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EddyP
Friday 18th January 2013, 00:56
Thought you guys might be interested to see what i've been up to with a T5 lump.

I originally built the car with a Honda V6 in it, but decided I wanted more power, improved reliability and something a bit different, which is why I decided on T5 lump.
First off, out with the Honda:

19958

19959

19960

19961

19962

Next job was to prove the fit on a spare chassis and fab up a couple of mounts, bit easier on a chassis without a body on:

19963

Its a bit tight:

19964

It fits:

19965

M-R-P
Friday 18th January 2013, 01:11
Err, that things gonna be a blast! Watching this one with interest ;)

Wobbly Dave
Friday 18th January 2013, 01:11
How have you mapped it?

EddyP
Friday 18th January 2013, 09:40
Dave - you're jumping ahead there ;)

These pics are about 2 years old, the car is actually done, although in bits at the moment as I broke the landing on a Mahle piston.
It's running on an Emerald ECU, which was mapped by Dave Walker at Emerald. In fact i've got the original ECU for sale at the moment as i've upgraded to the next version to gain a few features that I want, mainly so that I can get rid of the dizzy.

Made a new mount for the M66 gearbox:

http://www.talkaudio.co.uk/ipb/uploads/1286751406/gallery_269_3218_17736.jpg

http://www.talkaudio.co.uk/ipb/uploads/1286751406/gallery_269_3218_21085.jpg

http://www.talkaudio.co.uk/ipb/uploads/1286751406/gallery_269_3218_9426.jpg

Plasma cutters are great:

http://www.talkaudio.co.uk/ipb/uploads/1286751406/gallery_269_3218_15169.jpg

Add a bit of triangulation in to suit the new nose mount:

http://www.talkaudio.co.uk/ipb/uploads/1286751489/gallery_269_3218_80970.jpg

850 engine, with 19T and other mods ready to be detailed:

http://www.talkaudio.co.uk/ipb/uploads/1286751435/gallery_269_3218_51405.jpg

Cleaned and painted:

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_38571.jpg

Before:

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_23778.jpg

After:

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_41111.jpg

stribo
Friday 18th January 2013, 09:47
Wow, that's some top notch work, can't wait to see more.

partsforvolvos.com
Friday 18th January 2013, 10:08
that's awsome!! i bet it is a totally different experience having the t5 engine but without it dragging 2 tonnes of volvo behind it !!

Wobbly Dave
Friday 18th January 2013, 11:56
Sorry about the gun jumpin'. Just looking at the 19T & how small it looks in comparison to my GTX!

EddyP
Friday 18th January 2013, 15:36
Bits shot blasted ready for paint:

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_70880.jpg

Painted

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_78022.jpg

Some bits polished, before:

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_26219.jpg

After

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_26020.jpg

Idle Valve

http://www.talkaudio.co.uk/ipb/uploads/1286751489/gallery_269_3218_19844.jpg

http://www.talkaudio.co.uk/ipb/uploads/1286751489/gallery_269_3218_50361.jpg

Detailed

http://www.talkaudio.co.uk/ipb/uploads/1286751489/gallery_269_3218_82281.jpg

Original 4 stud hub

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_44174.jpg

Welded up the original holes, faced the hubs off, and redrilled them for Audi 5 stud PCD so that I could fit better brakes and nicer wheels

http://www.talkaudio.co.uk/ipb/uploads/1286751453/gallery_269_3218_35636.jpg

Volvostorm
Friday 18th January 2013, 16:09
I remember reading about the project in PPC, glad to see it still improving :)

EddyP
Friday 18th January 2013, 18:37
A standard flywheel, a TTV flywheel to suit an M66 and an S60r clutch:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1228.JPG

I needed to fit the Focus ST selector , i've modified the brackets on the gearbox so that the cables work from the opposite direction, this meant the selector itself needed to go backwards too, then custom cable were made up

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1177.JPG

An airsaw is an essential tool

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1179.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1181.JPG

Catch can and charge cooler header tank

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1182.JPG

Charge cooler radiator, mounted in the side air intake

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1186.JPG

Oil cooler, mounted in the air intake on the other side

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1185.JPG

Walbro pump fitted

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1205.JPG

At the same time I changed the rear De dion suspension from a panhard rod to a Watts linkage, this helps with the travel of the De dion, so that there's less risk of popping a driveshaft out, which could be a risk as my driveshafts are going to be pretty short
https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1214.JPG

