Kenny's 1990 740 GL

[linuxman51]

:tux: Why not, since everyone else is whoring their rides out, might as well eh? :)

Current mods breakdown..
Engine:
Heebspeed intake manifold/Q45 throttle body
Ported and flow matched 1000262 16v head
Folksracing FS324 cams, stock gears
RSI pistons and rods, with a target CR of ~ 9:1 (shoulda gone higher, oh well...)
1995 block, Aq171 crank, block pinned per Jonathan@RSI's recommendation
MS II v3.0, Error/Glensgarage daughter card v2.1, 4 bar rs-auto MAP, etc.
T3/T-67, .83 A/r housing
Go-Autoworks intercooler piping, custom intercooler designed for a skyline
TiAL BOV y0...(I honestly haven't heard it yet, the car is too damn loud)
Nitrous Express dry kit (approx 75hp shot) controlled by MS
Profec-b SpecII
Custom fuel system.. fuel cell in the trunk, two bosch 044 pumps, -8 feed and return, all AN.
1000cc injectors
Dale's under drive pulley, but the jury is still out (its a wonderful piece, but the way I have my accessories mounted might require a re-think due to size. the weight difference however from stock to dale's is night and day. until I run into belt slip issues, it stays)
Fidel's billet crank gear, because the oem stuff sucks.
sdturbo's timing belt tensioner kit and solid accessory bushings

19psi, 435rwhp.

Exhaust:
3 inch turbo back, tial waste gate with an open dump, single mangaflow muffler.

Drivetrain:
Modified AW71. Th350 in the bullpen

3.73 millerlocked rearend
Spherical bearing torque rods and a reinforced rear subframe. we shall see....

Suspension:
Bilstein HD's on all four corners
poly radius rod bushings
ipd swaybars (25/25)
tme lowering springs

Cosmetics: not much..
fresh paint
side marker lights. Had. Need new ones.
a few discrete, yet in-your-face stickers.
Not sure what kind of 240sx wheels they are, but they were cheap. Yes, you need adapters.



Other noteable mention: It was big pimpin in the new york times on march 4th, 2005

pics (oldest to newest):
http://www.pbase.com/kdh51/image/31238927.jpg

http://www.pbase.com/kdh51/image/31238930.jpg

http://www.pbase.com/kdh51/image/40996424.jpg

http://www.pbase.com/kdh51/image/43802481.jpg

http://www.pbase.com/kdh51/image/43924865.jpg

http://www.pbase.com/kdh51/image/43924867.jpg

http://www.pbase.com/kdh51/image/43924866.jpg

http://www.pbase.com/kdh51/image/45813005.jpg

So that brings things up to july 2005. Obviously there has been more going on since then....

hung a turbo off a modified SSA manifold
http://www.pbase.com/kdh51/image/47141678.jpg

this had ok results, but fell apart shortly afterwards
7psi:
http://www.pbase.com/kdh51/image/47202191.jpg

14psi running out of injector:
http://www.pbase.com/kdh51/image/47752416.jpg

new manifold:
http://www.pbase.com/kdh51/image/55040701.jpg

installed:
http://www.pbase.com/kdh51/image/56293494.jpg

then it was time to ditch the npr:
http://www.pbase.com/kdh51/image/59745405.jpg

http://www.pbase.com/kdh51/image/59745404.jpg

the net effect:
http://www.pbase.com/kdh51/image/59745406.jpg

then there was some downtime after SE 6, I got rear-ended which jarred the radiator out of its moorings, the car probably overheated, and a few days later it was apparent that I'd roached a headgasket. It sat up from the fall of 06 to around may-june of 07, when a whole new slew of ideas was put into effect-

ported head ~1 inch into runners, for a planned intake upgrade
http://www.pbase.com/kdh51/image/80913932.jpg

engine went in
http://www.pbase.com/kdh51/image/81635539.jpg

pump gas powa
http://www.pbase.com/kdh51/image/82972506.jpg

Ran 12's at the SE meet with a busted t5, put a new transmission in and ran 11.8@120 about two months later, but then I killed the new transmission and clutch on consecutive runs
http://www.pbase.com/kdh51/image/89614481.jpg

So I went in and spent most of 08 mucking around with automatics, building intake manifolds, tracing down issues from previous work, and basically didn't get **** done. Car dynoed 500 rwhp lookin' like this:
http://www.pbase.com/kdh51/image/100999467.jpg

lower power is off the spray
http://www.pbase.com/kdh51/image/108185334.jpg

in hind sight, we probably jacked something up on the dyno when MSLVV mis-burned the maps and ****ed up the nitrous timing, but the car didn't appear to suffer anything immediately, so we pressed on. A second far more violent mistake involving the nitrous pressure proved to be the final episode of what was largely a disappointing year for team heebspeed.
http://www.pbase.com/kdh51/image/107325256.jpg

http://www.pbase.com/kdh51/image/107325263.jpg

http://www.pbase.com/kdh51/image/107359364.jpg

I did get some bling:
http://www.pbase.com/kdh51/image/105946179.jpg
Although really, it was a set of almost new tires and wheels for $200. They could have been pink and I would have bought them for the rubber alone.

So with a blown motor comes progress, usually-
http://www.pbase.com/kdh51/image/107888355.jpg

I took the down time to clean up as much under the car as I could (since I have to work on it, and I'd much rather not constantly be covered in tar-y black ****)
http://www.pbase.com/kdh51/image/107888356.jpg

sanded down the engine bay
http://www.pbase.com/kdh51/image/108467732.jpg

de-coated the wheel arches (as well as most of the under carriage)
http://www.pbase.com/kdh51/image/108467733.jpg

picked up some baller RSI hardware:
http://www.pbase.com/kdh51/image/108467734.jpg

Drilled a few holes in my block
http://www.pbase.com/kdh51/image/108587141.jpg

bed-liner'd the wheel wells
http://www.pbase.com/kdh51/image/109270658.jpg

bought a flow sensor setup and started building my flowbench
http://www.pbase.com/kdh51/image/109624766.jpg

put **** together:
http://www.pbase.com/kdh51/image/110347306.jpg

bedlinered the engine bay (it got touch-ups after this)
http://www.pbase.com/kdh51/image/114581424.jpg

And started putting stuff where it goes.
http://www.pbase.com/kdh51/image/114893404.jpg

A bit of undesireable (but doesn't slip!) belt routing.. never mind the oil feed..
http://www.pbase.com/kdh51/image/115866818.jpg

on its way:
http://www.pbase.com/kdh51/image/115866821.jpg

A quick way to blow $1000:
http://www.pbase.com/kdh51/image/115992481.jpg

http://www.pbase.com/kdh51/image/116745371.jpg

http://www.pbase.com/kdh51/image/116745372.jpg
(no worries, the jack-leg setup was for mock-up only. I got a BALLER T1 dual 044 bracket setup. make that a quick way to blow $1100....)

oops wait where'd the belt go?
http://www.pbase.com/kdh51/image/116745374.jpg
(I was probably shimming the cams at this stage in the game)

And its out and running! I'll let you figure out which one is faster
http://www.pbase.com/kdh51/image/117794815.jpg

New intercooler piping, 'in race trim' as they say.
http://www.pbase.com/kdh51/image/118044635.jpg

Really fast AFR tuning on the dyno, the day before SE 8.0
http://www.pbase.com/kdh51/image/118359735.jpg
horrendous torque curve, this is the result of pulling a lot of timing out of the whole map, and then not going back and touching the timing map again (except to pull out more for the nitous-which is the 511 run).

You might ask- why all the work for an 11 hp gain? Well, the previous numbers were made at 25psi and a warm bottle (500), and then the 465 number was made at 27psi no spray.
This time, I got the boost controller set to a reasonable 19psi and didn't touch it again (in fact, I still haven't). So the numbers will eventually be made, for those who care to know them, but the only digits I'm really concerned with were these:
http://www.pbase.com/kdh51/image/118191872.jpg

Two 11.0's with 1.9-2.0 60's, an 11.4 (Sam) with a 1.8 60 (he forgot to click it into 2nd), and then sam ran the 10.8, but had to let off so the transmission would shift into 3rd.

Thats 4 hits and done, for the aw71 (heeyy that rhymes!)


Remember kids, its not how much boost you run, its what you do with the boost you run that counts.

latest dyno graph:
http://www.pbase.com/kdh51/image/121458550.jpg

[klr142]

Yo Kenny, is that side picture before the lowering springs? And when're you going to get wheels for that thing? It'll look sooooooo much more better. Otherwise, mad props, you know it, great paint color... Gonna be schweet.

[linuxman51]

Yo Kenny, is that side picture before the lowering springs? And when're you going to get wheels for that thing? It'll look sooooooo much more better. Otherwise, mad props, you know it, great paint color... Gonna be schweet.


that would be like two months before i even purchased the lowering springs. it looks a little odd atm, but i reckon i can snap a pic or two. perhaps when i get the nos situated, grab an underhood shot as well.

