Another 940 project!

[Sweep]

So ever since watching Bamse's Turbo Underpants, I've been wanting to build a silly Redblock powered RWD Volvo! I looked at converting 240's/740's but this came up cheap cheap.

I already had a complete engine/box/look etc for conversion, so that's now being built up with some KG Trimning goodies in the shape of their KG-0004 cam, 38mm exhaust valves and double valvesprings, there will also be a set of rods going in too. Target for a start is 300 at the wheels, then start creeping it up until my T34 runs out of puff, then it'll be Holset time.

It's a late spec 2.3 HPT with M90 and all the goodies, bar an open diff...

Plan for the time being is to run the stock motor with the T34, big cooler, injectors, port matched head, ported exhaust/inlet fanimold and something like a K cam with a ££££ton of boost down its neck, see how long it lasts.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/IMG_20150620_184146_zpsfxcfb6rk.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/IMG_20150620_184146_zpsfxcfb6rk.jpg.html)

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150620_182554_zps0oieg3pn.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150620_182554_zps0oieg3pn.jpg.html)

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150621_190913_zps7spcbu3e.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150621_190913_zps7spcbu3e.jpg.html)

Paintwork is horrendous, which for a bufty like me is painful to see, but it adds to the sleeper appeal, outside will be staying stock bar a side exit and possibly banded steels.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150621_191938_zpsivmtskie.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150621_191938_zpsivmtskie.jpg.html)

Drove back from Birmingham with this, plenty of miles in them!

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150625_180040_zpsdrwwgnnj.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150625_180040_zpsdrwwgnnj.jpg.html)

Goodies from Sweden.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150626_211135_zpsb6bctaqg.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150626_211135_zpsb6bctaqg.jpg.html)

So long A/C.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150627_095320_zpsz4bnv0gl.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150627_095320_zpsz4bnv0gl.jpg.html)

Turbo downpipe flange I made and had machined.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150627_175722_zpsruuery19.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150627_175722_zpsruuery19.jpg.html)

T34 needs clocking though, the compressor outlet aims right at the manifold at the moment :(

Going to DIY coilover the standard shocks for the time being, might do the same with some B4's later on, unsure on the rears yet though.
4 pots on the front from something, will depend on what wheels I decide on!

Will keep you updated!

[Dangerous Dave]

Sweet :D It'll probably take quite a punishing.

My bro wrecked his 940 turbo :( though he has an NA 940 estate for the bits to go into sometime in the future :).

[Sweep]

Hopefully so! It's going to be a weekend toy so it's no biggy if it goes pop.

[smithy]

Sounds like a nice build .i wish I could do stuff like this .

[Dangerous Dave]

sounds like a nice build .i wish i could do stuff like this .
lol :)

[Doingitsideways]

Sounds like a nice build .i wish I could finish stuff like this .

Sorted that for you :)

[Sweep]

Had to send the T34 off to Owen Developments for them to rotate the turbo as I could not for the life of me get it turning. Turned out it needs a rebuild, so that "1200 miles tops" turbo is poop. Which has now been replaced by this :D

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150803_173410_zpspgzbxzhj.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150803_173410_zpspgzbxzhj.jpg.html)

[barkster1971]

When you put the rods in get everything balanced as it'll rev a lot easier to get that bugger spooled up.

[Sweep]

Apparently they're really good on spool considering the size, I guess as they're designed to run on low revving diseasel engines!

[barkster1971]

but they're usually 6.5 litre engines!

[deeman]

nice project...will follow with interest. will be embarking on another 940 myself soon....I need to scratch the itch!

[barkster1971]

any progress?

[Ettienne]

Good project, I'll have to watch this for when I start mine for real (still at paint) I managed to snag a 98 car, low miles 2 owners.

[Sweep]

Little bit of an update, I've promised a lotta people that it will see the road by summer so I need to pull my finger out a bit!

Originally I was just going to get some tophats machined up and use the standard rubber top mounts to sit them in and then do the camber mod, but I figured I'd just do it proper and as ClassicSwede now stock adjustable camber plates, I snapped a set up.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20151226_083221_zpsowug9gww.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20151226_083221_zpsowug9gww.jpg.html)

Might pull them apart and anodize them, unsure yet.

