240GLT T5 conversion

[antz]

Well Ive had a busy few days collecting parts!

Last Wednesday I went down to pick up my long awaited gearbox. I finally managed to get hold of a Whiteblock M90 manual gearbox and propshaft from a 960.


Heres a few bits I picked up from The Flying Moose a while back but never got round to photographing. 16T turbo and White injectors.



Also swapped the original crappy washer jets on the 240 for some V40 Phase 2 ones that spray a mist instead of a piss poor jet.


Then by pure luck I managed to find a badly listed Rover 820 Turbo Vitesse frll interior listed on eBay which happened to include the front Recaro seats. A quick bid later and I went to Doncaster today to pick them up for a pricely sum of £40. The drivers side if knackered so its going to become a seat in the unit but the passenger is good so Ill use that as the passenger in the 245 and my previous Passenger seat as the drivers seat as thats a good one too.



And I painted myself up a nice engine cover a few weeks ago whilst I was bored:

[The Flying Moose]

Look good Antz, keep us posted. Will be nice to see it all coming together.

[antz]

Thanks dude! Its a a bit annoying all my updates are just of stuff Ive collected so far but the more I get now the more I dont have to buy later!

Last night my mate also brought me a genuine German Volvo dealership numberplate surround that he got from a German V40 in the scrapyard. It needs a couple of lugs fixing that hold the plate on so I might make some up and plastic weld them on or glue them..not sure yet but itll add a nice touch of euro class to the tailgate

Coincidentally Ive just de-activated my Facebook account so I can get on with working on it as Facebook is just a waste of time that was taking up far too much of my life. Im possibly going to push the old girl out tonight and attack the engine bay with some industrial strength floor cleaner to get it all nice.

Ive also been thinking about how to mount the seats on the Volvo runners. Ive got a mock up in my mind of how Im going to do it, its just building the adaptor plates to fit the seats and the runners.

[WOODY T5]

looks like its all coming together now just need an engine now mate ;-)

[antz]

Tonights lovely job was to try and get the engine bay as clean as possible whilst there was no engine in there so I could climb in and move around.

Que a whole lot of de-greaser, some elbow grease, a hose pipe and more water on myself than the car and we got from this:


to this:


and after a final wipe down we ended up with this!

[M-R-P]

Says a lot for these cars when they clean up so well after all this time. Good job mate.

[antz]

Says a lot for these cars when they clean up so well after all this time. Good job mate.

Im really impressed with how solid she is for a 23 year old car!

The only rust on it is 3inch patch on sill in the drivers door shut as its peppered into a hole.

Theres a couple of surface patches which Ive just dabbed with some kurust and hammerited over. job done!

[biggbn]

wow what a great project..always wanted something like this...keep up the good work bro

[martybelfastt5]

bay cleaned up a treat pity the t5 lump going to hide most of it lol,,,

[Jim S70R]

Thats come up really well, job well done

[antz]

The last couple of days have been spent drinking coffee...lots of coffee.

In between the coffee I managed to slap some kurust on the tailgate and give it a coat of hammerite to prevent the tin worm attacking it any more.



and I finally got round to cleaning up the left over gunk from the foam and rubber that covered the bulkhead. Here it is now:

[antz]

more cleaning on the engine bay. IT NEVER ENDS!!!!!

Also fitted the bonnet rubber strip thingy back in plasce after I did some rust treatment on the lip.



Then tested out my genuine volvo upper strutbraces which came all the way from Australia

[antz]

we have engine!!!!!

Got the engine from Dean on Tuesday night, its done 220k but itll be an ideal tester engine for fitting, mods and if it goes bang then its no great loss for what it cost me.

First job was to start taking off the old bottom engine mount which went in the bin, took off the front cover cos I like the look of seeing the timing pulleys and generally get to know a T5 engine by poking it, wire brushing it, wondering how Im going to get it in the bay etc etc.

Also raised it up and dropped the oil out afterwards and as usual I dropped the sump bung AND socket in the oil....muppet!


I also managed to source a manual pedalbox which has arrived but my free Sparco pedals wont fit due to the mount screws so I'm going to buy the same sort I had on my old 245 which were ace and fit them instead.

I'm off to the scrapyard on Saturday to try and find a fuel rail and such bits and bobs Im missing.

[The Flying Moose]

Very nice, its the lump from Fridge Movers car which did a 13.9 on the strip.

I have a couple of fuel rails mate if you need one, come to think of it nearly a whole car!

[the young mechanic]

going to be a good car that

[antz]

Very nice, its the lump from Fridge Movers car which did a 13.9 on the strip.

I have a couple of fuel rails mate if you need one, come to think of it nearly a whole car!

Cheers dude! No doubt you have everything I need, I'm running extremely low on cash though after buying the gearbox, all those bits from you and an engine hoist all in the last month.

Good to know some history on the engine, Dean did say it was pushing some large power before it was removed from the car! Ive got the ECU to go with it but Im not sure what im doing about ignition and engine management yet so I dont know if Ill be using it. Itll be an ideal tester unit for chopping the sump, fitting and setting everything up and if it runs sweet in the end its a bonus but if it tries to eat itself its no big loss.

[graemewelch]

great project. i might be able to help you with the sump. well can weld it for you but you,d need to cut it

[antz]

great project. i might be able to help you with the sump. well can weld it for you but you,d need to cut it

Thanks mate but Im going to whip it over to Ralloy who do all the alloy fabricating for rally cars near York. Hopefully they can fit it into their schedule

[antz]

Well it may seem like progress is slow but I am working my arse off on this. Just the updates dont show it.

The other day I spent 3 hours making brackets for the Recaro seats. First off I stripped the Volvo runners down as much as I could to this:


And created some brackets like this:


After bolting it in I discovered a problem, Im too low, too close and too far to the left which is a problem so Im going to use these mounts as the passenger side and have a re-think on how to mount the drivers so Im actually comfortable.


Also I finally ordered my nice new Pressed numberplates from eBay which were a bargain at £26 for the pair. They come with all the UK complient numbers, are standard font and I didnt have to send off all my documents for them either. Ordered them Sunday and theya rrived today!


Slotted nicely into my genuine German Volvo numberplate surround my mate got me from the scrapyard.


Ive also been in discussion about some engine mounts, a nice man in Germany has offered to make me some so I dont need to weld them which is a bonus.

[JT]

making engine mounts??

tell me more