Additional info, notes, and errata
Since there's a 55 image/smiley max in a single post, and my thread is about 450,000 posts deep, I thought I would put further pertinent information on page one, along with some extra pictures, etc. That way it's easier to read the meat of the thread, with the fun and fluff later :-D

First off, Airflow is horsepower. Its not about how much boost you run (boost is merely a means to an end), but what you do with what you've got. To that end, a number of things were planned/have been planned/some have been executed with this build.. It started off as a means to an end, the old 8v engine retired itself from service after a rapid series of unfortunate events, and I had this 16v setup hanging out in what was the 'race car' at the time. Some stuff done in haste at that point did and occasionally continues to bite me in the ass now. The old adage of 'fast, reliable, cheap - pick two' has never been more appropriate at times.

Stock for stock, the volvo 16v head rapes any oem 8v head, and it was foretold that with some cleanup work, a decent port job on a 16v head could easily smoke a pretty heavily worked 8v. Being that I was, at the time, broke (and a junkie for trying different things to this day), the logical progression after my 531 checked out was to of course step up to the next better production piece. A stock head suited me well for quite a while (and in fact, I would postulate that anyone building a mild street turbo setup would need to go no further than a stock head and cams, stiffer valve springs, and a nice intake and exhaust manifold-plenty of fun to be had there).

But after four years of playing meddling trying breaking and trying again, it was becoming apparent that the stock head was starting to hold me back. Running obscene amounts of boost is fun, and for those who partake in that thing, throwing out a large boost number is the internet equivalent of saying you've got a big dick. Again, however, what good is it if you can't use it effectively; or conversely; if you're not getting where you want to go with it. So around 2007, after hitting the first of many 'walls' with the oem intake manifold, we set out to see what could be accomplished with a better, more balanced, and most importantly, higher flowing intake manifold. Not much was changed on the cylinder head during this process, I port matched (sorta) the head to fit the runners, and then promptly put the oem intake manifold back on while we built the new manifold. This, as has been documented, joked, snide-commented, etc; took quite some time, far more than initially anticipated, and at a much higher cost than initially calculated. But hey, life is a learning experience right?

Armed with a more appropriately sized turbo for my goals (T04r aka T67/t3), and with this finally completed intake manifold, we attacked the dyno in late summer 2008, and learned that we had in fact, killed one of the large impediments to making power. Where the setup before hit its torque peak and promptly headed south, it now gracefully tapered for quite a while (another ~ 1000 rpms or so), even with the 'lame' stock cams. Boost was a comfortable 1.0-1.1 bar. I forget what power it made, probably upper 300's. Not one to leave well enough alone, shortly before the SE meet (and right in the middle of a move) I decided that I needed hotter cams, so I borrowed a set from Ken Lanham. This kicked off a three month period of trouble and trouble shooting, capped by the discovery that years ago when the engine was first assembled, we machined the valve reliefs on one of the pistons in the wrong place. Oops.

Back on the dyno in late december, it was the last hurrah for 08, and we fully intended to go out with a bang. Pump gas numbers on a fairly decent tune yielded 400hp at about 20psi, race gas was swapped in, the nitrous bottle was hooked up, and the sky was (theoretically) the limit. With the boost turned up to an at the time huge amount - 27-28psi, the power the car made was a less than stellar 465. not to be deterred, we tuned for the nitrous, and stacking a large amount of nitrous on top of slightly less boost (24-25psi) allowed me to break the 500 mark.. but only just. I was simultaneously thrilled by the results and disappointed. There remained a significant bottle neck, quick tuning alone was not to blame here. The car rewarded my abuse the next day with four broken pistons (o.k., so it wasn't the abuse, it was a faulty nitrous gauge). A full build was in order, and things needed to change, somewhat drastically.

At this point a side note is required.. it is worth mentioning that when things went pop, my DD evo was encroaching on the volvo's previous best mph, with similar boost and no nitrous. And my best friend's nissan was sitting well north of 500 rwhp, another buddy's civic was almost to the 700 fwhp mark, in short, I was (and still am) getting my ass kicked by anyone with four tires. This will not do.

Enter the 'build'. Efficiency and abuse were the key parts of this build. I wanted to increase power across the board (as much as one can do with a huge turbo and laggy ass turbine wheel), but I also wanted something that could take the heat if need be. A fair amount of research went into a number of different things, a lot of time was spent reading and looking at what the swedes were doing (at least the ones that were getting things done), and a plan was drawn up. I still don't like the idea of handing someone a big wad of cash to do something that I might be able to do, and I'm still a tinkerer; so- I bought the stuff to set up a flow bench, got a couple spare junk 16v heads, and went to town. (well, after reading as much about porting and airflow as I could get my hands on). If I'd had to pay myself I would still be in the hole, but the results were in line with what I was looking for -
~40% better intake flow and ~25% better exhaust flow.
I also sourced a different set of cams from Folks Racing (FS324's), said to be a somewhat mild rally cam, the specs worked out to be fairly similar to the camshafts that I now have in my EVO.
Intercooler piping was vastly improved, both in size and consistency as well as fluidity.
The block was reinforced a bit (pined), tanked and checked and bored out for the new lower profile pistons (shorter pistons longer rods) everything was double and tripple checked during assembly, and aside from some growing pains regarding the solid lifter conversion I did (valve noise after its warmed up-kinda like an 8v without silencers) things seem to have worked out.

I have not yet gotten a chance to really tune the car out on the dyno, it was suspected and confirmed, that after the above work, the volvo automatic just would not stick around for any amount of time.. so with that in mind, we set the boost to a moderate 19psi, put the race gas in, and tuned the air fuel ratios (~4-5 passes total), and settled for an ugly 435rwhp. Looking at the torque curve, I imagine the same number of pulls spent on ignition timing would pick up another 25 rwhp, if not more. uuuugly. Given the powerband the car has, we needed to tune the nitrous as well (high rpm powerband, low rpm stall converter = dog off the line), mainly to get the car off the line at the drag strip. We took the same shot as before (75), pulled more timing out of the already sad timing map, dropped in ~10% more fuel, did a test pass with the bottle off to verify that it was going extremely rich, and then did a single pass on the nitrous. 512 rwhp. pulled the car off the dyno, drove home, and swapped in a new transmission for the 1/4 part of SE 8.0

Now, it is currently waiting for the next round of upgrades. It will get a th350 with a higher stall converter, I really need to build/buy/find a better exhaust manifold before too long, and the intercooler is going to get upgraded. I haven't decided if I want a really nice air to water, or just a high-flow garrett core.

[3liter914-6]

Looking good. I like the body matched valve cover. Nice touch. Any plans for the wheels? I'm thinking of sticking with steelies too, but maybe getting a set of the old chrome hub caps(not wheel covers). Sort of a Swedish Caprice Classic look.

http://iesforums.org/5oh-style.jpg


throw some tintz on so you can have a little privacy when you're in the back loving up a lady.
http://iesforums.org/tintz.jpg

[linuxman51]

tint is definitly on the shortlist, now that the a/c is finito. the wheelz i got are 740 turbo wheels to be refinished in gunmetal, since i dont want black and i dont think theres a dark enough grey to match the car (and body color wheels are kinda odd anyway. I suppose i could paint em bronze-anyone wanna pchop that on there?)

[BDKR]

Wow, that thing looks pretty cool with the steelies.

[Chigga 744SE]

looks hot with the caprice -style stuff.

[SwedishFish]

i concur with chigga
go for the swedish undercover look

[Neil Peart]

Looks nice kenny...I do like that caprice look.


Scare the rice. All ya need is a spot light and a big antenna.

[linuxman51]

The culmination of almost a year and a half of work finally runs in the 90, not the choice of vehicle but time and money constraints led the charge on this one.

http://www.pbase.com/kdh51/image/30921457.jpg

http://www.pbase.com/kdh51/image/31094366.jpg

http://www.pbase.com/kdh51/image/31094375.jpg

http://www.pbase.com/kdh51/image/31515063.jpg

http://www.pbase.com/kdh51/image/32103426.jpg

http://www.pbase.com/kdh51/image/32103430.jpg

http://www.pbase.com/kdh51/image/45845103.jpg

[linuxman51]

what i didnt take a pic of, the pistons were then balanced and cc'd (they're +- 2 grams or so, i dont recall anymore), the rods all weighed out the same, the crank looked like a crank, the chambers were polished a little, the valves were polished front and back.

[adrianpike]

Are you running EDIS?

EDIT: is that a blaster hiding underneath your intake mani?
EDIT2: And a capless dizzy? What are you doing to make the cap clear the thermostat housing?

[Matt Dupuis]

Answer to all three quesitons: Kenny hates 240s.

[n xntrx volvo]

Answer to all three quesitons: Kenny hates 240s.
thats a shame since 700's hate him.

[Matt Dupuis]

:cheers:

[linuxman51]

Answer to all three quesitons: Kenny hates 240s.

244's i'm looking to buy a 242 ;).

i'm not putting a cap on the 240 distro, its being used for reference only. look towards the back of the motor. its the same coil that was on the 8v

[Neil Peart]

make a visit up here...3-4 242's and some 16V heads and other stuff ya might wanna look at.

[socalsean]

244's i'm looking to buy a 242 ;).

i'm not putting a cap on the 240 distro, its being used for reference only. look towards the back of the motor. its the same coil that was on the 8v

buy mine.

