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  1. #121
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    Wierdly beardly

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    Stunning job that DD, thanks for the write up - love your plastic printing work too
    Currently - '96 850R auto

    Previously - '97 S70 T5 manual, '98 V70R AWD auto, '98 V70R Auto in Nautic Blue Mica with LPG (went to Germany!), 1996 850R Auto, lots of various 940s, 960s and a crappy 850 2.0

  2. #122
    Ghost Rider
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    oblark's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    That was the problem. Going to the wideband control and having leaner cruise fueling I thought my mpg would increase but it just didn't.

    Still got a lot of testing to do but so far it's looking good. I'm getting 34-35mpg on country roads with the occasional boot down for overtakes.
    I wouldn't mind try this bin file when you have finished testing it just see how it compares to mine 608 bin file.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 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,

  3. #123
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    Dangerous Dave's Avatar
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    Quote Originally Posted by oblark View Post
    I wouldn't mind try this bin file when you have finished testing it just see how it compares to mine 608 bin file.
    I've just got one issue at the moment which is sometimes it won't start first time, it always starts second time. Though I think I know why, I've just got to change the setting and test it.

    No probs I'll send it over once I've worked that last issue out, it will be good to get another tester to see if it's just a fluke.

    I was also looking at modifying the later model awd/2.5 ecu binary to see if any improvements can be made as the ecu in my car was from a V70 AWD and originally was the 609 binary.
    Last edited by Dangerous Dave; Thursday 27th August 2020 at 17:48.
    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  4. #124
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    DD i’ve been reading this thread with interest, very impressive! I love the the little motronic 4.4 display that you have, can it rear boost pressure and air inlet temperature?

    I’m after something similar as I have an m4.4 ecu. You don’t remember what its called or where to find one do you? Was it complicated to install and program?

  5. #125
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    Dangerous Dave's Avatar
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    Thank you mate, I love doing these little projects, keeps me busy.

    Motronic 4.4 doesn't have a pressure sensor as standard, you have to add one to the ecu and modify the software to log the boost pressure.

    There is an intake air temp sensor on the x70 range but it takes the temperature from the front of the car so outside the intake system.

    Unfortunately the display is home made using an arduino prototyping board and a generic TFT display. It plugs in to the OBD port so not had to install. The code is all my own work, using the simple arduino language.
    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  6. #126
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    Dangerous Dave's Avatar
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    Wow, can't believe it's been over 2 years since the last update on this thread.

    Unfortunately not a lot has been done to it. I still need to remove the entire rear suspension and fuel tank to refurb them. I did change some bushes on the rear but they are so awkward to do it's best done with the unit outside the car I guess. Will have to wait for the warmer weather

    Some time ago I purchased an S60R exhaust manifold so I decided it was time to upgrade and change the turbo turbine housing to an angled outlet. I managed to get a cheap used turbo with a 3 inch angled outlet.

    Problem was I needed to change the downpipe and 3 inch flanges are expensive and not readily available so I purchased some 10mm stainless plate and made my own.



    Then I bought some 3 inch stainless bends and started mocking up the route around the angle gear.



    I've only got a MIG welder so purchased some stainless MIG wire and ended up with this. Not too bad I guess, the flange warped a bit due to being stainless so learned a bit from that but I flattened it the best I could and purchased the 3 inch downpipe seal used on the later cars.


    Did a bit of porting on the turbine housing


    Added a 3 inch 200 cell cat and fitted it to the car.

    Engine/turbo now runs/spools so much better.

    Only issue now is the turbine housing has a crack in it So the next upgrade will be a TD04HLX housing and 9 blade wheel :
    Name:  16144207412501116685861.jpeg
Views: 0
Size:  151.7 KB


    Recently changed the handbrake shoes only to find the O/S handbrake cable was stuck. The AWD cables have a flaw in the anchor point to the wishbone, the the outer cable wears on the cable clip and lets in all the dirt. Really badly designed unfortunately.
    Last edited by Dangerous Dave; Friday 30th December 2022 at 19:42.
    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  7. The Following 2 Users Say Thank You to Dangerous Dave For This Useful Post:

    MoleT-5R (Saturday 31st December 2022),NECC (Sunday 1st January 2023)

  8. #127
    Gearbox Killer
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    MoleT-5R's Avatar
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    Nice job Dave, that downpipe looks awesome, not the easiest of jobs to do with the added issue of the angle gear being in the way.

    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/usr/quik.connection

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    Dangerous Dave (Saturday 31st December 2022)

  10. #128
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    JT's Avatar
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    Nice work!

    So jealous of you guys that can fabricate things

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    Dangerous Dave (Saturday 31st December 2022)

  12. #129
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    Quote Originally Posted by MoleT-5R View Post
    Nice job Dave, that downpipe looks awesome, not the easiest of jobs to do with the added issue of the angle gear being in the way.
    I was quite impressed with it myself, I even made that support bracket, looks exactly like the original (just a bit longer).

    The other side of the flange doesn't look the best unfortunately, hard to weld with MIG neatly in such tight spaces (that and I'm an amateur).

    Quote Originally Posted by JT View Post
    Nice work!
    So jealous of you guys that can fabricate things
    I've only got basic tools; a 30 year old Clarke MIG welder, an angle grinder, a bench drill with step bit, a die grinder with carbide bit and cellotape. That's all I used.
    Last edited by Dangerous Dave; Saturday 31st December 2022 at 19:53.
    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  13. #130
    Gearbox Killer
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    MoleT-5R's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    The other side of the flange doesn't look the best unfortunately, hard to weld with MIG neatly in such tight spaces (that and I'm an amateur).
    Looks good to me and as long as it functions as it should, then it is a job well done in my book.

    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/usr/quik.connection

  14. #131
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    JT's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    I was quite impressed with it myself, I even made that support bracket, looks exactly like the original (just a bit longer).

    The other side of the flange doesn't look the best unfortunately, hard to weld with MIG neatly in such tight spaces (that and I'm an amateur).


    I've only got basic tools; a 30 year old Clarke MIG welder, an angle grinder, a bench drill with step bit, a die grinder with carbide bit and cellotape. That's all I used.
    CELLOTAPE

  15. #132
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    Dangerous Dave's Avatar
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    Quote Originally Posted by JT View Post
    CELLOTAPE
    Sorry, I mean "sticky backed plastic" no brand names here

    Yeah just for mocking it up instead of tack welding it you can see it in the 3rd and 4th pics
    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  16. The Following User Says Thank You to Dangerous Dave For This Useful Post:

    JT (Thursday 5th January 2023)


 

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