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  1. #81
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    You can pick the cheapo ones up off ebay as you only need the housing so you can swap in the sensor from the standard maf.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  2. #82
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    MoleT-5R's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    You can pick the cheapo ones up off ebay as you only need the housing so you can swap in the sensor from the standard maf.
    won't the 850's maf surface area be under size for the housing then, or do you then adjust the scaling to allow for the smaller surface area of the 850's sensor to the diameter of the maf housing, else I could see some massive leaning out is due to happen as the throttle gets opened.. ??

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
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  3. #83
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    There is a program (available on the M4.4 wikia site) that adjusts the scaling in the ecu to account for the increase in housing size. Basically the stock values are multiplied by 2.24 for the 3.5" MAF
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  5. #84
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    Oooh, it's been a while

    So I haven't been happy with the fuelling settings of the ecu. After some research it turns out the VXR 470cc injectors aren't 470cc they actually flow the same as the 'big greens' at approx 440cc. The only difference between the two injectors is the greens are 12ohms impedance and the vxr blues are 14.5ohms impedance.

    Not that much of a big deal though as they were cheap enough and they flow the same as greens.

    Just need to change some settings and hopefully that will sort things out.

    Next project is getting the 3.25" MAF to fit (unfortunately it's not a 3.5" like I first thought but still better than standard)
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  6. #85
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    MoleT-5R's Avatar
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    Nice to see an update Dave and I look forward to hearing how you get on with the new MAF.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
    My Ebay Items http://www.ebay.co.uk/sch/moleadrian...p2047675.l2562

  7. #86
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    Also been getting on with the epic that is the 320mm brake conversion.

    The calipers and brackets are a bit rusty so I made my own blasting cabinet out of a huge IKEA storage box.

    Got one bracket done and sprayed up, now to do the rest...
    Last edited by Dangerous Dave; Friday 15th March 2019 at 12:36.

  8. #87
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    Looks good, sand blasted?

  9. #88
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    Quote Originally Posted by kmb View Post
    Looks good, sand blasted?
    I'm using a 20/40 grit Garnet media. Not a perfect finish but gets all the rust off.

    Here's my bodged blast cabinet
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  10. #89
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    Fair do's Dave, looks ok and is a fully functional bit of home made kit, can't be classed as botched in my book, nice work Sir.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
    My Ebay Items http://www.ebay.co.uk/sch/moleadrian...p2047675.l2562

  11. #90
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    Quote Originally Posted by MoleT-5R View Post
    Fair do's Dave, looks ok and is a fully functional bit of home made kit, can't be classed as botched in my book, nice work Sir.
    Thank you

    But now my air compressor is dying (making funny noises and slowing down)

    There's a local shotblasting company so may see how much they charge just to get it done as I've got to move onto the next stage of the brakes, brackets
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  12. #91
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    This project is all over the place at the moment, need to make a list and start doing one job at a time.

    So far I've got one of the brake calipers/bracket ready and have managed to get a set of 320mm discs dirt cheap so I can fabricate an adapter (as I like to do it the hard way). The discs are from a V70 P2 with the 68mm centre bore. This means that they fit without needing to be machined but the offset is 2mm different to the V50 320mm discs which then means an 8mm adapter plate won't work so I have an idea......watch this space.

    Also got a pair of XC90 calipers dirt,dirt cheap so may have a look at what I can do with those on my spare hub.

    Anyway, on to other bits I've got sorted.

    Finally I made the 3.25" MAF adapter with my 3D printer (5.5 hours of printing later)



    And after some cutting of a spare airbox lid, some superglue and 'hot snot', fettling a 90 degree silicone reducer and some aluminium tubing I have this:


    I modified the ecu binary to account for the increase in size and all is working great
    Last edited by Dangerous Dave; Tuesday 7th May 2019 at 23:24.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  13. The Following 3 Users Say Thank You to Dangerous Dave For This Useful Post:

    kmb (Wednesday 8th May 2019),LeeT5 (Thursday 4th July 2019),Ric@rdo (Saturday 15th June 2019)

  14. #92
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    So it was time to make the brackets for the 320mm conversion.