[linuxman51]

buy mine.


there is but one 242 floating around that is worth my attention :-P :-D

[n xntrx volvo]

there is but one 242 floating around that is worth my attention :-P :-D
but i dont have a 242?

[BDKR]

I wonder what iroller thinks of that.

[linuxman51]

I wonder what iroller thinks of that.

he knows all about it, in fact it was discussed at great length long before any of it ever leaked out to the board :-P

[linuxman51]

today was spent fabbing up the turbo manifold and test fitting it (band saw, 16v header flange, black iron pipe, and a SSA manifold = 16vT manifold)

no pics (didnt have camera handy and we were in a little rush to get to the pool after the mockup work), but it required the relocation of some subtle frame rail material (altho nothing into the frame rail itself so i doubt theres any structural compromise, however if the powerstroke goes in the car there might be...)
it will also be recieving a tial 38, and all new exhaust (since, obviously, the stock **** wont bolt up)

[linuxman51]

New additions as of this afternoon/evening (all in before midnight):

3inch HS-tuning exhaust (don't ask)
to4e-50 trim, stage V turbine wheel (60 a/r compressor, 63 a/r turbine)
tial 38mm wastegate
custom modified xs power manifold (yea, i'm saving for a real one ;) )
HS-tuning hotside IC piping

currently running 7psi. est hp: hm, ask me in a couple days. its fast tho.

[BDKR]

New additions as of this afternoon/evening (all in before midnight):

3inch HS-tuning exhaust (don't ask)
to4e-50 trim, stage V turbine wheel (60 a/r compressor, 63 a/r turbine)
tial 38mm wastegate
custom modified xs power manifold (yea, i'm saving for a real one ;) )
HS-tuning hotside IC piping

currently running 7psi. est hp: hm, ask me in a couple days. its fast tho.

Bitchin! :twisted:

That thing is going to be a monster once it's tuned.

[linuxman51]

http://www.pbase.com/kdh51/image/47141675.jpg

http://www.pbase.com/kdh51/image/47141677.jpg

http://www.pbase.com/kdh51/image/47141678.jpg

http://www.pbase.com/kdh51/image/47141673.jpg

http://www.pbase.com/kdh51/image/47141674.jpg

and that PHAT exhaust setup would be the brainchild of deathwagon.

[jpbturbo]

That is of course amazingly pimp.

[BDKR]

Is it just me or has a new evil been unleashed on American streets? I really wish I was coming this weekend now.

[volvorsport]

youve stolen all my ideas :rofl:

1, ssautochrome header to 16v

2, ebay special turbo

3, oil line heebiness

great how 2 minds think alike

altho i now hoave bragging rights in that i have in my posession an FT manifold for a 16v :-P

[olov]

i really like that turbo placement. glad to hear it came together pretty easily

[linuxman51]

youve stolen all my ideas :rofl:
2, ebay special turbo

3, oil line heebiness


You're mistaken. Thats $650 worth of garrett factory turbo (i've got the box it came in), that puppy is *brand* new and factory fresh baby :) (got tired of the monthly turboswaps on the 8v)

the oil line is 1/4 inch compression fitting custom line made downtown at the hydraulic store. the return line, while it might resemble heater core hose, is 4 ply double nylon braided 300 psi hydraulic hose. it was interesting to say the least to route it, as its not exceedingly flexible (but moreso than stainless braided)

[Neil Peart]

u fkucin rock..I really wish I could make it to Se to see this thing. But since you guy's irresponsible, wreckless, and insanely....fun antics kept me from going, im gonna stay here and wait for video.


Amazing work...great job!

[DeathWagon]

i really like that turbo placement. glad to hear it came together pretty easily

easily NOT. this whole project was definatly a pain in the heeb. We spend alot of time getting everything just right. The car has come together soo quickly due to kennys good planing and preperation for every possiable situation. I am glad its done now hopefully it will stay together for a while.

Sam

p.s. you cant believe the sounds this car makes

[Neil Peart]

I want video..now

[linuxman51]

p.s. you cant believe the sounds this car makes


hmm, is this good or bad?

[olov]

easily NOT.
well i meant, easy enough that it's done now, as mine still isn't.

good luck with the new turbo, did you get a warranty with this one? :P

[ZVOLV]

Nicely done! Good to see another 16vt running! The bar is being raised even more around here and I like it.
I just picked up another 16v head for my next build. (that makes 4 in the garage now, but this one is complete) Too bad Volvo wouldnt sell me the b204ft exhaust manifold. They said it was "Code 55: Not for this market." But they had a b204ft intake manifold in stock in New Jersey that I picked up.
Also, the distributor does seem to be the same between 8v and 16v. I was wrong.

I thought you said last week you were running without piston cuts? Did that work for you? Apparently you are running WITH them now.

And is that manifold an 8v mani with a 16v flange on it?

[BDKR]

The bar is being raised even more around here and I like it.


You guys are leaving us plain jane 8v TI guys in the dust.

[linuxman51]

Nicely done! Good to see another 16vt running! The bar is being raised even more around here and I like it.
I just picked up another 16v head for my next build. (that makes 4 in the garage now, but this one is complete) Too bad Volvo wouldnt sell me the b204ft exhaust manifold. They said it was "Code 55: Not for this market." But they had a b204ft intake manifold in stock in New Jersey that I picked up.
Also, the distributor does seem to be the same between 8v and 16v. I was wrong.

I thought you said last week you were running without piston cuts? Did that work for you? Apparently you are running WITH them now.

And is that manifold an 8v mani with a 16v flange on it?

the pistons have been cut from day one actually, i didnt want to run the risk of anything getting friendly.

the manifold is a modified 8v manifold.

[volvorsport]

i was just comparing kenny actually - that just looks like everything i got - yes my oil line is braided up stainless covered hydraulic pressure pipe that dont wanna bend wit a compression fitting on the end .

I do have a turbo techincs T4 with warranty on the shelf.

ill say the 1/4 line looks small - 3/8 was what i had with mine .

do you see any comparisons ? oh were using SPM rods :-P

[DeathWagon]

i was just comparing kenny actually - that just looks like everything i got - yes my oil line is braided up stainless covered hydraulic pressure pipe that dont wanna bend wit a compression fitting on the end .

I do have a turbo techincs T4 with warranty on the shelf.

ill say the 1/4 line looks small - 3/8 was what i had with mine .

do you see any comparisons ? oh were using SPM rods :-P


yea, but mine *runs* :-P

[242Fast]

sam, which one are you in the pics on pbase? and is that your uber drill machine that you're cutting up kenny's pistons with? i'm not going to be able to make it this weekend argh. wow this is sweet

[Tenacious Todd]

AWESOME!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!

[linuxman51]

sam, which one are you in the pics on pbase? and is that your uber drill machine that you're cutting up kenny's pistons with? i'm not going to be able to make it this weekend argh. wow this is sweet

sam's the redhead, and the vertical mill is the property of BNR Supercars
I'm the one with the curly hair.

[linuxman51]

Updates on the car for today:
-Battery relocation to the passenger side trunk (sam style)
-Hooked the knocksense back up (and then went silly with ignition timing and got reigned back in by the led of death)

-check valve'd the pcv hose to the inlet (need to finish clamping all my other intake lines)
-mounted the expansion tank (but its in a bad spot, might have to re-think that one and maybe do something else)
-hooked the wideband up
fixed a rattle (sorta..)

[ATI_RAGE_]

I like it, looks great.

[DeathWagon]

KENNY

http://www.pbase.com/sam3481/image/38151197.jpg

Sam

http://www.pbase.com/sam3481/image/38151202.jpg

[isaac]

and Sam has finally gone full blown lumberjack.

[242Fast]

do you guys borrow bnr's shop to do all these fun things to kenny's car?

[Dr Dokeh]

So what drivetrain part is gonna break first? :-P

[Neil Peart]

Im gonna make a phone call and talk to you boys later today, on erics phone

[linuxman51]

http://www.pbase.com/kdh51/image/47202191.jpg

First pull, 7 psi. on the pumpgas goodstuff. I need bigger injectors

[stylngle2003]

wicked cool

although from the looks of it, with the exception of richening it up slightly, and the timing adjustments you could make from that at the top end, it seems like it's pretty much stopped making power by redline, so i would think 7psi may be good for about 280-285 max with a really good tune

now, 14psi is a whole nother story :badboy:

[BDKR]

Wow! :omg:

[JW240]

thats amazing with 7 PSI!! I want to build such a monster too one day. (u are my hero!)

[BDKR]

thats amazing with 7 PSI!! I want to build such a monster too one day. (u are my hero!)

Remember that that's a 50 trim t3/t04e. 7 PSI there is a bit more than 7 PSI out of a TDO5-12B or .42/.48 T3.

But whatever the case, there is going to be a lot of schooling jumpin' off.

[BDKR]

http://www.pbase.com/kdh51/image/47202191.jpg

First pull, 7 psi. on the pumpgas goodstuff. I need bigger injectors

Looking at the graph again, I have to say that's a pretty steady line there as the RPM increases. There seems to be no point in the range where the engine suddenly comes alive. At the same time, there are no dips or holes, which is pretty amazing for a multi valve is you ask me.