Weld a pivot on, in the centre of the De dion

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1238.JPG

Turn a boss, and weld it into the chassis tube

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1211.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1239.JPG

Paint the chassis now that all the mods are complete:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1245.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1246.JPG

EddyP
Friday 18th January 2013, 18:48
Engine going in

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1270.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1276.JPG

Suspension back on

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1275.JPG

Now for the driveshafts, Volvo inner needed, and an Audi outer as i'm using Audi hubs, so I started off with a Focus ST shaft, and chopped it up

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1283.JPG

Then did the same with an Audi shaft

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1277.JPG

Luckily, the Focus shaft is sold, and the Audi shaft is tubular, so with a bit of turning of the Focus shaft

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1285.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1284.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1279.JPG

Now for welding them up, I V notched the ends of the tubes to add in some surface area for welding, then a kind mate Tig welded them up

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1288.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1289.JPG

Done

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1291.JPG

Bit of wiring next, wanted it to look smart, but didn't want to spend a fortune on Raychem boots, so found these in a breakers yard, Audi/VW use them a lot:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_2000.JPG

EddyP
Friday 18th January 2013, 18:51
Then with a pen and some bright heatshrink some nice labels can be made too
https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1292.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_2005.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_2003.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1292.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1294.JPG

EddyP
Monday 21st January 2013, 09:10
Anyone want more pics then? ;)

lance
Monday 21st January 2013, 09:29
Yes please

stribo
Monday 21st January 2013, 10:05
Anyone want more pics then? ;)

Always, it's looking great so far. How did you balance the driveshaft?

volvokid
Monday 21st January 2013, 10:35
This is looking awsome

The White Knight
Tuesday 22nd January 2013, 13:18
Anyone want more pics then? ;)


:B_thumb:

EddyP
Tuesday 22nd January 2013, 22:12
Got, few more pics for you.

With my ECU I can send it an EGT signal for it to alter the timing/fuelling if things start getting a bit too hot, with the existing manifold and turbo housing being cast I didn't want to get into welding a boss onto it as the expansion rates would be different and then ultimately it would crack, so I got a little adapter made:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1296.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1298.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1297.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1302.JPG

Now time to make the exhaust, 3" all the way, start off with a load of bits from Jetex

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1305.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1309.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1310.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1311.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1313.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1314.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1317.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1322.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1327.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1331.JPG

EddyP
Tuesday 22nd January 2013, 22:13
https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1329.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1354.JPG

All TIG'd up:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1840.JPG

stribo
Tuesday 22nd January 2013, 22:26
Progress looks to be going well, I'd have been tempted to have twin outlets for the exhaust, purely for aesthetics.

EddyP
Tuesday 22nd January 2013, 22:39
The body is designed around a single outlet, but I do know what you mean, my daily drive is an S2000, and I love the symmetry that twin outlets have.

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/225913_10150237862521171_3060052_n.jpg

LiamT4
Tuesday 22nd January 2013, 22:48
that looks different to most s2000s you see.

EddyP
Tuesday 22nd January 2013, 23:13
that looks different to most s2000s you see.

S2000 daily driver, Vortex (this car) weekend toy ;)

EddyP
Tuesday 22nd January 2013, 23:45
Modified the original oil thermostat pipes to go onto the braided hoses to my new oil cooler:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1343.JPG

Mods to the turbo oil/water pipes as it's now in a different place due to my EGT spacer

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1347.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1350.JPG

Next job was to mount the Audi hubs, machined up some adapter plates in order to bolt them to the de dion axle, was important to get the depth of these right as it sets the disc location within the calliper too

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1356.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1355.JPG

Audi RS4 brake discs, alloy bell cast into the steel disc, nice and big but lightweight!

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1665.JPG

Handbrake cable mount modified

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1648.JPG

Next, I wanted to use a braided fuel line, but the volvo connection is a weird thread, so modified it to be standard, starting with a connector I faced one end off:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1318.JPG

Then drilled it to suit the diameter of the Volvo fuel fitting, and brazed it together

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1319.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1321.JPG

M-R-P
Tuesday 22nd January 2013, 23:58
WOW!

There's some serious projects going on these days, this is one of them. So clean and methodical.

Nuff respect!

stribo
Wednesday 23rd January 2013, 12:07
The body is designed around a single outlet, but I do know what you mean, my daily drive is an S2000, and I love the symmetry that twin outlets have.

https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-ash4/225913_10150237862521171_3060052_n.jpg

Yeah, looks alot better with the body on.

