240GLT T5 conversion

[M-R-P]

Aah tuere you are lol.

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

[antz]

Aah tuere you are lol.

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

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

[the young mechanic]

comeing on slow but good

[y2blade]

Following with interest

[antz]

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

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

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

Battling with the stupid 6cyl:






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

[M-R-P]

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

[antz]

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




Now my next worry is...how the heck do I get this:


Into here (Ive removed the front lights to stop them getting broken)


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

[tattoo101]

looking good buddy.

[antz]

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

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





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



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

Sadly the R32 Skyline intercooler is WWWAAAAAYYYYY to big to fit anywhere in the car so thats back to the drawing board. I was told Sierra Cosworth RS500 intercooler should fit. Johnners disapproving thumbs down says it all...


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

[antz]

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

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

Live and learn...

Scratch was already there....not my clumsy doing!


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

M90 behind view with M47 crossmember bolted up for a coat of looking at. How do we make this work...



Like this: These are pictures of Homers crossmember over on Turbobricks. He made my engine mounts and after looking carefully at the position of my gearbox, we just need to copy this. Measure twice cut once obviously.



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


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

[M-R-P]

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

[Volvostorm]

Coming together nicely mate

[antz]

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

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

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

[antz]

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

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

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

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




And fitted up it looks like this...excuse the bad pictures again



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


Then we drilled the bulkhead out and fitted the clutch cylinder! Its nearly there from its auto to manual conversion.


Stay tuned for more kids...

[johnners]

Great progress dude

[antz]

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

Bolted up the clutch cylinder and attached the clutch pedal. Auto to manual conversion is almost done!


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


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

Gear lever arms test fitted to see how much they need shortening by. I forgot to measure this but according to photos Ive seen I think they will need shortening roughly the length of the gear lever hole itself.:




More to follow in a few days...

[the young mechanic]

pretty good

[antz]

So today we set about adapting the turbo to fit.

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

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

After a while of trying to get the studs out (one snapped) we managed to drill the cast housing out so it looked like this:


turbo slotted on!:


Im using a 16T for now just to keep things easy. Rather fit it all up and get it running, then think about upgrades:


And shot from underneath:


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

[antz]

small update today.

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

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

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

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

[antz]

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

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

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

Original GLT bar Vs IPD bar:


And fitted up! Dead easy job but would of been much quicker with 2 people rather than trying to hold the bar, insert the bolt, adjust the shock absorber and put the nut on the end all in one go.


More another day...