What options do you have for cams?

[Morley]

What kind of fuelpump(s)/injectors?

Mother of all engine Gods, that's an impressive first pull. I'm almost calling bluff-dyno on you :-P

[ATI_RAGE_]

That is very awesome.

[CountOfNowhere]

so, basically, what you're saying is that 8v heads are worthless? :)

bastard... that's so hot.

[Chigga 744SE]

what's the total cost of building such drivetrain? incld tranny & engine.

[linuxman51]

~$1k for the t5 swap including clutch, tranny and plate (might be for sale, shifter position hasnt grown on me)
Locker $260
npr $200
head was $150
pistons $260
rod bearings $25 (federal mogul)
hg set $75
oil feed and return stuff $55
850 TB $15
ms&s $300 (For yall)
manifold $300 after all is said and done (ebay header and a 16v flange, plus extra for materials)
turbo was 650 from garrett (to4e-50 trim, stage V turbine wheel, 60 a/r compressor and 63 a/r turbine)
$200ish on the exhaust to date (needs another muffler and a flex joint, flex joint comes first)

so yea, not exactly a budget build, but you're starting off with a fully rebuilt motor, etc.

and countless hours of research dating back to before I ever did the f+t on the 87.

Future stuff will include a better intake manifold, maybe the powerstroke to clean up the bizzare intercooler piping, and all the interior bits that are out are going back in (or i'll just buy another DD)

[Chigga 744SE]

um............ very tempting to drive down to your house and buy ur drivetrain and drive back up.

[linuxman51]

http://www.pbase.com/kdh51/image/47752416.jpg

[pwschuh]

Very nice Kenny. What changes from the last one or is this just more fine-tuning?

[linuxman51]

Very nice Kenny. What changes from the last one or is this just more fine-tuning?

more boost, very little tuning

[MattP]

What kind of fuelpump(s)/injectors?

Mother of all engine Gods, that's an impressive first pull. I'm almost calling bluff-dyno on you :-P

I would also like to know what size injectors you are using.

[linuxman51]

460 cc @ 3bar, walbro 255 in tank(former rex car, so its the only pump) and they peg out 100% at 7 psi and somewhere around 130% at 14psi.

[SwedishFish]

Man, that is just flippin insane. I mean, just goddamn. 300+ hp. 300+ ft-lbs. Bastard.
I bet you've got a good chance at whuppin some GN ass, drive that bitch over here and we'll start somethin.
And if you ever, ever sell the bitch. DIBS

[linuxman51]

The on going battle between car and owner continues, i'm slowly gaining the upper hand (my cd player started acting wierd tho the other day, so its about time for a system upgrade, thinking a pair of 6x9's in the deck lid and some thump in the trunk to go with my pioneer door speakers and soon to be pioneer headunit... I love my employee discount)

anyway, gotten the interior under control... sorta. replaced the glove box (damn lower panel wouldn't stay glued, i'll be putting a few strategic screws in it in the near future), will have to adjust the bundle of stock wiring and wideband wiring in the passenger side foot well to put the stock panel back on over it, it *allmost* fits. Got the fuse panel in an agreeable position after fighting with it for months, which in turn allowed me to put the cig. lighter back in the car (unfortuneately the wiring for it has vanished into the center of the beast, so its not serviceable at the moment. but i dont some so i dont care), leaving me with the problem of covering up the area once occupied by the ashtray. It wont be going back as the shifter won't allow for it, so i've gotta figure out some sorta panel with blinking lights or something to be cool (think flat black plastic/thin steel in reality, with nothing on it)

Wideband and knock light are going to be moved Poi style to where the clock once was, more so I can see that **** during the day time (and have service of that vent again), and i'm in dire need of a decent shift boot (and a non apc shift knob would be nice as well. perhaps i'll ring the ford dealer and ask what a mustang shift knob costs). that should round things on the inside out nicely in a decisivly understated kinda way, a vdo black faced 30psi boost gauge will likely be purchased in the near future to take the place of the dave barton gauge that is maddeningly inaccurate (i suppose i could grab a gauge out of another dash i've got laying around, but wheres the fun in that?).

Oh, and the wheels themselves, thats right. the wheels are almost done, we're calling this an experiment with colors, if I like the current color i'll get em powder coated, otherwise i'll probably just grab a set of 16' 850 turbo wheels and spacers and let it ride out.

now for the pics. updated underhood pics to come soon, theres a few things to be taken care of under there, and i'm waiting for parts from volvo.

no, they're not this much lighter than the car
http://www.pbase.com/kdh51/image/48941957.jpg

http://www.pbase.com/kdh51/image/48941958.jpg

http://www.pbase.com/kdh51/image/48941956.jpg

freshly washed and waxed:
http://www.pbase.com/kdh51/image/48941955.jpg


on the performance side of things, i've started to play around with cam timing, more on that later, but i've gotten the car to start spooling 500 rpms sooner without a noticeable loss of top end.

[klr142]

i've started to play around with cam timing, more on that later, but i've gotten the car to start spooling 500 rpms sooner without a noticeable loss of top end.
F'n insane man, keep it up.

[linuxman51]

havent updated in a while (car hasnt really moved in a while either tho)

started building the manifold last week, it looks like ****

http://www.pbase.com/kdh51/image/51392029.jpg

but i've got someone else i can pass blame on ;)

http://www.pbase.com/kdh51/image/51392031.jpg

[olov]

u da man! well both you and sam

and i didn't know you mounted alloys, looks hot IMO

[linuxman51]

u da man! well both you and sam

and i didn't know you mounted alloys, looks hot IMO


they're still not on the car, havent been able to get it to the tire shop to get my tars mounted

[BDKR]

So what's up with the intake manifold? Aren't you doing a custom one or still just in the "thought" stage?

Oh, and employee discounts for the win. I did a short part time stint in a Pep Boys. Got my Pioneer head and 1000 watt amp for 75 bucks combined! They were old display items. :badboy:

[linuxman51]

So what's up with the intake manifold? Aren't you doing a custom one or still just in the "thought" stage?


its in the thought stage, but soon to be implemented, as I've got a feeling the stock manifold is whats getting restrictive right now

[RoadRacer4Life]

new work in progress pics (i'm such a pimp it hurts)

http://www.pbase.com/kdh51/image/51716951.jpg

http://www.pbase.com/kdh51/image/51716953.jpg

http://www.pbase.com/kdh51/image/51716952.jpg

and meeee (Yeah, check the halo)

http://www.pbase.com/kdh51/image/51716954.jpg

[740ATL]

Sam, I knew your car was fast, but wasn't sure of the real source of your powers until now...

:)



http://www.pbase.com/kdh51/image/51716954.jpg

[luke242ti]

new work in progress pics (i'm such a pimp it hurts)

http://www.pbase.com/kdh51/image/51716951.jpg



Looks good. Nice use of the SSAC header :)

[linuxman51]

new subframe pics:
http://www.pbase.com/sam3481/image/56395212.jpg

http://www.pbase.com/sam3481/image/56395215.jpg

http://www.pbase.com/sam3481/image/56395214.jpg

and sam getting ready to adjust something.
http://www.pbase.com/sam3481/image/56395210.jpg


Pics of the new manifold installed on the car: (and the downpipe to go with it)

http://www.pbase.com/sam3481/image/56395217.jpg

http://www.pbase.com/kdh51/image/56293496.jpg

http://www.pbase.com/kdh51/image/56293494.jpg

[BDKR]

Man I need to learn how to weld.

Keep it up! Nice to know there are Brickers somewhere out there kickin' arse!

[linuxman51]

minor update. Swapped in some 550cc rx-7 injectors, that turned out to be not so hot. After tuning what at least on a wideband seemed to be a safe 12:1 afr, the numbers on the dyno didn't match up with previous performance numbers (15psi, 290 tq, but only about 240 hp), the graph also showed a fair amount of inconsistency above 4k, and the knocksense was arbitrarily going nuts.
After investigating matters further (and the power not responding to fuel changes, etc) 3 plugs were fairly consistent (lean) and one was pretty far on the rich side of things. Boost was not to be controlled either. So I swapped my 460's back in, afr's didnt change much at all, power was consistent (well nonexsistent haha, timing stuffed back in, and it runs like a scalded dog). So no more fooling around, next set of injectors is gonna be new, and big.

Oh and I've got a couple stroker cranks on the way

[linuxman51]

Updates to this thread:
new intercooler:
http://www.pbase.com/kdh51/image/59745404.jpg

http://www.pbase.com/kdh51/image/59745405.jpg

and the new intake for the turbo (need some sorta expansion chamber, but i'll deal with that later
http://www.pbase.com/kdh51/image/60082052.jpg

looking through the tow hook cover:
http://www.pbase.com/kdh51/image/60082050.jpg

[MikeSr.]

Looks good,man- really like the intercooler.

[klr142]

Expansion chamber where? After turbo or before? Interesting, looking forward to seeing/hearing more about that.