    Made some templates with different offsets to see which would work the best


    Chose a 13mm offset and transferred to the 6mm steel plate.


    Some drilling, tapping and grinding later


    The plate is a bit thin so made an outer support with some 8mm steel and a spacer


    Just need to weld up the spacers and spray the brackets.

    In the meantime the spare parts for the compressor have arrived so I can get on with blasting the other caliper to get ready for painting.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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    Just read through your thread. I like how you’ve made all your bespoke fittings yourself. Very interesting read.
    BMW F80 M3 carbon ceramic brakes & MK7 Golf GTI DSG.

  17. #94
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    Quote Originally Posted by simonc View Post
    Just read through your thread. I like how you’ve made all your bespoke fittings yourself. Very interesting read.
    Thank you, kind of a necessity as they aren't available to buy anywhere. But also part of the fun of having a project
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  18. #95
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    The kit is all ready to go on, just waiting for the weather to get better

    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  19. #96
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    Finally got some good weather

    All fitted with new hose (old one too short)


    Old vs New




    Braking is a whole world better

    Now to move onto the rear brakes.....
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  20. #97
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    Excellent improvement, 320mm disc fills the wheel a whole lot better too!

    What's the plan at the rear?

  21. #98
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    Quote Originally Posted by kmb View Post
    Excellent improvement, 320mm disc fills the wheel a whole lot better too!

    What's the plan at the rear?
    Yeah it did look a bit chavvy before with tiny looking discs inside big rims.

    The good thing about them is I can use the 320mm disc off the V70 so I don't have to machine the centre of the disc like when using the 320mm V50 disc.

    Also managed to get some brembo pads for 35, though they are not performance pads. Performance pads are quite expensive unfortunately.

    The rear discs are solid on mine, so I'm looking at fitting the vented discs and calipers off the XC90 which are also a bit bigger (and fill the wheel better ).
    Last edited by Dangerous Dave; Wednesday 3rd July 2019 at 14:15.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  23. #99
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    I take it you couldn't use 330mm discs and calipers from a V70R/S60R?

    2004 V70R 6spd manual:: Custom JRtuning REMAP @ peak 21psi :: Custom 2.75" exhaust :: TTV SMF + 07 Clutch :: WG 5.0 psi :: Tints :: IPD R gauge Rev.3 :: CFWerks door pod :: Forge CBV + yellow spring :: Windowed stock housing + blue filter :: Powerflex :: Superpro Engine mount :: Brembo Dot 5.1 :: TW FMIC :: Eibach 5mm spacers :: Brembo 330mm drilled discs :: iMiV 'Classic'+ BT :: D2R XENARC 5500k + LED H7 + LED H3 :: VolvoTech CFE OBD-V1 :: See garage for full mod list

  24. #100
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    Quote Originally Posted by LeeT5 View Post
    I take it you couldn't use 330mm discs and calipers from a V70R/S60R?
    Unfortunately not, my budget doesn't allow for that kind of spend. Plus the calipers seem quite rare, a quick ebay search found none.

    I thought about using the 330mm discs but they are too wide for the calipers at 30mm vs the 25mm of the V50. The V70 ones I'm using are 28mm and fit but I had to shave 1mm off the caliper bracket as I got the offset wrong. .

    This was a budget build too, the old calipers were in need of a refurb so I thought I'd 'upgrade' (as it were).

    Total costs (for anyone interested): calipers 80, discs 40, pads 35. Brackets and bolts cost around 30 plus the time fabricating them, brake hoses 14. Sandblasting and paint were extra but not 'essential'.
    Last edited by Dangerous Dave; Thursday 4th July 2019 at 09:31.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.


 

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