EddyP
Wednesday 23rd January 2013, 23:09
Next was a lot of plumbing, thanks to http://www.siliconhoses.com/ for great deals on the huge amount of hosing.

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1366.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1367.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1368.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1434.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1438.JPG

Made a pipe for the idle valve and to get the throttle body to clear my gear change cable mount

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1642.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1959.JPG

Chargecooler

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1955.JPG

Charge cooler pump

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1956.JPG

Charge cooler header tank

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1960.JPG


Ready for the ECU
https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1372.JPG

Always hard to keep this many wires tidy

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1993.JPG

marct1980
Thursday 24th January 2013, 22:51
This is one of the best threads that i have ever followed! great stuff !

woody
Thursday 24th January 2013, 23:02
Fantastic workmanship! Love it!

EddyP
Thursday 14th February 2013, 23:03
So next it was rolling road time for mapping:

20309


http://www.youtube.com/watch?v=t-XI0g-B_JY

jotter22
Thursday 14th February 2013, 23:27
what an amazing write up but if i am not mistaken did someone say s2000? if so 243 BHP as standard more than a standard T5 and with a jackson racing super charger 330BHP i am not sure i understand all the work? But i am drunk so might have got it wrong!

Tony.

EddyP
Thursday 14th February 2013, 23:32
S2000 is my every day car, this is my weekend car which originally had a Honda V6 which was only 160bhp, hence the change :)

jotter22
Thursday 14th February 2013, 23:38
Ahh i see now even though i am now in the volvo clan i have a soft spot for Honda having owned a import 4th gen prelude for 5 years if the 2.2 vtec could deliver more torque i would have nothing else the sound is addictive!

Tony.

stribo
Friday 15th February 2013, 00:05
So next it was rolling road time for mapping:

20309


http://www.youtube.com/watch?v=t-XI0g-B_JY

So come on then what figures did you get? BTW sounds great.

EddyP
Friday 15th February 2013, 00:47
Unfortunately we couldn't complete the mappping, as the air intake temp sensor wasn't working right. So a basic map got done and she did 308bhp.
After the mapping session a few mods were done, things like the air intake temp sensor sorted, lots of interior bits to the car, I also put a few thousand miles on the clock.
Went to a few shows and she was looking good:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_0807.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_0839.jpg

Now in October 12 I took the car back to Emerald to be remapped, to finally wind the boost up, and see what real figures could be achieved.

The day didn't go too well, the first power run was on the same map as last time and the power had dropped off, to 292bhp, wasn't sure why, but we carried on mapping, and with the boost turned up a bit she did 333bhp @ 1.6bar.
I wasn't too happy with this, and so when I got back decided to do a full health check, and did a compression test to start with, which is when I found that No.4 was considerably down, 65/70 psi down!

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_0981.PNG

So I did some test and pressurised the cylinder with the airline to see if it leaked into the crank case or not, and it did, so knew it was engine out time:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1139.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1142.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1144.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1145.JPG

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1147.jpg

Santa
Friday 15th February 2013, 08:52
I remember reading about the project in PPC, glad to see it still improving :)

First time I've seen this thread (my bad) and was thinking "I've seen this before!". Brilliant build/project thread and many thanks for sharing! :)

EddyP
Saturday 2nd March 2013, 21:34
Bit of an update:

Upon stripping the engine down, I found a bit of damage to the piston:

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1157.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_1159.jpg

So it was time for a full rebuild, after much deliberation i've decided to go with:

Oversize AE pistons, current H beam rods, new crank (later, lighter version), new mains etc..

Things then took a turn for the worse, I took the block down to a very well known machine shop locally, supplied them with one of the new pistons, gave them the clearance, and asked for a rebore. The next week I get a call to say they've made a mistake and as a result one bore has been over bored and they're going to fit a liner. I wasn't too happy with this, so went down to see them and in the end they agreed to pay for a new block if I got one.
So I sourced a new block, got it machined and started to clean it up, after much wire brushing it looks like

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2010-02-2013%2014%2013%2046.jpg

Unfortunately when cleaning it I found out there was a snapped head bolt in one of the holes:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2023-02-2013%2010%2035%2051.jpg

This delayed things quite a bit, luckily we'd got some left handed drills at work, so I made a guide bush up, and then started to drill it nice and square:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2023-02-2013%2010%2045%2048.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2023-02-2013%2010%2035%2040.jpg

It came out really easy! so so relieved!!