[linuxman51]

Expansion chamber where? After turbo or before? Interesting, looking forward to seeing/hearing more about that.


before. already got one after.. its called an intercooler ;)

[klr142]

Lol, true true... So what'll be the purpose of having one before? I don't think I've seen many, if any setups(not just on Volvos) that have had some sort of expansion chamber before the turbo. On a modified car anyway.

[linuxman51]

turbos breathe from the sides moreso than the middle.

[klr142]

Hmm... :badboy: Definitely interested in seeing how you manage that...

[linuxman51]

Yeah, still working on that concept (trying to find something off the shelf, more on that when i've got free time to think for myself hahahaha).

Currently the exhaust manifold is back off the car, Two broken studs this time (I knew one was going to break, the other was a shock) so I'm going to take it up the ass at the dealer tomorrow and get 9 new studs, and my buddy is going to hook it up with inserts (not helicoils).
This after trashing out the power steering pump whilst taking things off, I get to drain the power steering system (maybe the chunks that are keeping it from leaking will come out eh hahha) to get the pump off to fix the bracket I completely ****ed up. Should be fun and greasy. then I'm washing the passenger side engine bay with something a bit abrasive (but I think the paint is for the most part, done, as the parts affected by the SSAC-itis have turned a completely different shade of grey). paint will likely follow when the engine is out for replacement later this fall.
There are a few other items on the list of things to do, but i've gotta save a little for later ;-)

[thelostartof]

is there a rush toget the car back on the road .. you can get new studs from me for $1 each that are longer than stock nevermind prob a bit better

[BDKR]

turbos breathe from the sides moreso than the middle.

Have you looked at the front of a turbofan?

http://highsidecafe.com/volvo/7-1d.gif

If something akin to that cone could be mounted in front of compressor blades more of the incoming air could be forced out to the sides right? Is this what you're getting at?

Anyway, I have an idea or two on how to do this. Curious to hear what your thinking on it.

[linuxman51]

got a little side-tracked:

http://www.pbase.com/kdh51/image/61892818.jpg

[klr142]

Is that an individual coil pack?

[blkaplan]

COP for teh win

[socalsean]

Have you looked at the front of a turbofan?

http://highsidecafe.com/volvo/7-1d.gif

If something akin to that cone could be mounted in front of compressor blades more of the incoming air could be forced out to the sides right? Is this what you're getting at?

Anyway, I have an idea or two on how to do this. Curious to hear what your thinking on it.

All of Turbonetics' turbos have a cone shaped compressor retaining nut.

[linuxman51]

porsche parts ftw. Not on the car yet, but in case anyone was wondering, they're cayenne turbo coils. I'm one short of a set.

In the mean time i get to play with msd, which will then be relocated to the daily d upon completion of the cop for the 16v.

Just completed:
drilling out and tapping the exhaust side and t-serting it
new studs washers and nuts
oem exhaust manifold gasket (by far the best one of the three styles i've seen. the reintz/layered metal /paper gasket absolutely sucks and the elring isnt too bad).
took it out briefly for the first time in a month, promptly fouled a plug trying to launch it and went back home (well there were more events in the middle that you might hear about later).
tomorrow afternoon, the msd.

[fengler]

wow, props to the amount of work

[linuxman51]

productive day. Met 740ATL at the bham junkyard (and bennfynn), got a turbo off a 940 for project Y, an electric fan for project X, and a 16v brake booster for my car. Got home this afternoon to discover that while the booster in fact does bolt right up, its hardly a direct swap. 3 hours later i'm fully bled out with new dot4, clearance on the intake side, and hell, while we were in there we put the msd on the car.

Lets just say I'm pretty sure the predicted 20hp gain up top from the msd was off, the car ****ing flies.

[boosted]

the cayenne coils are not doing to hot, they are all cracking.

if you want i can bring a set to the SE meet for ~$75

[linuxman51]

the cayenne coils are not doing to hot, they are all cracking.

if you want i can bring a set to the SE meet for ~$75

already gotta insider(several in fact) at the local dealer.....finally.

And haven't heard anything about the coils yet. Same part number as the new 997 turbo.. it makes a cool 480hp/500tq (and godDAMN it flies).
and my good buddy is the head porsche mechanic, so i'm the first to hear about the strangeness of the cars.
apparently 997's are having issues with a/c coming off the trucks.

[boosted]

i work for porsche

[boosted]

i drove a new gt3 a few minutes ago.. WHOOOOOO i wish i had money!!

[linuxman51]

modernized the mod list.

[MattP]

CBR600 COP's work also. They are a lot easier to get. Go ebay!

[linuxman51]

Yay for updates:
Blew the motor up...well it runs actually, but the oil had stuff in it that doesnt come out of the container, lifters don't work so hot anymore, not sure if its a cylinder head issue thats contributing the crap in the pan or something else, but rest assured a couple of things:

1) the engine has to come out.
2) the headgasket is blown.
3) several lifters are non-func from a hydraulic standpoint, not sure if that means they're broke or if they just dont get sufficient pressure anymore
4) Well, I've got a 2.5 crank, two sets of H beam rods to choose from (oh **** i still gotta hit stereophile with the rest of the payment), and it'll get some forged slugs.

Time to research some cams, and put pennies away for my cylinder head work.

[the poi]

oooo, weak. but hey, forged stuff is fun. did you get your stuff from stereophile yet? :???:

[thelostartof]

@ least the rods never let up

i want them back if you are done with them

[740ATL]

yeah... first part booo...

second part, yaaaaay.

PS... I will be awaiting your diagnosis of the head+lifters... I'd like to knwo what one looks like after what you put it through.

keep on truckin.

[linuxman51]

@ least the rods never let up

i want them back if you are done with them

unconfirmed. its got a low hole that i'm assuming is hg related. and just cause it still runs doesnt mean they're all straight ;)

[BoxDriver2]

All of Turbonetics' turbos have a cone shaped compressor retaining nut.

No, they don't. I have 2 sitting here, that do not, and one is recent.

[linuxman51]

Update 12/11/06:

head has been off the car for almost a month now, after I drove it home NA to save off potential turbo damage from degrading internals.
Removed head, found a nicely blown headgasket, and I suspect I will find some nicely flatspotted rod bearings in the bottom end (either that or I destroyed a bunch of lifters and they puked metalic **** into my oil.. I'm going with rod bearings)

Plan is to pull the motor this week, perhaps as soon as tomorrow, will see, and I'm going to borrow a 95 b230f from Tom so I can move the car around (no, its staying NA, so don't get any ideas guys. its not even going to have anything past the y pipe for exhaust, so I won't be moving it much, either) and finalize the wasted spark installation I started on back in july.

The motor thats in the car is coming out (obviously) and pending various machine-type things, will be reassembled with a penta crank, big rods, big pistons, and balanced within an inch of its life. I'm sourcing yet another spare 16v head, I won't get to see it though for a while cause its going straight to Winston's shop in NY, and I suspect it'll be there for a month or two getting some creative port work, bigger valves, and a large dosage of profanity.
When thats done with him, the head will come south to me, where I will stuff a nice set of aftermarket cams, solid lifters, and more than likely another dose of profanity in it, and then on the car it'll go.

Fret not, however, as soon as the bottom end is done, it'll go back in the car with the towerymt spare head for break-in and fitment of a different intake manifold.

And once the engine is sorted, we're going to build a new exhaust manifold with a divided flange outlet, perhaps a pair of gates, and a nasty turbo.

The rear suspension, that will be a surprise, but rest assured, it will be up to the task.

[IceCold4x4]

what about a tranny. . . .

[linuxman51]

what about a tranny. . . .

read the whole thread.

a better question is, what are *you* doing for a transmission? start your own thread to answer that one...

[Poik]

Where are you getting your solid lifters from?

[linuxman51]

Where are you getting your solid lifters from?

chuck noris

[adrianpike]

chuck noris

Roundhouse kick to the lathe!

[740ATL]

dammit we keep trying to catch up with you and you keep moving the line...

[linuxman51]

hehe. picked up the 95 motor, i'll get to plug air injection holes again, might try to come up with something sneaky, or just leave em be. pending weather tomorrow, will be borrowing an engine hoist and swapping **** out weds.

[linuxman51]

motor and trans out, got the flywheel, etc off the engine, and flex plate/converter, etc off the other engine. ran into a slight snag with the pilot bearing and it started raining, hopefully tomorrow the new (temp) engine shall be in the car.

[socalsean]

No, they don't. I have 2 sitting here, that do not, and one is recent.


How recent is "recent"?

[linuxman51]

finaly tore the motor down tonight (well, finished) the sum total of spraying a 75 shot on top of 20psi with your twin cam:

1 x blown headgasket
1 x oil pump transfer tube sneaking out (goddamnit)
pistons look great, havent gotten the rods off them yet to check for straightness, but everything in the bottom end looks beautiful. too bad none of it is going back in :-D

[klr142]

So that was indeed 20psi and the nitrous on this setup?
Mods breakdown..
Engine:
ported 262
stock cams, two adjustable cam gears
custom fly cut b230ft pistons
1995 b230f bottom end with oil squirters
megasquirt & spark extra
t3/t04e 50 trim with a stage V turbine wheel in a .63 a/r turbine housing
Custom intercooler designed for a skyline
Snow Performance stage2 boost cooler*
Nitrous Express wet kit (approx 75hp shot)
What is the estimated hp level at the headgasket failure? Somewhere around 400 crank? More? Less?

