320123.jpg

Here is a pic of my first single wiper conversion attempt. The wiper blade could be a couple of inches longer and I will be playing about with the sweep in the next few weeks by making the main armature adjustable in length.

http://i1187.photobucket.com/albums/z383/Rydell850/31320122.jpg

A little pic of the cut-off switches with their corresponding stickers!

http://i1187.photobucket.com/albums/z383/Rydell850/31320121.png

Just waiting on my Samco water hose kit now.

I have just made an offer on a HML 304 ECU and some blue injectors and intercooler piping. Waiting to hear back from the guy as we speak!

Will actually get down to some work on the car next weekend. Stay tuned.

bigrotch
Saturday 31st March 2012, 14:49
looks good mate replied to ya pm my koni fsds would be nice on that ;0)

Rydell
Wednesday 4th April 2012, 18:24
Well, its been an eventful few days to say the least.

I have managed to secure some blue injectors, throttle body and IC pipework to suit and a HLM 304 ECU from a forum member (cheers bigrotch).

I also thought I had sourced a suspension kit through another forum, but that has fallen through!

So, I have now spoken to Kev a BC Racing about their coilover kit for the 850. Very knowledgable chap and happy to talk about all things suspension, unlike others I have tried! Even discussed the possibility of developing a external reservoir kit with them if the factory agrees! What a mine field.

I am just waiting on some advice from another source before finally deciding which way to go with it. Things are starting to get interesting now!

claymore
Wednesday 4th April 2012, 18:29
Always look forward to updates on this car :) , getting a bit closer to completion now.

JT
Wednesday 4th April 2012, 22:00
Must be starting to gain that smile,that goes from ear to ear!! lol

cant wait to see this finished!

Rydell
Thursday 5th April 2012, 18:27
Must be starting to gain that smile,that goes from ear to ear!! lol

cant wait to see this finished!

Well, I was until I started delving into the merky world of suspension!
I've spoken to everybody from BC Racing to Ohlins! OMG

JT
Thursday 5th April 2012, 19:14
Well if it makes you feel better, I'm still struggling with my set up 18months in! Lol

charlesboya
Friday 6th April 2012, 10:28
Beautiful project, just what Volvo Cars UK are missing, a bit of passion at grass roots level. Well done on such a fantastic effort to make a dream come true. Love the car !

Rydell
Friday 6th April 2012, 11:02
Beautiful project, just what Volvo Cars UK are missing, a bit of passion at grass roots level. Well done on such a fantastic effort to make a dream come true. Love the car !

Thank you very much!

Rydell
Monday 9th April 2012, 12:09
Don’t seem to be getting much free time at the moment, which is a bit frustrating, as I have quite a few bits for the car waiting to go on!
Managed to get to the workshop this morning due to the fowl weather. Bits that have arrived this week include:
Roll cage padding
Blue injectors, large inlet and intercooler piping
HLM 304 ECU
So the first thing I did was fit the padding.

http://i1187.photobucket.com/albums/z383/Rydell850/090420126.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/090420128.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/090420127.jpg

Need another length for the main hoop where it passes over my head and something to glue to the cage foot adjacent the pedal box. That could make a mess of my ankle if we get a knock!

http://i1187.photobucket.com/albums/z383/Rydell850/paddingrequired.png

Here are the other bits. Didn’t really have time to do anything with these yet.

http://i1187.photobucket.com/albums/z383/Rydell850/090420124.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/090420129.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/090420122.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/090420123.jpg

http://i1187.photobucket.com/albums/z383/Rydell850/0904201210.jpg

Just ordered one of these:

http://i1187.photobucket.com/albums/z383/Rydell850/BrakeBias.jpg

Now I have my 17 inch wheels, I can get my larger caliper brackets fitted and the brakes plumbed in from the original master clylinder. Just need to measure how much brake hose I need and find out which ends to order to suit the callipers and master cylinder etc. The rear brake pressure will be controlled in the car with the valve.

Plenty to be getting on with. Hopefully back in the workshop next weekend.

Rydell
Saturday 21st April 2012, 17:08
Not an update I will enjoy writing or posting after all this progress!
Due to pressure of work and family commitments and losing my workshop facilities, I now have to let this project go to a new home.
Serious thanks go to Stuart at RWS for all the time and hard work he has put into this car, not to mention putting up with me dropping in when I can.
I took some time out this week to put the car back together as far as I can. Gave it a quick polish and removed the film from the Lexan windows. Also fitted the last bit of roll cage padding above the drivers head.
Here is the car as it stands today.

http://i1187.photobucket.com/albums/z383/Rydell850/photoph1.jpg

Now up for sale and will be kept under wraps until a new owner is found.

http://i1187.photobucket.com/albums/z383/Rydell850/photoph4.jpg

claymore
Saturday 21st April 2012, 17:11
That's not good news :(

Gunscrossed
Saturday 21st April 2012, 17:54
Not an update I will enjoy writing or posting after all this progress!
Due to pressure of work and family commitments and losing my workshop facilities, I now have to let this project go to a new home.
Serious thanks go to Stuart at RWS for all the time and hard work he has put into this car, not to mention putting up with me dropping in when I can.
I took some time out this week to put the car back together as far as I can. Gave it a quick polish and removed the film from the Lexan windows. Also fitted the last bit of roll cage padding above the drivers head.
Here is the car as it stands today.

http://i1187.photobucket.com/albums/z383/Rydell850/photoph1.jpg

Now up for sale and will be kept under wraps until a new owner is found.

http://i1187.photobucket.com/albums/z383/Rydell850/photoph4.jpg
How much you looking for?

Rydell
Sunday 22nd April 2012, 07:04
Dont have enough posts to put up a for sale ad! Dont want to upset any moderators.

The car stands me at £4500 at the mo. I already have takers for the seat, harness and steering wheel. Open to any sensible offers.

JT
Sunday 22nd April 2012, 10:49
not good news!
:(
if I had the money.................:(

JUDGENINJA
Sunday 22nd April 2012, 10:58
Get it on race car sales website. You may get a far bit more than from one of us..

JT you buy it and finish it... I'll be your second driver!!

JT
Sunday 22nd April 2012, 11:31
Get it on race car sales website. You may get a far bit more than from one of us..

JT you buy it and finish it... I'll be your second driver!!

I would if I could! :B_steerin

claymore
Sunday 22nd April 2012, 12:09
I's a shame the cage is welded in :(

AndysR
Sunday 22nd April 2012, 13:42
That's an update I wasn't expecting :(

Good luck with the sale of the car though..

martybelfastt5
Sunday 22nd April 2012, 16:24
sorry to hear she is for sale,,,

Kerry_T-5R
Monday 23rd April 2012, 13:23
Thats a shame, was hoping to see a good update! Good luck with your sale.

spesh
Wednesday 25th April 2012, 11:40
Pm'd

Rydell
Thursday 26th April 2012, 10:59
Pm'd

Pm'd back!

Gunscrossed
Friday 27th April 2012, 16:27
Keep coming back to this, what would it take to make it road legal again?

Rydell
Friday 27th April 2012, 21:10
Spesh has currently got first refusal on the rolling shell. Car should be sold by 9.00am tomorrow. Will just be left with a pile of parts!

Rydell
Saturday 28th April 2012, 12:53
Rolling shell has gone to its new home in Wales. Cant wait to see it running 500bhp!

charlesboya
Saturday 28th April 2012, 14:08
Good to know the project is still alive.