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  1. #61
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    Quote Originally Posted by MoleT-5R View Post
    Very interesting. ..come on spill the beans I'm intrigued
    All will be revealed.....as soon as the weather gets better and I can fit the exhaust and get some pics and a vid
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  2. #62
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    Another update, having to dodge the showers. Really need to get a garage

    Chopped the nearside box in half to add a branch from the main exhaust path


    Added a pipe to go straight out the box


    Chopped the offside box to make the outlet central


    And here's one I made earlier Added the RS tips with the valve and sprayed it all black


    And fitted to the car. Maybe the only/first Volvo 850 with Focus RS tailpipes in the UK?



    Now to make the actuator control box. Got a cheapo Arduino Nano off ebay for 3, some stripboard, a remote control receiver, a transistor, some wires and a plastic box to put it all in. Mixed it all together, left it to bake for 30 minutes and this is what it came out like


    Luckily the power supply for the tailgate wiper is switched by the ignition and is routed through an easily accessible connector on the D pillar. So the power is connected, just got to route the actuator wiring through the boot floor somewhere and then test it
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  4. #63
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    MoleT-5R's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    Another update, having to dodge the showers. Really need to get a garage

    Chopped the nearside box in half to add a branch from the main exhaust path


    Added a pipe to go straight out the box


    Chopped the offside box to make the outlet central


    And here's one I made earlier Added the RS tips with the valve and sprayed it all black


    And fitted to the car. Maybe the only/first Volvo 850 with Focus RS tailpipes in the UK?



    Now to make the actuator control box. Got a cheapo Arduino Nano off ebay for 3, some stripboard, a remote control receiver, a transistor, some wires and a plastic box to put it all in. Mixed it all together, left it to bake for 30 minutes and this is what it came out like


    Luckily the power supply for the tailgate wiper is switched by the ignition and is routed through an easily accessible connector on the D pillar. So the power is connected, just got to route the actuator wiring through the boot floor somewhere and then test it
    I'm looking forward to the demo video of this mod Dave, and the exhaust looks lovely with it's new tips, at least there is some good uses in the world for RS Focus bits.....lol

    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

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  6. #64
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    Quote Originally Posted by MoleT-5R View Post
    I'm looking forward to the demo video of this mod Dave, and the exhaust looks lovely with it's new tips, at least there is some good uses in the world for RS Focus bits.....lol
    Thanks bud, it's looks ok, maybe sticks out a bit but i think i just wanted to see the shiny lol.

    Got it all working now. Can't get a video just yet as it's raining again.

    Exhaust note is quite deep when the valve is open and when closed it's great for cruising without the droning exhaust in the background.

    Eventually i want to integrate it into my data display project so i can set it to open at a certain throttle position.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  8. #65
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    Quote Originally Posted by Dangerous Dave View Post
    Won't the exhaust just come out of the near side silencer ?

    As it has further to travel to come out of the off side.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  9. #66
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    Quote Originally Posted by oblark View Post
    Won't the exhaust just come out of the near side silencer ?

    As it has further to travel to come out of the off side.
    There is a valve in the nearside tailpipe to divert the flow through offside silencing route.

    The only drawback is when cold the steam coming out the back only comes from one tailpipe when the valve is open/closed.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  10. #67
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    Quote Originally Posted by Dangerous Dave View Post

    The only drawback is when cold the steam coming out the back only comes from one tailpipe when the valve is open/closed.
    I have the same problem, mine when cold only comes out of the off side pipe.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  11. #68
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    Finally managed to get a video done

    Use headphones for the best sound experience, as the difference is really in the lower frequencies

    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  13. #69
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    What a week! Went out for a drive on Thursday and on the way back a noise appeared from the NS front wheel. This noise got louder which I reckoned was the wheel bearing. The next day I took the front assembly apart to find that the hub nut had come loose which meant the wheel bearing had separated and dried up.

    This was because the locking mechanism on the hub nut was defective (what happens when you buy cheap parts, I know). Fortunately I had a spare bearing.

    Then yesterday the car developed a loud whooshing from the intake system which turned out to be a split hose on the top of the turbo. Easily rectified though.

    Ok so moved on a bit with the exhaust control system.

