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-   -   Olga the Second Revised (https://forums.tbforums.com/showthread.php?t=314945)

JerryJS8 10-30-2015 09:20 AM

Olga the Second Revised - 740(SE) Turbo 16V
 
1991 740(SE) 16v turbo rebuild project

TL;DR Bought car 2004, built car 16v turbo 2006, put car in family care/storage 2008, sold car 2013, bought car back 2015, imported car 2016, got it registered and on the road in the fall of 2017, cancelled registration two months later and parked it in the garage for some repairs and a new intercooler plus an M90 swap over the winter of 2017/2018, springtime 2018 car back together and stage 0 completed. Summer 2018 Now back on the road as a daily driver and slowly getting all the pesky little gremlins sorted out.

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Long-time member, now getting back into the game after a many year hiatus.

A little bit about me – born in Florida, now living in Germany. Always driven a Volvo, first car was a 89’ 240 that taught me a lot about problem diagnostics and got me on a first name basis with the local pull-a-part. After that I had about 4 or 5 740’s and a 960 that I fixed up and sold mostly to friends and family. Moved to Europe in 2007 and got an introduction to Volvo’s European counterparts with a 480 "sports car" (at least my insurance argued it being one on paper) and a V40 being prime examples of hodge-podge value chain management and minimum viable rust prevention manufacturing that both ended up being sold for export to countries with governments that don’t have as much to say about regulations concerning transport vehicles.

A bit about my project car – bought the car off eBay in 2004 for around 500 dollars with blown turbo seals, cracked rear window and other busted stuff I can’t remember. Best part was that the motor had been laying a nice thick layer of anti-rust film all the way to rear bumper which lead to not having a spot of rust anywhere on the chassis. The name of the car “Olga the Second” comes from it being the second blue 740 sedan I had owned having the same personality of what I would imagine a Swedish lady with a remarkable half-tank construction would be like.

A bit about the project - years before I had started collecting parts for a 16 valve conversion and by the summer of 2006 I had found an SE body kit in the junkyard, fully upgraded the suspension with Bilstien HD’s, IPD 25/25 swaybars, Lesförd lowering springs (only in the front, the back was squatting with em installed), adjustable panhard rod, aluminum control arms, Virgo rims, lockin diff with 4.10 final ratio, 5-angle valve seats and matched porting on the B234 head etc.. Biggest hurdle was of course the exhaust manifold, but after getting through that being the last piece of the puzzle, the project had to be completed.

In the pics below you can see the progress/final result of the car as it stood back in the summer of 2008.

http://i.imgur.com/CRGguHw.jpg

http://i.imgur.com/ZHpM0jO.jpg

http://i.imgur.com/FPDL20d.jpg

http://i.imgur.com/6lxGtEi.jpg

http://i.imgur.com/DgTKHCI.jpg

http://i.imgur.com/YyDl4bN.jpg

http://i.imgur.com/J6EzWON.jpg

http://i.imgur.com/ak72tbS.jpg

http://i.imgur.com/QaInjI1.jpg

http://i.imgur.com/oK5Etj2.jpg

http://i.imgur.com/3syv4Rd.jpg

http://i.imgur.com/BeVgoAN.jpg

http://i.imgur.com/dCWz781.jpg

http://i.imgur.com/GrFEZEv.jpg

http://i.imgur.com/KRybJdl.jpg

http://i.imgur.com/T6de7by.jpg

The moderately sized but responsive 50 trim T3

http://turbocharged.com/catalog/comp...mages/Fig3.gif

A bit about the interim - in 2008 I put the car up for sale, but got cold feet about parting with it for good and was able to convince my family to take care of it for a while.

Link to my sales thread just for fun

In 2013 I ended up selling the car to a buddy of mine cause I had moved to Europe and couldn’t fit it in my carryon luggage, and my family was tired of babysitting it.

There the car proved to be quite a headache for him considering the non-standard build that most of you here are familiar with and those typical Volvo electrical issues. Sad to say, the Florida sun wasn’t kind to the paint and daily life took its toll on both the interior and motor. Last year I contacted him to ask how the car was treating him to find out he was putting it up for sale.

My wife knew how much I loved building that project (cause I often would be sitting at my computer looking at pictures of it or other turbobrick projects) and suggested importing it to Germany. Before she could even think about regretting it I told my buddy we’d take it. It was a long wait, but visiting my parents in the spring gave me the chance to get the car road ready to drive it down to Miami and get it on a boat. Here’s the car as I bought it back in Florida.

http://i.imgur.com/6zwHPm5.jpg

http://i.imgur.com/XRGytHM.jpg

http://i.imgur.com/xl0pKCk.jpg

http://i.imgur.com/QUybhgX.jpg

http://i.imgur.com/c63Hp5x.jpg

http://i.imgur.com/iivHyZQ.jpg

http://i.imgur.com/00njKrv.jpg

http://i.imgur.com/ilBXaEE.jpg

http://i.imgur.com/OIxFd06.jpg

And here it is getting off the truck in Germany.

http://i.imgur.com/Rr4L4d5.jpg

http://i.imgur.com/mtrb4di.jpg

The white hood and door I installed before putting it on the boat for Germany and were from taken from the only 740 in the local junkyards (coincidentally that car also belonged to the former owner). At that point the car didn’t need to look good for shipment, it just needed to be functional.