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2023-02-2013%2010%2056%2027.jpg

Next I masked the block up for painting:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2023-02-2013%2016%2053%2003.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2002-03-2013%2015%2054%2045.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2002-03-2013%2015%2055%2000.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2002-03-2013%2019%2036%2018.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2002-03-2013%2019%2036%2023.jpg

I've also got a very expensive set of bags and boxes on my table ready for some real work tomorrow

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2028-02-2013%2023%2012%2009.jpg

p fandango
Saturday 2nd March 2013, 22:05
Very nice, 1 very expensive table

i see you got a later crank then. I don't suppose you've weigh'd it to confirm the weight difference have you?

t5 pete
Saturday 2nd March 2013, 22:23
All coming together and looks lovley with the silver paint do you happen to know the part numbers for the pistons
Cheers

EddyP
Saturday 2nd March 2013, 22:41
I'll weigh the new crank tomorrow and put pics up of both, it's a brand new crank i've got too :D

Pete - do you want the part number of the old or new pistons?

t5 pete
Saturday 2nd March 2013, 22:46
the new ones please eddy

p fandango
Saturday 2nd March 2013, 22:46
I'll weigh the new crank tomorrow and put pics up of both, it's a brand new crank i've got too :D
thanks, & YOUCH :o

EddyP
Saturday 2nd March 2013, 23:10
the new ones please eddy

I think it's 243668, it's the only number cast inside them. AE is stamped there, and 0.4 is on the crown, so it's the Oversize 1 set i'm using. I can check on Vadis for you if you want?

t5 pete
Saturday 2nd March 2013, 23:17
Thats brilliant thank you i will be ordering a set in the next week or 2 and its always nice to know part numbers before i go in lol

EddyP
Saturday 9th March 2013, 19:24
More progress:

When inspecting the rods, I noticing that one of the little end bearings and turned slightly, so I pressed it out, then got some high temp loctite, warmed the rod up, froze the bearing, and put it back in.
Induction warming the rod up
https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2007%2051%2059.jpg

Next I dropped a load of bits off to be shot blasted as I want to repaint them all and make them look like new:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2010%2042%2030.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2010%2042%2033.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2020%2031%2059.jpg

Then I went to see a man in a shed to balance the engine components, people like really are golden, barn on a farm, loads of kit and some beautiful bits being engineered there, the man himself, immense skill and all the bits to do everything, he even let me stay with him during the process and explained how it all worked, 3 hours there and the bargain price of £80!!

First off the pistons, rings, clip and pins are weighed:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2011%2056%2015.jpg

Some material was taken out of the back of the piston skirt until each set of components had an equal mass:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2011%2059%2037.jpg

Then the rods are weighed using the special fixture:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2012%2023%2007.jpg

Again a bit of material was taken off the relevant end of the rod until they're all equal, this was done by just linishing the small end.
Once the little ends all weigh the same, the rods were weighed normally, and material was taken off the big end until they had an equal mass again.

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2011%2056%2020.jpg

Once all of this is done, through some calculations the weight on the journal of the crank can be found, this is then replicated with some bob weights, which are clamped to the journals of the crank, and the crank goes onto this machine:

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2012%2025%2005.jpg

https://dl.dropbox.com/u/56281588/T5%20Conversion/Photo%2007-03-2013%2012%2025%2027.jpg

Stupidly I didn't take any pics of the crank all bob weighted up, basically the machine tells you which end is out of balance and at what angle, you then add or remove mass to make it true, then repeat the process again with the flywheel, again with the clutch pressure plate, and again with the crank pulley.
Each item has a bit of mass taken out of it until it all balances up. Then the most important step is to mark it all up, so when you take it apart you know where to put everything back again.

stribo
Saturday 9th March 2013, 19:34
That's some serious work, should give some really good power figures once it's all built.

claymore
Saturday 9th March 2013, 19:38
Nice, informative writeup Ed

T5frankie
Saturday 9th March 2013, 19:59
how did i miss this thread, awesome mate, well done, how much does the car weigh altogether?

EddyP
Saturday 9th March 2013, 20:17
Car weighs in at 1200kg.
If I really wanted to I could make it lighter and loose the zircon, stereo install, electric seats etc... but i'd rather just give it more power and keep the creature comforts ;)

I'm hoping for 350bhp when it's back together, it did 333 with compression down on one cylinder. I've gone for a later crank that's lighter and the later pistons i'm using are also lighter, so it might be a bit more revy now too.