    I had enough of using the remote to control the exhaust flap so added some code to the arduino that allows the flap to be opened automatically. I wanted to have different modes of control; constantly open, active (open at certain throttle angle or rpm) and closed.

    To switch between the modes I dug out an spare dash 'Info' switch, got a pinout for it and wrote some code for it to interface correctly. It also keeps the dash looking 'factory' and neat, just need to change the 'info' text on it somehow.

    Next was to link the arduino box and the exhaust control box in the boot. I ran a length of ethernet cable from the obd connector down the conduit on the passenger side and got some female ethernet sockets to add to the obd port and the exhaust control box.



    Then added some pins to the obd port so I didn't have wires running all over the place. The exhaust flap control utilises the second serial port on the arduino

    So now I have a sort of CAN network rigged up which I can add to if needed.

    The only thing left was to add switched power to the obd port (as the obd power is always on) so another pin was added which gets power once the ignition is on. Fortunately the obd port had some space to add these extra pins.

    Vid of the working system:


    Like the exhaust graphic?

    So the rotary switch changes the modes, a short press of the button changes screens and a long press/hold starts the data logging.....that is something I'll look into next Also may look at partial opening of the flap at various throttle angles or rpm, it wouldn't be hard to do.
    Last edited by Dangerous Dave; Sunday 29th July 2018 at 23:20.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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    kmb (Monday 30th July 2018),MoleT-5R (Monday 30th July 2018),oblark (Monday 30th July 2018)

  15. #70
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    Nice work Dave and very smart graphics, are you about at all soon for a demo???

    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

  16. #71
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    Quote Originally Posted by MoleT-5R View Post
    Nice work Dave and very smart graphics, are you about at all soon for a demo???
    Graphic shamelessly stolen from a VAG button which has a twin tailpipe graphic which I edited to a single. May add some lines to it to show the valve as open.

    Have PMed you
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  18. #72
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    Look what the Parcelforce guy dropped at my door today

    Managed to get them cheap.

    Now to clean them up and make some brackets

    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  19. #73
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    Quote Originally Posted by Dangerous Dave View Post
    Look what the Parcelforce guy dropped at my door today

    Managed to get them cheap.

    Now to clean them up and make some brackets

    I see no image......guessing brakes. .?

    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

  20. #74
    Gearbox Killer
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    Lol just as I posted that the image appears....pmsl

    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

  21. #75
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    LOL mate you need faster internet.

    Yeah, calipers from a V50 for the 320mm disc conversion. Thought I'd go for it as the current 280mm standard setup needs new discs and pads and one of the calipers needs a rebuild too. That and the total crappiness of the 280 setup from the start.
    Last edited by Dangerous Dave; Saturday 4th August 2018 at 15:15.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  22. #76
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    Just had a full set of drilled and grooved discs for gul, 302's for the front instead of the standard 280s she currently has. Olive will be next and will move up fron her current 302's, but to what I'm not sure, I'll be watching your upgrade with keen interest, you can be sure of that.

    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

  23. #77
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    The 320mm calipers look a better design too, more metal for strength and heat dissipation (I guess)

    Also got a larger MAF to fit but need to work out if I'm going to adapt the standard airbox or make something up.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  24. #78
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    Quote Originally Posted by Dangerous Dave View Post
    The 320mm calipers look a better design too, more metal for strength and heat dissipation (I guess)

    Also got a larger MAF to fit but need to work out if I'm going to adapt the standard airbox or make something up.
    How bigger MAF did you get..?

    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

  25. #79
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    Quote Originally Posted by MoleT-5R View Post
    How bigger MAF did you get..?
    It's a 3.5" ID MAF from a BMW 740i. Should allow up to approx. 1800kg/h flow instead of the 826kg/h of the standard MAF which apparently can be easily reached by a 15G.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  26. #80
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    Quote Originally Posted by Dangerous Dave View Post
    It's a 3.5" ID MAF from a BMW 740i. Should allow up to approx. 1800kg/h flow instead of the 826kg/h of the standard MAF which apparently can be easily reached by a 15G.
    Something I should be considering really, as the standard one must be maxed out pulling 301.2hp on the dyno with the lowly 15g, I do have a 3" here to play with, but it may be easier just to go up to the bigger bmw jobbie now, than change again later.

    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


 

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