And now the project “Olga the Second Revised” begins

First things first – blue door. The white hood doesn’t bother me so much, but that ther’ stock-car racing deal ain’t gonna work. So I found some local enthusiasts parting out a blue 740 and had an impromptu party getting to meet the gang while filling up on spare parts.

http://i.imgur.com/o4XLyLK.jpg

Next improvement – my current daily driver is a 1989 16v 740 SW which originally comes with the 3” throttle body so I swapped manifolds :oogle:

After that I converted to an e-fan, but I’ll need to update with a pic of that since I can’t find any on my phone right now…

Dem Eyes so sad – much better with E-Codes

Before

http://i.imgur.com/2kOSssj.jpg

After

http://i.imgur.com/GjFiS1v.jpg

In all my (revised)project planning, I decided the turbo is too small, and that before I get a new one, it would only make sense to first have a larger air filter. So what I’m currently up to is fabricating a stock-ish looking airbox to furnish a huge air filter. Bigger box needs moar space, so I relocated the stock wiper fluid reservoir, and relocated the battery to accommodate it.

http://i.imgur.com/aXhOs08.jpg

http://i.imgur.com/vRM0Mfi.jpg

So my winter project is to fabricate said air filter box, and spiff up the interior with said collected spare interior parts from said cannibalized former enthusiast owned Volvo 740. Before springtime I need to also (re)complete Stage 0 for the import registration in Germany. Meanwhile I’ve been having some fun with some 3-D concepts for a bigger turbo. Someone say EFR 6758 Twin scroll?

http://i.imgur.com/OMYsyrp.png

http://i.imgur.com/m2zWk1Y.png

Coupid 10-30-2015 11:16 AM

What a total sleeper! That's awesome that you get to reconditioning it after the person you sold it to ruined it. There are a few cars I've sold that I wish I could have helped out like that...

JerryJS8 10-30-2015 11:40 AM

Thanks!

Just means I get more project for old my project car :) But I wouldn't go as far as saying he ruined it. Just missing a bit of its old glanz ;-)

okoye 10-30-2015 08:36 PM

I met the guy who bought this car . He was telling me the story on it. Glad to see its back in good hands and being restored to its former glory.

JerryJS8 10-31-2015 10:51 AM

Got to swapping the Virgos to my DD and the Remotecs on the project 744.

http://i.imgur.com/wjfx4Sr.jpg

Not sure how I like the look of these... but they are 7.5 inches wide, which makes them interesting.

Kinda up in the air on these or a set of Geminis, even though a 225/55 tire would go on Geminis just fine.

okoye 10-31-2015 12:10 PM

keep the remotecs and lower the car.

JerryJS8 10-31-2015 12:38 PM

Well the car is lowered already, and with the streets here in town I'd be afraid of going any lower.

Also got these hanging out in the garage.

http://i.imgur.com/EBEbvqb.jpg

But the remotecs with new paint are kinda growing on me.

Coupid 10-31-2015 01:48 PM

Use the Gems

amerbritcan 10-31-2015 11:18 PM

I love those remotecs on the car, but gems are my favorite OEM wheels. Tough choice.

JerryJS8 11-11-2015 05:22 AM

Found a good reason to use the Gemini rims.

http://www.volvoforums.org.uk/showthread.php?t=156900

Always aggravated me how quickly a new set of stock rotors started warping... :grrr:
Hopefully some 302mm brakes will be the end of that.

+Kardboard+ 11-11-2015 05:59 PM

Very nice!

MadDog_945 12-24-2015 04:41 AM

Whoa awesome... So im not the only 16v turbo guy in germany anymore? :) i think we need to phone some day about 16v's n stuff :) !!

JerryJS8 01-03-2016 03:33 PM

Quote:

Originally Posted by MadDog_945 (Post 5304339)
Whoa awesome... So im not the only 16v turbo guy in germany anymore? :) i think we need to phone some day about 16v's n stuff :) !!

Sounds like a plan! But at the moment you may be the only owner of a registered 16v turbo ;-)

nordmaschine 01-03-2016 04:03 PM

Senn was one of my favourite people on the board, as you can see from my sig. lol


Good to see it's getting reborn.

Glass sunroof?

