240GLT T5 conversion

[claymore]

It's coming on great bud.

[graemewelch]

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

[daza-b]

looking good bud

[antz]

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

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

[antz]

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

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

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

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

Standard on top and V6 on bottom :


fitted:


New bottom arms with polybushes fitted:


And the rear wishbone bushes fitted which were an absolute bitch! They are now done though which is good.



And thats it.....

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

[antz]

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

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

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

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

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

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

[M-R-P]

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

[tattoo101]

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

[antz]

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

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

[tattoo101]

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

[Volvostorm]

Coming together well mate

[antz]

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

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

[p fandango]

It can be done with the ME7 manifold but I havent looked into sorting a way around it yet

[antz]

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

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

Lower mounts & spacers fitted after being all braced up and powder coated:


Both mounts fitted:


finally it sits on all 4 wheels! WOO!

[Volvostorm]

Why are you breaking the 960?

[antz]

Why are you breaking the 960?

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

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

Original Nissan Skyline R32 GTR intercooler. Its massive!......and it was free!

[M-R-P]

Oooh! Naughty

[Volvostorm]

You can never get better than a freebie

[antz]

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

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

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

[antz]

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


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

But less of the French tat...

My turbo manifold arrived which I bolted to the engine, although it seems most of the threads in the engine block have gone as it wont tighten up properly. Ill have to helicoil all that. FUN!....Not.



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


And a final shot of my very full workshop. One battle ship coming to bits and one slowly having bits put on it.