Coolness. Waiting to hear about the rest of the bottom end! :)

[linuxman51]

So that was indeed 20psi and the nitrous on this setup?

What is the estimated hp level at the headgasket failure? Somewhere around 400 crank? More? Less?

Coolness. Waiting to hear about the rest of the bottom end! :)


easily over 400 crank, if i had to guess (based on how bad me and rob raped the STI and the race with the 240sx)

[klr142]

:-D I don't doubt it. Can't wait for the next iteration!

[linuxman51]

looks like there is going to be a 1.5 iteration before going to 2.0.
Note that this shall not greatly affect the build timeline (however it will let me accelerate other areas of the final product).


Spent the better part of today bolting up the b230f, filling it up, hooking things up, plumbing it all up, etc. and was in good shape to start the car around 3:45 this afternoon... save for two items. The waterpump on the motor was so badly worn out that it leaked water about as fast as I could pour it in the expansion tank (this is potentially bad for the cylinder head, but the motor builds excellent pressure even turning it over by hand, on all 4 holes, and the plugs, altho about 80k old, looked good too), and the battery is so dead that I can't get more than one or two revolutions out of the car with the plugs in and the charger on crank.

The plan right now is to get the car running so I can move it up the street to the new house without a lot of dragging drama (its always easier to stash a running car than push a dead one), I'll probably run a couple short oil changes through it to make sure there's no random **** in it from the jy and p.o.'s, and then the fun begins.
No Im not going to slap a turbo on the side of it as it sits...
rather, I'm going to yank that wretched 8v head, seal up the deck except for the pistons, and, you guessed it, cut reliefs air grinder stylez. then its on with the spare 16v head, a shake down run NA to make sure its all behaving itself, and back to higher compression turbo fun, which will allow me to fabricate the intake manifold, perfect the COP, and redo the wiring with the correct setup in the car. And who knows, maybe even a fast pass or two this year.

pic or two tomorrow, but there's really nothing to see but a big mess. Oh, and I'm going to take the car to the car wash.

[740ATL]

hell yeah! All the reliefs have to do is clear... they don't have to look pretty.

I like it!

[linuxman51]

Roared to life today, in all of its greasy loud 8v NA-ness, clearly hadn't been run in a while (at least two months in my possession, but likely a lot longer than that). early problems:

Water pump so bad it came out as fast as I could pour it in (altho in retrospect this could have been resultant from other abuse post removal from the donor vehicle)
Water in the crankcase. In my haste to start it up and start flushing oil through it to de-funk things, I didnt first check for **** in the pan (after draining it in november), and well, there was some in there. I'm hoping that it was condensate/rain/etc, but we'll see. Its on the second of 3 oil cycles, and this time around it hasnt gone straight to milk.

back off outside to ponder some things and figure out how to plug the air holes in the head, at least temporarily.

[linuxman51]

plugged air holes, still no worsening of the oil, so hopefully thats resolved. now it sounds like the engine might have a slight knock, going to be hard to tell.

[linuxman51]

definite knock at low (read:freshly changed) oil pressures, but it goes away the second the oil light goes off. new set of rod bearings, assuming nothing as spun rob prince style, should see the few thousand miles of torture I plan to subject the motor to.

[linuxman51]

drove it up the hill, drained the coolant (mostly water, freezing temps, not going to risk it).
Friday afternoon the head comes off and prep work starts for the cutting saturday.

[linuxman51]

HAHA A coup has taken place!
I stole the 740atl piston tool!

Not really, Mike generously loaned it to me. I'm going to make a few mods and clean it up a bit so that it hopefully works a little better. Ideally I'll be cutting reliefs this week, maybe even replacing the rod bearings in the motor (which is about the last thing stopping me from dropping a head on the bitch and riding out).
And I've got,well I will have mike's maps from the dyno to accompany the 10:1 cr goodness.

Pics of the nastiness to come in the following days.

[linuxman51]

Head is off the car (NOOOO RIDGE WOOO!), will be testing and documenting 740ATL's 16v relief tool with the pistons in the car (but then i'm going to pull them out for re-ringing and new rod bearings).
Hoping for a bewsted twin cam wasted spark beeotch within the next 14 days :)

[klr142]

Hoping for a bewsted twin cam wasted spark beeotch within the next 14 days :)That would be nice, wouldn't it... And then, once you get it tuned up real nice, feel free to send it my way...

[linuxman51]

:nod:

[linuxman51]

so that didnt happen. The jury is out as to wether or not I'll bother with returning the car to the road right now, or just wait til the new motor is built. With the new job, there has been a dramatic change in plans and power goals.

stay tuned.

[linuxman51]

Change of plans (possibly starting as soon as this weekend).
Car is getting:
completely re-wired (painless FTW).
Heater/ac box is going to come out and get modified (a/c delete, just heater and minimal vent control)
looking into lexan replacement for glass, but we'll see. I'd rather a set of manual window regulators, but seeing as that would almost have to come from overseas, I dont see it happening. Probably won't have power windows in the back.

Gas tank comes out, fuel cell will be going in. Haven't decided on a fuel pump, I hear the 996TT Porsche has a pretty slick coffee-can sized unit.

front seats will be addressed eventually, back seat is going away. Planning for a roll cage will start shortly thereafter.

Rear suspension: stay tuned. on the drawing board: frame link, 4 link kit, and more than likely an 8.8

Transmission stays until it breaks, i'll evaluate things again at that point.

Engine? Yes. (rods pistons crank, head, cams, big turbo, new ms setup, with big FAT injectors)

I figure if I can do everything I want to do the way I really want to do it, and can come out for at or around $5k I'll be doing pretty good. Realistically, this is going to cost me about 7 or 8k. It *might* be running for SE6, but I'm in no rush.

p.s. I really like this new job :-D

[klr142]

Sweeeeeeeeeeeeet. I need to find me one of those new jobs, that I like.

[linuxman51]

swinging by the house to get my spare pistons and head, time to kick the intermediate part into high gear.

[linuxman51]

http://www.pbase.com/kdh51/image/77965080.jpg

hmmmm

[Poik]

Oh you slut.

[Hank Scorpio]

Nice!

[JW240]

this is turbobricks as it was meant to be! :-D

[740ATL]

are they done yet? how do they look?

[linuxman51]

not done yet. might play with them this evening, it could be as long as three-four weeks tho. Trying to get a gym routine established, keeping on top of people's ms stuff, and sleep all seem to come quickly right after work. This weekend it looks like i'll be roped into helping the gf do some interior decorating (read: pealing wallpaper, gag me), next weekend god help me, is the atlanta meet (**** i still need the front underpan for the 240. time to phone a friend), weekend after that is a wedding shower for sam... etc.
I think i'm going to quit building megasquirts, its not that they take a long time to build or that it takes a long time to do a harness (start to finish tho takes me longer than building a v3 board), i just never have 5-6 hours at a time to sit down, which in turn adds probably another 4 hours to the process of building one, if you factor in the setup and cleanup. friday night and saturday were a bit of a fluke, i had about 5 hours to play with car stuff, so i honed the wristpins on the hbeams, started taking apart my other 16v head and cleaning it, and laying things out on my workbench. Then it was 3 hours of fiddling and fudging with the valve as a cutting tool before I completely wrote that idea off as fairly unfeasible, even with the plethora of cutting and sanding discs I have, achieving a good smooth cutting implement on the valve just didn't seem to want to happen. in between cleaning the house and helping my other roommate move into the house I managed to find just enough time to get out to the store and find the bit pictured above. I'll have a full writeup in addition to some schematics for a real jig, the estimated total cost minus the drill press is going to be in the neighborhood of around $40 bucks, but I'm hoping for something closer to about 25 or 30, or less depending on what one already has available. An efficient clamping mechanism is going to be the hardest part and I think I've got a pretty slick solution in mind for that.

[klr142]

Jiminy christmassy. Quite the busy bee, eh? I wish I could snag a 2.4 PnP before you retire, but alas that's not feasible... Won't be decent year or three or five yet. Think you'll pick it back up someday? Lol.

Anywho, progress is progress!

[Sp3aK]

hmmmm

[740ATL]

amen dude. I dont' know how the f i managed to get valve cuts as good as the first 2 or 3 were... but then after that... nothing I did could seem to replicate the initial cuts. Got pretty tiring after a while... I gave up on it too... glad to know you found another alternative.

Mike

[benflynn]

if i drive down can i use it, what was this new job?

[MikeJr.]

That f*cking awesome man! Whats yor address I'm gonna mail you a box of pistons :-P

[Vol242vo]

Jezzzuusss! I had no idea you had done all this to your 744!:omg: Pure beauty!

[linuxman51]

intermediate engine goes together this week.
modified pistons, hbeams, spare stock 16v head. Will be shooting for a COP setup, need to go back and peruse mike's list of caps needed for the task.
pics to follow later.

[klr142]

:) Intermediate engine number :-P xx?