JerryJS8 01-03-2016 05:36 PM

Quote:

Originally Posted by nordmaschine (Post 5310438)
Glass sunroof?

Yeah, I grabbed a glass sunroof some years ago in a junkyard, should have swapped the headliner as well... I'm missing that optional sliding shade!

JerryJS8 01-19-2016 11:36 AM

The mailman brought me a new present today! The car has made it this far on a square-toothed belt...

http://i.imgur.com/saBEwX4.jpg

And since this had been a Florida car probably all its life, this might be the first time it's seen snow!

http://i.imgur.com/kOO1eWa.jpg

Jack 01-19-2016 12:06 PM

looking good.

I always thought the P80 chassis front calipers would work. Nice cheap upgrade!


also how much for your "old" header?

JerryJS8 01-21-2016 09:46 AM

Quote:

Originally Posted by Jack (Post 5321150)
looking good.

I always thought the P80 chassis front calipers would work. Nice cheap upgrade!


also how much for your "old" header?

I got a lot of other stuff to do to get it registered and made into a reliable daily driver before I start on the twin scroll upgrade.

okoye 01-21-2016 10:03 AM

let me buy those remotecs!

JerryJS8 01-22-2016 02:59 AM

Quote:

Originally Posted by okoye (Post 5322752)
let me buy those remotecs!

Ok, but you also pay shipping from Germany...

JerryJS8 02-15-2016 06:37 AM

Update
 
So, the weather finally got warm enough to be able to work outside, so I took the chance to do some work before the snow rolls back in. Was working on cleaning up the motor from all the oil leaks and replacing the gaskets one by one when my garage neighbor asked why I wasn't just pulling the motor if I had so much on my to-do list.

Me: I don't have a crane to pull the motor.
Him: I do, so now what's your excuse?
Me: ... I need a beer, then I'll be over to get the crane

And so the fun begins...

http://i.imgur.com/sdMO4G5.jpg

Nastyness in the engine bay, gotta take car of that before the motor goes back in

http://i.imgur.com/irb37UT.jpg

Source of nastyness in the engine bay, gotta take care of that before the motor goes back in

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Then I pulled the head to see what the past 10+ years have done to it.

http://i.imgur.com/lBhG3op.jpg

http://i.imgur.com/FkeX3cB.jpg

#4 - Nice grooves man...

http://i.imgur.com/puP7mVJ.jpg

#3 - More groovyness

http://i.imgur.com/fWZJstc.jpg

#2 - And the song continues

http://i.imgur.com/a12zswS.jpg

#1 - Ah sweet! No grooves, just rust....

So it's not what was wrong with cyl#1, but what happened to 2,3 and 4... Guess I'll be needing a new block, since I don't think they'll be gone with the next bore up and already running once overbored.

On a side note, this is why we don't like the stock 16v intake on boosted motors

http://i.imgur.com/H36XmgM.jpg

http://i.imgur.com/XSXzuAC.jpg

So fortunately I just happen to have a low mileage b230f block laying around the garage. Just needs a light hone and drilling all the oil lines for the turbo.

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Still happy with the exhaust manifold though, held up to a lot of abuse with those ugly welds...

http://i.imgur.com/XmzHqhp.jpg

http://i.imgur.com/RJxy9zc.jpg

http://i.imgur.com/Nvvj9C2.jpg

So now I'm ordering gaskets and such, getting my shopping list together. While the weather's cold again, at least I got part of my project in the garage next to the heater :)

MadDog_945 02-15-2016 06:50 AM

Ask FT-Albert.de for parts... Give him a greet from me ;) Or... No.. dont... Just say to him dass er die Dichtungen nicht knicken soll, damit sie in den umschlag passen ;)

he's the best source for parts in .de

I like the manifold.. What material and dimensions? Selfmade?

JerryJS8 02-15-2016 07:01 AM

Quote:

Originally Posted by MadDog_945 (Post 5338653)
Ask FT-Albert.de for parts... Give him a greet from me ;) Or... No.. dont... Just say to him dass er die Dichtungen nicht knicken soll, damit sie in den umschlag passen ;)

Funny you said that, look what recently came in the mail...

http://i.imgur.com/FS09oXv.jpg

:pow:

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Manfold is self made from mild steel elbows and a sheet of old metal I had laying around the shop back then. Cutting out those flanges with an acetalyne torch then rounding em out with a dremel took a good amount of time...

MadDog_945 02-15-2016 07:08 AM

HE DIDNT ?!!!!! Gerhard... You Prick!! :D

JerryJS8 02-15-2016 07:18 AM

Quote:

Originally Posted by MadDog_945 (Post 5338660)
HE DIDNT ?!!!!! Gerhard... You Prick!! :D

Ruhig Blut! I didn't order it from him, some eBay shop out of the UK.


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