Stripped/blasted/painted the lower arms, which considering we only have a real fine glass bead in the cabinet worked very well indeed! Standard issue poly bushes of course.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160123_102125_zpsrggd4rub.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160123_102125_zpsrggd4rub.jpg.html)

Eventually got sick of seeing the turbo laying around, so got my arse into gear and figured out where I wanted it mounting, the first Holset I got turned to be a dud one too, learned my lesson buying second hand turbos, don't! Sourced a brand new HY35W for a very good price, got the fancy anti surge compressor housing too.
So with a bit of jigging/hanging, got my collector tacked into place.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160102_135119_zpskvzffppj.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160102_135119_zpskvzffppj.jpg.html)

Bit of progress..

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160103_153623_zpszv0g19jr.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160103_153623_zpszv0g19jr.jpg.html)

It soon got heavy so had to chock it up!

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160117_135753_zpsdexlhx7j.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160117_135753_zpsdexlhx7j.jpg.html)

And all tacked up now, will start welding it this week once I get my two-way regulator back from work to purge it.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160124_160849_zpsgpcdlgue.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160124_160849_zpsgpcdlgue.jpg.html)

Once it's welded I've got drill into the side of the collector to then weld in a piece for the external wastegate.

And a little comparison of the Holset to the 13C

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20150912_134944_zps2tqh7jze.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20150912_134944_zps2tqh7jze.jpg.html)

[t5 pete]

Looks good will you be purging it in 1 piece or will you dismantle all the pieces and weld them together 1 at a time to make sure there arnt any imperfections or slag to break off down the pipe line and hit the exhaust wheel

[Sweep]

Looks good will you be purging it in 1 piece or will you dismantle all the pieces and weld them together 1 at a time to make sure there arnt any imperfections or slag to break off down the pipe line and hit the exhaust wheel


Yes mate I'll be taking one runner off at a time, there's no way I'd get my torch in some places as it is anyway.

[Basil]

I take it you have done some "snake charming" before?! What is the material if you don't mind me asking? It looks a very good effort, will you be adding turbo and w/gate supports?

[Sweep]

Nope, first attempt! I am a fabricator by trade but nothing like this, I'm quite chuffed with the outcome! It's all 316, the elbows are SCH10 (if I remember rightly) and the tube was donated to the cause by one of our friendly companies, slightly smaller OD but the inside is the same, made it tricky lining them up!

Definitely, although there's not a huge amount of options on where to bolt a support to, will have to see when it's all in place.

[jamesy12345]

Nope, first attempt! I am a fabricator by trade but nothing like this, I'm quite chuffed with the outcome! It's all 316, the elbows are SCH10 (if I remember rightly) and the tube was donated to the cause by one of our friendly companies, slightly smaller OD but the inside is the same, made it tricky lining them up!

Definitely, although there's not a huge amount of options on where to bolt a support to, will have to see when it's all in place.

(schedule) 10S elbow...sorry...old piping joke

Looks well mate, looks like you are managing all positions up to & including 6GR there

[barkster1971]

Now what are you doing for engine management, chips and a big maf won't really cut it with a turbo that big, plus you'll be needing a decent clutch.

[barkster1971]

and you'll have to make me a decent exhaust manifold for mine!

[Sweep]

Now what are you doing for engine management, chips and a big maf won't really cut it with a turbo that big, plus you'll be needing a decent clutch.


and you'll have to make me a decent exhaust manifold for mine!

Chips! TLAO ran over 400bhp on them, that's fine for me for a start. Eventually I'll be looking into MS, I think someone does a plug-n-play job for LH? Not sure what to do on the clutch side of things yet, definitely a TTV wheel though, any thoughts on clutch?

I'm sure the manifold can be arranged, space is an issue though and I need to give the inner wing a bit of convincing with a hammer for some clearance on cylinder 3.

I'm also looking at doing an aluminium plenum, although that'll be something for the future.

[Sweep]

Progress!

I'd definitely do the manifold differently next time, I didn't take into account the depth so I've got to notch the chassic leg a little, no biggy though.

Mocked the engine up quickly http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/IMG_20160309_175234_zpsueaz0fun.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/IMG_20160309_175234_zpsueaz0fun.jpg.html)
http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160309_173309_zpsq2bgkeir.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160309_173309_zpsq2bgkeir.jpg.html)

Also got the suspension assembled, although I think I might need to run a shorter spring yet.

http://i1233.photobucket.com/albums/ff386/CrOwSoN15/Mobile%20Uploads/20160312_172427_zpsbaheo50d.jpg (http://s1233.photobucket.com/user/CrOwSoN15/media/Mobile%20Uploads/20160312_172427_zpsbaheo50d.jpg.html)

I'm off for 6 days over easter so hoping to get the front end back together and make a start on the rears which I'm hoping isn't going to be too much hassle.

[wiganer31]

built looks good, are the coilovers home brew? they look awsome

ceers