T5frankie
Saturday 9th March 2013, 20:23
Car weighs in at 1200kg.
If I really wanted to I could make it lighter and loose the zircon, stereo install, electric seats etc... but i'd rather just give it more power and keep the creature comforts ;)

I'm hoping for 350bhp when it's back together, it did 333 with compression down on one cylinder. I've gone for a later crank that's lighter and the later pistons i'm using are also lighter, so it might be a bit more revy now too.

you're on the limits of a 19t pretty much already at where you are now

EddyP
Saturday 9th March 2013, 20:31
I'm going to try a billet wheel in the 19T, if I get bored with that i'll just have to get a GT3071, there is someone who's selling one at the moment and it's pretty tempting! need someone to buy my old Emerald ECU first though.....

T5frankie
Saturday 9th March 2013, 20:34
I'm going to try a billet wheel in the 19T, if I get bored with that i'll just have to get a GT3071, there is someone who's selling one at the moment and it's pretty tempting! need someone to buy my old Emerald ECU first though.....

i think with a car looking as nice as that it needs to be alot quicker than a t5, so stick a big garrett on there for 450bhp

EddyP
Saturday 9th March 2013, 21:03
On a rather brisk drive last year from Santa Pod to Silverstone with a load of Vipers, I didn't have too much trouble keeping up, and that was only with 300bhp ;)

https://dl.dropbox.com/u/56281588/T5%20Conversion/IMG_0839.jpg

T5frankie
Saturday 9th March 2013, 21:09
how does it handle?

EddyP
Saturday 9th March 2013, 22:00
Pretty well, although i'm still working on the setup. It's got double wishbones at the front, and a De Dion rear axle, which is a sort of semi independent suspension.
The main issue i've had handling wise is bottoming it out, I like it a bit lower than it should be, so i'm playing with spring rates to try and help with that, it's a lot better now than it was a couple of years ago.
I also did a mod to the steering last year which transformed the feel of the car, also managed to get rid of the bump steer.

There's no shortage of traction, i've yet to properly light it up, but I do treat it with respect, too much time and money has gone into it to treat it like a Volvo ;)

EddyP
Thursday 18th April 2013, 21:16
Thought it was about time there was an update:

Started off with my nicely painted block:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2008-03-2013%2013%2056%2050.jpg

Then spent even more money with TMS Volvo:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2008-03-2013%2014%2001%2053.jpg

New shells in, with some assembly lube on them:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2008-03-2013%2014%2009%2025.jpg

Later, 3.7kg lighter crank, brand new too!

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2008-03-2013%2014%2023%2025.jpg

Lower deck going on, and torquing up:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2009-03-2013%2013%2007%2021.jpg

Assembly of the rods and pistons:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2009-03-2013%2014%2053%2020.jpg

Bit of tape to stop the rods scratching the bores on their way down:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2009-03-2013%2016%2029%2032.jpg

Squeeze my ring

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2009-03-2013%2015%2014%2026.jpg

More assembly lube on the big end:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2009-03-2013%2015%2022%2046.jpg

Repeat 4 times and you get:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2025-03-2013%2020%2052%2042.jpg

New head gasket:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2006-04-2013%2012%2035%2029.jpg

Head on

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2006-04-2013%2013%2038%2003.jpg

EddyP
Thursday 18th April 2013, 21:16
Now to dress the engine:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2006-04-2013%2015%2028%2033.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2014-04-2013%2011%2011%2046.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2014-04-2013%2011%2011%2037.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2014-04-2013%2015%2037%2010.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2014-04-2013%2018%2002%2041.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2014-04-2013%2018%2002%2030.jpg

Also decided to repaint the inlet manifold, first off I blasted it clean, then primered it:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2007-04-2013%2014%2012%2019.jpg

Then painted it and baked it:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2007-04-2013%2017%2013%2000.jpg

Having to do some interior bits on the car now, it's due to be at a show on the first weekend in May and it's not even trimmed yet, so picked up my seats today, they're Recaro sport lines, had them retrimmed in leather and alcantara:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2018-04-2013%2016%2019%2006.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2018-04-2013%2016%2019%2027.jpg

claymore
Friday 19th April 2013, 17:16
What happened Ed?


https://www.youtube.com/watch?v=4M4q0sktbOM

EddyP
Friday 19th April 2013, 17:22
Don't post that, it's embarrassing :(

Most of it was my error, never having been on a 1/4 mile before didn't realise quite how little traction there would be, only did two runs, this was the first, the second run was much better as I had a slight feel for it, but even then there was no grip, not helped by it being a soaking wet freezing cold day. Once there was grip it did fly, just they didn't show that bit on film, I can dig out the times somewhere and it does show it has potential once I could launch it better.