Cool. Will it stay together?

[norcal505]

your a mad man for what youve been doing to this 700.:lol:

[PreteristVolvo]

intermediate engine goes together this week.
modified pistons, hbeams, spare stock 16v head. Will be shooting for a COP setup, need to go back and peruse mike's list of caps needed for the task.
pics to follow later.


COP - Car Of Poomorrow.

As in, "why poo today what you can poo tomorrow".

kent

p.s. nice tool:-P

[linuxman51]

:) Intermediate engine number :-P xx?

Cool. Will it stay together?

its got dem stereophile rodz boi it oughta hang arount.


Shortblock is assembled torqued lubed & ready
Valves have been cleaned, seated, new stem seals

today:
front and rear covers come off the bottom end (new seals), gotta dig up the oil pan with the return in it (got lazy and didnt drill the block + I forgot until it was already together)

reinstall valve springs, bolt head on block, profit.
Should be stuffing the engine in the car tomorrow.

[Bricknoob]

http://www.pbase.com/kdh51/image/77965080.jpg

hmmmm

Damnation, poor forstner bit!

[MikeJr.]

intermediate engine goes together this week.
modified pistons, hbeams, spare stock 16v head. Will be shooting for a COP setup, need to go back and peruse mike's list of caps needed for the task.
pics to follow later.
Cool man I can't wait for the demon to come back to life. What coils are you gonna use?

[linuxman51]

Cool man I can't wait for the demon to come back to life. What coils are you gonna use?

cayenne turbo coils.

[MikeJr.]

cayenne turbo coils.
Are those the same as the red ones in an audi s4? Do you have them already?

[linuxman51]

Are those the same as the red ones in an audi s4? Do you have them already?

yes i have them, I have no idear if they're the same or not haha

oh hell that reminds me i need to order some caps.

[MikeJr.]

yes i have them, I have no idear if they're the same or not haha

oh hell that reminds me i need to order some caps.
I was just wondering cause I can sometimes get the red ones out of the audi s. Thats what I gave Mike as a going away present. I also saved a set for me :) . I may even be able to get my hand on the audi harness for the plugs.

[klr142]

Jeezus.

[linuxman51]

:spin:

[str8krewzn]

:spin:

Done?

[linuxman51]

no but close. the engine is hanging from the hoist. Its been a long day, I started getting spastic towards the end and called it quits. Probably early twinges of heat exhaustion, it was a hot mother****er today.

so:
gotta get the old pilot bearing out, put the new in, clutch & flywheel and bolt up trans, then it goes in. I ran into a snag with the timing belt, more on that tomorrow, I have some ideas tho.

[linuxman51]

engine's in.

[adrianpike]

engine's in.

That's hard on a grandpa series.

edit: good work though cap, I expect some slips in my PM box soon. :-D

[linuxman51]

That's hard on a grandpa series.

edit: good work though cap, I expect some slips in my PM box soon. :-D

its tricky when you dont have a load balancer and you're doing it by yourself :-P

all bolted up, intake's on, almost all of the under-hood electronics are hooked up, gotta pull the intercooler out and clean it.
Other things:
Get the manifold and y pipe on
clamps on the fuel return
adjust throttle cable
Radiator, belts, alt.
Drive shaft
....
Profit?

[linuxman51]

And a side note: if you're making an adapter for your transmission mount, it would be a really good idea to do so with *good* motor mounts.
made life interesting today when I replaced the driver's mount with the other poly bushing. :-/

[linuxman51]

pics
http://www.pbase.com/kdh51/image/81133110.jpg

why the stock 16v intake sucks balls:
http://www.pbase.com/kdh51/image/80913927.jpg


stock vs ported (1 inch in just to match up with whats going to be built):
http://www.pbase.com/kdh51/image/80913932.jpg

[klr142]

Much potential to be had, eh?

[linuxman51]

Much potential to be had, eh?

one hopes.

[linuxman51]

Down to the last couple of things. to be completely nit-picky:
I have to drop it off the stands after tieing off the exhaust
hook up the injectors and the megasquirt, and hook up the battery.

all fluids topped, all items installed, almost time to play :)

[adrianpike]

hell.

yea.

[Ruckus]

Your build is sick.

I love the shifter... and can't wait to see what you do with your intake manifold.

[Biesey]

/\ that was me, bro was signed in...

[klr142]

So... Does that mean it's going to DRIVE tomorrow? :)

[linuxman51]

yeah it should. gotta knock the cobb webs off it, probably run down to the car wash and give it a good once over. Wish the rota group buy would hurry up and finish haha

[linuxman51]

cranked off and idled on the first try :)

[MattP]

cranked off and idled on the first try :)


We don't care about your private life, how did the car run?

[adrianpike]

you were expecting something else? :???:


edit: ^^^ ****ing glorious. well played, sir, well played.

[linuxman51]

you were expecting something else? :???:


edit: ^^^ ****ing glorious. well played, sir, well played.

trip around the block yields:
need to bleed the clutch system (probably has a bad seal somewhere, so need to look into new master/slave, or a rebuild kit)

and some rediculous timing is needed. I might have to add 6-7 degrees to get it to drive decent, oh well it drives.


and damn is it loud. where are my ear plugs?

Drove it around some more last night, runs good, has good mid-range torque, but I haven't wound it out past about 4500 yet. might hold off on that til its turboed, its so painfully loud NA...

[linuxman51]

cleaned up a few things (not much), and got some gear on the car
http://www.pbase.com/kdh51/image/81635537.jpg

[linuxman51]

update: turbo plumbed up, wasted spark with dsm coils (gotta figure out what to do with the porsche coils, they look soooo nice on the car) runs good. Time to tune!

[linuxman51]

A bit more of a comprehensive update:
For those of you already set up with the 60-2 wheel decoding, I cannot stress how much of a difference the coilpacks made over the distributor in terms of idle quality. Seems smoother cruising and in accel too, but the car isn't tuned worth a **** right now (save for the dwell settings) so I can't comment on relative power yet.

The por paint is holding up well (so far) everywhere but on the external gate dump back into the downpipe where its blistering a little. All in all the effect is still very nice.

[boosted12a]

hey, did you do waisted spark or individual coils?

[500dollar744ti]

very nice, your car has always been my inspiration to start a 16v build and now im making some progress... your car is awesome

[linuxman51]

hey, did you do waisted spark or individual coils?

wasted spark. u needa call me.

[shaved240]

are you using the vw tensioner or the suby tensioner?

[740ATL]

A bit more of a comprehensive update:
For those of you already set up with the 60-2 wheel decoding, I cannot stress how much of a difference the coilpacks made over the distributor in terms of idle quality. Seems smoother cruising and in accel too, but the car isn't tuned worth a **** right now (save for the dwell settings) so I can't comment on relative power yet.

The por paint is holding up well (so far) everywhere but on the external gate dump back into the downpipe where its blistering a little. All in all the effect is still very nice.

hell yeah.

[IceCold4x4]

so you gonna have her running in time for SE6.0?

[BDKR]

Now I'm just waiting for the Brutal 744 demo. ;-)

Nice work mang! :-D

[linuxman51]

so you gonna have her running in time for SE6.0?

runs fine, just needs a tune and some cleanup.

[IceCold4x4]

well like i told ben tonight, don't blow it up before SE, i gotta see this one run.

[linuxman51]

well like i told ben tonight, don't blow it up before SE, i gotta see this one run.


i'll try not to. finding time to finish the last 1% is difficult tho.

[boosted12a]

wasted spark. u needa call me.

yea, i know been bussy, sleep and work. only time im awake is 1-4 am....this weekend tho

[linuxman51]

yea, i know been bussy, sleep and work. only time im awake is 1-4 am....this weekend tho

i'm never not busy anymore. this week was bad, next week by the time friday afternoon rolls around i'll be supprised if i still know my head from my asshole.

[jpbturbo]

i'm never not busy anymore. this week was bad, next week by the time friday afternoon rolls around i'll be supprised if i still know my head from my asshole.
Your face, your ass, what's the difference??
[/duke nukem]

[linuxman51]

Your face, your ass, what's the difference??
[/duke nukem]

meh, let god sort em out.

[mikes02ls1]

Looks good but those welds look rough, but I bet they get the job done though.

[linuxman51]

Looks good but those welds look rough, but I bet they get the job done though.

you gonna be here in a month foo?

[shaved240]

are you using solid lifters and subie tensioner?

[mikes02ls1]

you gonna be here in a month foo?
Whats going on in a month?

[CaptainWhoosh]

Ive been lookin around for the old vid of this car, anyone have the link?

[impulse922]

Whats going on in a month?

SE 6.0.

biggest, craziest, heebest meet of the year

[linuxman51]

updated to reflect current status.

[linuxman51]

new numbers. 413whp, 409wtq

[adrianpike]

That badge under your name is outdated.

[thelostartof]

That badge under your name is outdated.

yea it should be the "weeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee" club

[740ATL]

congrats man!

[boosted12a]

****

[klr142]

:-D Sweet man. What's changed? Boost level?

