WOW Nice Hole

[BLOWN240]

I started cutting the tranny hole in the firewall/floor of the 122 today. I have to remove the driveshaft before I can finish it.


Pics:

http://www.hardcars.com/blown240/122%20pics/floor1.jpg

http://www.hardcars.com/blown240/122%20pics/floor2.jpg

[blkaplan]

nice

[eight_fitty]

i never seen a nicer hole than that, i tell you h-wut!!

[n xntrx volvo]

thats a mighty big hole you've got there. looks like it got stretched out good, sticking something big in there? find a replacement tunnel, or going to fab?
-Aaron

[pisco]

That's some serious Fred Flintstone sh*t there.

[vurbo]

wow, hope none of that metal was structural!

[BLOWN240]

wow, hope none of that metal was structural!No none of it was. I was real careful about that.

And I am going to fab a new tunnel. I am going to make it removeable so that pulling the tranny will be easier.

[Blackbrick]

It's all structural, but if he rebuilds it right it will not be an issue at all. Also considering the added torque and weight, I am sure there will be much reinforcement.

[tjts1]

And I am going to fab a new tunnel. I am going to make it removeable so that pulling the tranny will be easier.
Do you plan to pull the trans through the cabin with all 4 wheels on the ground? Nice hole. is there going to be any room left for the accelerator?

[BLOWN240]

Do you plan to pull the trans through the cabin with all 4 wheels on the ground? Nice hole. is there going to be any room left for the accelerator?
No the trans will not come out from the insied. but I want to be able to get to all the bolts. so a removable tunnel would be perfect.

And actually there is alot more room than I first thougth for the pedals.

[Hank Scorpio]

smart idea about a little trap door for bolt access.

Mike, look into www.cachassisworks.com they have preformed tunnels that you can just trim to size.

Doug

[n xntrx volvo]

No the trans will not come out from the insied. but I want to be able to get to all the bolts. so a removable tunnel would be perfect.

And actually there is alot more room than I first thougth for the pedals.
need me to look at vans in the j/y?

[pgringo69]

1970's-80's dodge ramchargers and i think trucks also have removable trans tunnels. fyi.

[forelan740]

That's some serious Fred Flintstone sh*t there.

did someone say fred flintstone... (points to sig)

[vurbo]

No none of it was. I was real careful about that.

And I am going to fab a new tunnel. I am going to make it removeable so that pulling the tranny will be easier.


that's a cool idea.

[Sean]

I am surprised you don't have a plasma cutter... btw.. can't wait to see the finished product..
Sean

[JohnMc]

That's slightly bigger than the hole I had to chop into my PV just to put in an M41.

The tunnel is a structural component on a Volvo. Although it isn't alone in carrying the load it also helps spread the forces fed into the firewall by the front subframes into the roof and floorpan. The A pillars and sills also help. Chopping it out will leave the car slightly more flexible. I think this is more of an issue on the PV body than the 122, however. The front subframes on a PV are more isolated structurally and there is less subframe connecting them to the floorpan.

On my swap I used a 122 tunnel and welded it in securely. It was a lot of work but getting a 5th speed was definately worth it.

[242GTMD]

Everytime I click on this link, I expect to see a picture of a pretty girl.

[The Aspirator]

Nice, what did you use to cut the hole? Just that angle grinder in the pic? If so, cool, cause I'm finally picking one up soon.

[BLOWN240]

I started the holes with the angle grinder, and finished them with a sawzall once I could get the blade thru.

[MistrThou]

nice hole

[wagonboy]

Everytime I click on this link, I expect to see a picture of a pretty girl.

Hmmmmm...I should think that, but i've been expecting to see where a rod has "ventilated" a block!

[Unregistered]

OMG, I never thought I would feel so sorry for a 122.

[JohnMc]

I started the holes with the angle grinder, and finished them with a sawzall once I could get the blade thru.
I find the angle grinder easier to use on things like that. The sawzall kept jamming, breaking blades, jumping around. Probably just a personality conflict, but me and the angle grinder get along just fine.

[grebnut]

thats pretty impressive! im liking the progress pics too... thanks for sharing! later,

ben

[isaac]

I am going to make it removeable so that pulling the tranny will be easier.

I find that only using the bottom 3-4 bolts also facilitates removal.

[MikeHardy]

I find that only using the bottom 3-4 bolts also facilitates removal.
:rofl::rofl::rofl::rofl::rofl:

[the poi]

Nice, what did you use to cut the hole? Just that angle grinder in the pic? If so, cool, cause I'm finally picking one up soon.
bwahahaha, John your new avatar is hilarious.


And thats a purdy hole Mike. Now fill it up with motor and transmission!

[The Aspirator]

bwahahaha, John your new avatar is hilarious.Glad you like it :lol:, notice it's black and white to show my sorrow :-( .

[Hank Scorpio]

I find that only using the bottom 3-4 bolts also facilitates removal.

Thats what I do too. I never put the top bolt back in.

[isaac]

Thats what I do too. I never put the top bolt back in.

Only difference between my method and yours is you use twice as many bolts to bring your trans perilously close to the requisite eight.

[Hank Scorpio]

Only difference between my method and yours is you use twice as many bolts to bring your trans perilously close to the requisite eight.

lol its only what, 6 bolts total?

2 @ the starter, 2 @ on the opposite, 1 or 2 more up top right?

Trust me... were the same on this

[The Aspirator]

There's 8 bolts ;-)

[945ti]

There's 8 bolts ;-)
True, if you count the smaller wimpier (14mm head) bolts on the bottom piece that covers the back side of the flywheel/flexplate. I am not sure if those really take much of any load, but they can't hurt, and they are super easy to get to.

On a 7/900 the top bolt definately isn't much fun, but it isn't terrible to get back in. ON a 240, it is another story.
realistically, you could probably just use the 4 bolts, 2 starter, and the other 2 on the other side that are 18mm head. On a 240 even, getting one of the 2 top ones isn't terrible, it is the very top one that I remember being no fun...
I might be inclined to seal it all up for ridgidity/noise/fire reasons and just forget the top bellhousing bolt or two...
I like it so far...