Hey ho, we can't all be the Stig from day 1.

stribo
Friday 19th April 2013, 18:14
Great work mate, hopefully I'll get to see the car in the 'flesh' one day. Loving the seat colour choice. ;)

Wobbly Dave
Friday 19th April 2013, 23:06
oops - nevermind. My first run in the 855r way back when was about 16.

EddyP
Saturday 4th May 2013, 07:48
Bit more of an update, been a manic week, the car needs to be at Stoneleigh tomorrow, but currently has no interior, no MOT, doesn't run etc... :lol:

So this week, I painted the rear chassis:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2010%2055%2002.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2001-05-2013%2012%2013%2000.jpg

Finished dressing the engine

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2001-05-2013%2020%2045%2022.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2001-05-2013%2020%2045%2028.jpg

Put it back in

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2002-05-2013%2017%2000%2034.jpg

Connected everything back up, got the suspension back on etc...

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2022%2012%2039.jpg

Fitted a new headlight switch into the dash:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2028-04-2013%2017%2051%2059.jpg

Rubbed it down ready for trimming:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2014%2026%2009.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2014%2026%2009.jpg

EddyP
Saturday 4th May 2013, 07:49
Made a unit to hold this screen in the roof, have a look at Zada Tech, they do some awesome stuff!

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2025-04-2013%2020%2039%2017.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2025-04-2013%2020%2039%2051.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2025-04-2013%2020%2039%2050.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2025-04-2013%2020%2039%2041.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2013-04-2013%2010%2023%2045.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2022%2030%2031.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2022%2033%2026.jpg

Head liner got trimmed

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2014%2025%2045.jpg

Lots more trimming

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2014%2026%2022.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2011%2004%2001.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2011%2004%2009.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2011%2005%2037.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2022%2001%2052.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2003-05-2013%2022%2002%2056.jpg

p fandango
Saturday 4th May 2013, 07:52
hmm carbon fibre. I'm waiting to here what difference the billet wheels made :)

shame i'm away for the weekend or i'd of popped in to the kit car show

JT
Saturday 4th May 2013, 08:53
Awesome thread!! :B_thumb:

EddyP
Saturday 4th May 2013, 22:04
Well to be honest i'm amazed i've got as far as I have.

When I started this morning, the engine wasn't ready to start, there was no plumbing from the turbo to the charge cooler, no exhaust, no fluids in it, no rear brakes, no distributor or coil, no ECU connected, no interior, no seats, no engine cover, no rear bumper etc...

And the MOT was at 3pm.

Amazingly I made it:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2004-05-2013%2015%2004%2018.jpg

After a bit of cranking with no plugs in to get the oil pressure up, the engine started pretty much straight away, although had a pretty big fuel leak, note to self, remember to do up the bolts holding the injector rail on, petrol damages paint on freshly painted engine bits too :(

Amazingly it sailed through the MOT, just had to add a cable tie to a brake flexi as it was a bit close to the wheel.

Then when I got back from the MOT it was time to wash it, clean it, fit some more interior parts and make it semi presentable for the show tomorrow.

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2004-05-2013%2017%2017%2039.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2004-05-2013%2017%2017%2052.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2004-05-2013%2017%2018%2001.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2004-05-2013%2020%2025%2059.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2004-05-2013%2020%2026%2004.jpg

Needless to say, i'm now shattered.

To give you an idea of how much has been done in the last few days, the car looked like this on Thursday morning:

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2010%2055%2011.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2001-05-2013%2012%2013%2000.jpg

https://dl.dropboxusercontent.com/u/56281588/T5%20Conversion/Update/Photo%2030-04-2013%2010%2058%2021.jpg

timbo
Saturday 4th May 2013, 22:14
Great thread Eddy, the work that you've put into this car is amazing!

the young mechanic
Saturday 4th May 2013, 22:20
cool

JUDGENINJA
Saturday 4th May 2013, 23:26
Wow... The attention to detail looks amazing.... Any chance of bringing to to VPC meet sometime for us to drool at?!

partsforvolvos.com
Tuesday 7th May 2013, 11:50
you do interiors as well !!! the man's got Skillz ...........

:hail:

how did the show go ?

Squirtydog
Monday 27th May 2013, 20:22
Wow. Amazing build.

Biff
Monday 27th May 2013, 22:24
I don't do kit cars.....
You just changed my mind. I'd build one of those. It's awesome & good selection of mods.
Very impressive.