[linuxman51]

:-D Sweet man. What's changed? Boost level?

a touch of boost, a touch of timing, and a touch of nitrous (the off spray numbers tho are 383whp and 370ish tq iirc)

[linuxman51]

New trans is in, after what seems like forever (dug up a real shifter, took a while to get a transmission, and bought a ford racing bearing retainer). the new shifter is nice, will have to further modify my tunnel to get appropriate fitment (wider and taller).

then its time to builda de manifoldz, reinforce another subframe, and hopefully that'll be done in time for import face off in a month.

[Lucky the Smiling Pirate]

so uh, where'd your rad fluid overflow tanks/cup rest go?

[linuxman51]

same place off to the side. custom bracket.

[Lucky the Smiling Pirate]

hmmm, cant see it in those pics. unless its not on turbo side anymore, or was off when you took the pics?

[linuxman51]

probably off when the pics were taken.

[DurableSwedish]

you should get a race going with the v-shop's racecar. His crazy thing is like 400hp too. :omg:

[linuxman51]

you should get a race going with the v-shop's racecar. His crazy thing is like 400hp too. :omg:

Pete's car would stomp my asshole dry on a road course, and I don't think he has much interest in abusing his car at the dragstrip. Perhaps in the future I'll have time to get more seat time at the twisties (they're more fun anyway), but for now it wouldn't be all that entertaining (for me) to watch. hehehe

[klr142]

you should get a race going with the v-shop's racecar. His crazy thing is like 400hp too. :omg:
Nah, he's over 500whp now, but doesn't like to use dynos as a tool for measuring hp, only tuning... :lol:

[linuxman51]

Nah, he's over 500whp now, but doesn't like to use dynos as a tool for measuring hp, only tuning... :lol:

well in general its kinda silly to compare dyno numbers from different dynos, but at any rate the two vehicles have two entirely different intended purposes.

[klr142]

Wait, don't you guys both want to go fast?

Jk. I know. :) His is tuned for midrange torque and a super flat curve. Yet his peak is still higher than yours. :-P
(just giving you crap! I know you're still working on it and have spent much less...)

[linuxman51]

Wait, don't you guys both want to go fast?

Jk. I know. :) His is tuned for midrange torque and a super flat curve. Yet his peak is still higher than yours. :-P
(just giving you crap! I know you're still working on it and have spent much less...)

**** kinda works like that when you're rolling around with a small turbo ;) No worries.
Boxed in the subframe tonight (mmm I'm definitly going to buy a welder, woulda been done with this days ago) and bolted it to the body in the back (with two thin pieces of rubber to allow it to move/flex juuuuuust a little). might fabricate the side brace this weekend if I have time, and hopefully this will hold me over for the big change over from the volvo axle.

if all goes well it'll be ready for shakedown runs next weekend and then perhaps some serious runs the following weekend at import face off.

[boosted12a]

ah, your still gonna brake it. what did you do about the jello bushings in the outer lower arms? rx-7 irs! eh? but that would probbaly be to much work for you to do........baaaaaaaa

[linuxman51]

ah, your still gonna brake it. what did you do about the jello bushings in the outer lower arms? rx-7 irs! eh? but that would probbaly be to much work for you to do........baaaaaaaa

those have been long gone, its got adjustable rods with spherical bearings down there. i've been twisting and bending other odd parts.

[boosted12a]

ah, good
gonna share some pics?

[linuxman51]

not really. didnt take any, too busy getting an electric tan. Adjusted the intake manifold tonight, hood closes (but there is contact), time to space things out i reckon, any more angle on it and i'll have to start aiming the tb towards runners, would like to avoid that.

[Lucky the Smiling Pirate]

not really. didnt take any, too busy getting an electric tan. Adjusted the intake manifold tonight, hood closes (but there is contact), time to space things out i reckon, any more angle on it and i'll have to start aiming the tb towards runners, would like to avoid that.

remind us all again why its better having the tb down instead of on the end?

[linuxman51]

IC piping is the main reason. you'd need three tight radius 90's to get from most any ic to the throttle body, without significant alterations to ic mounting and inlet outlet location. even with a center in-out ic.

drove the car around tonight with the new t5, need to bleed the clutch hydraulics and fix an intake leak at the head. (this with the stock intake, the new stuff isn't anywhere near done yet). I did get my infiniti throttle body tho. I can't wait to start swapping out rear end suspension stuff and put a cell in the car, its going to make life so much easier.

[boosted12a]

have you atleast gut the interior yet?

[linuxman51]

nah, most of that won't make a re-appearance when the new chassis harness goes in.

[linuxman51]

So the results are in as evidenced elsewhere on the site, the car went 11.8 as currently configured, time to step my game up and fix the broken bits

[BDKR]

So the results are in as evidenced elsewhere on the site, the car went 11.8 as currently configured, time to step my game up and fix the broken bits

Broken bits?

[NativeJesus]

This is wicked.
Pure evil.
This is what every Volvo wishes to be !

[linuxman51]

Broken bits?

clutch, transmission (again)

[linuxman51]

new (intermediate) game plan: put these aw71's to the test and see what one can handle. I don't expect longevity, in fact I'll call it a win if I can get more than about 7 passes down the track with a junkyard unit. If one can take that abuse, I might have more info on things to do to get them to last a little longer, etc.

Car is in dire need of bigger injectors and about 7-8 more pounds of boost
The new intake manifold, and accompanying -10 rail and lines.

and most of all (but not likely to be the first thing done, more of a winter project):
re-wiring. Which will likely involve the engine coming out for a engine bay strip and repaint, more of a wire tuck than is currently done with the factory harness (yes, all of the bull**** under the hood that you can actually see is bull**** I put there, and yes it looks like ****), and at the same time more than likely a new megasquirt and new harness for it, so look for my v2.2 stuff to be for sale before too long.

[sethfc]

more boost mmmm....

[linuxman51]

new injectors oughta be here today, 1000cc fire-hoses. might even go in the car this evening. Also talking to another man about a horse (well, head work), bout time to start putting together yon 2.5 16v.

[Tom Wiley]

Holy ****.

[linuxman51]

replaced the coil pack with another unit, dropped cylinder issue went away (thank GOD). Worked on the warmup enrichments a bit and the acceleration enrichment a touch, turned the car off, and started working on installing a vw 90A alternator. No I will not post a how-to, suffice to say if you can't figure out how to get a different alternator on your car you shouldn't be trying.

A few touch-ups here and there, and it will probably make a return visit to the track sometime around the end of the month for the pre-spring shakedown.

[linuxman51]

car is back together and running (sort of, time for the annual tune). Made a coil bracket to hide the coils behind the cylinder head, replaced all the lifters and re-sealed the head halves. we'll see if this cures most of the leakiness.

Also put a hit out on a T67/P-trim so the power numbers are going to be going UP this year.
Still waiting on the internals for the stroker motor, started buying goodies for it tho (see the Sten Parner GB).

[740ATL]

:dance:

[Volvorules]

So is it an auto again?

[linuxman51]

So is it an auto again?

its been an auto since late october.

[linuxman51]

So I bit the bullet and got started on a project I've been putting off since last SE: Re-wiring the chassis & engine. My previous engine harness was tailored to the 8v (which it fit very well), and some parts don't quite reach right, and I've since added a couple other odds and ends, and the wiring was starting to look a little suspect. The chassis harness had a couple strange shorts in it somewhere (one with the blinkers, wtf is that ****), with things I didn't mess with, so its out with the old, in with the new.

Without further ado:
A fair amount of stock wiring, coupled with the awe and wonder that is a modified megasquirt harness.
http://www.pbase.com/kdh51/image/95258228.jpg

The dash harness. the base was custom modified to accomodate the t5 shifter, however all of the wiring was left intact and un heeb'd
http://www.pbase.com/kdh51/image/95258221.jpg

Matt holding the harness after it was removed. It weights more than the entire replacement harness:
http://www.pbase.com/kdh51/image/95258220.jpg

passenger side chassis/ECM harness. You can see where the clips were turned around to hide the harness behind the fender:
http://www.pbase.com/kdh51/image/95258224.jpg

and the car as it sits now:
http://www.pbase.com/kdh51/image/95258218.jpg

Bumper and fenders removed to facilitate the running of the wires, and the bumper itself is going to get greatly modified to reduce its mass (the 90+ bumpers are quite portly)

[linuxman51]

further work today yielded all of the factory wiring out (save for the door harnesses, those might stay after the fact, not sure yet), and the matrix box.

This is how much wiring is floating around in your average 740 GL:
http://www.pbase.com/kdh51/image/95358657.jpg

and the start of the new heater box. (hey you never know when you need heat/moving air)
http://www.pbase.com/kdh51/image/95358656.jpg

[WeezilUSA]

You've gotta have a fan of some sort (something our car is still lacking)... I recall being at an autocross where one of the otherwise fast prepared class CRX w/ lexan windows had to drive down the side of the slalom at about 5 mph since the windows were fogged up and had no way to rectify the problem:lol:

Your car is SICK Kenny! Is that gas can next to the wiring a suggestion of what might be happening to it?

[Karl Buchka]

Is that gas can next to the wiring a suggestion of what might be happening to it?

As in it's getting fueled up at some point? Probably.