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DavoS40 01-15-2007 12:54 AM

242 Build
 
The project originally started out as a 245 then in 2003 I decided to switch to a 242. I've been working on it off and on when I'm home from school the past couple years. I'm just going to start off with the work that's taken place since springbreak 2005.

Engine:
B21FT
-align honed mains, decked for .030 squish
-2nd oversize stock pistons, balanced
-stock rods resized, cyrotreated, new hardware, balanced
-reground crank, balanced
-bmw oil piston squirters
-meling oil pump

Cylinder Head:
-398 SCP
-port & polished, unshrouded exhaust valves
-40mm exhaust valves, stock intake valves
-K cam

Turbo Setup:
-Holset HY35
-Powerstroke intercooler
-SS header from Jonathan(Stereophile33)
-XS RFL blow off valve
-3 inch exhaust (half of it from Doug's old car!)

Suspension/Brakes:
-front coilovers 315 lb springs
-rear coilovers 250lb springs
-revalved/shortened Bilsteins (towery's specs)
-Kaphlenke camber plates
-IPD adjustable torque rods
-adjustable panhard rod (homemade)
-poly bushings from Dale (245gti)
-new rotors, calipers, pads, ss lines, master cylinder, junction block

Driveline:
-93 Cobra T5 tranny
-Pro5.0 short shifter
-custom Spec stage 2+ clutch/pp (Volvo pp and clutch with the T5 spline)
-3 inch aluminum driveshaft

Fuel/Ignition:
-MS'nS
-EDIS with Ford coil pack
-Ford CFI injector's
-walbro pump

B21 block fresh from the machine shop
http://i52.photobucket.com/albums/g1...e/DSC01573.jpg
http://i52.photobucket.com/albums/g1...e/DSC01575.jpg
http://i52.photobucket.com/albums/g1...e/DSC01576.jpg
http://i52.photobucket.com/albums/g1...e/DSC01576.jpg
Notice the spots machined for the squirters
http://i52.photobucket.com/albums/g1...e/DSC01578.jpg
Sprayed the garage down with a hose to keep the dust down
http://i52.photobucket.com/albums/g1...e/DSC01582.jpg
http://i52.photobucket.com/albums/g1...e/DSC01586.jpg
Test fitting the squirters
http://i52.photobucket.com/albums/g1...e/DSC01594.jpg
http://i52.photobucket.com/albums/g1...e/DSC01596.jpg
http://i52.photobucket.com/albums/g1...e/DSC01597.jpg

rods, pistons, oil pump installed
http://i52.photobucket.com/albums/g1...e/DSC01691.jpg
http://i52.photobucket.com/albums/g1...e/DSC01697.jpg

finished short block
http://i52.photobucket.com/albums/g1...e/DSC01702.jpg
http://i52.photobucket.com/albums/g1...e/DSC01707.jpg
http://i52.photobucket.com/albums/g1...e/DSC01708.jpg

the light! (40mm exhaust valve)
http://i52.photobucket.com/albums/g1...e/DSC01772.jpg

seam welding
http://i52.photobucket.com/albums/g1...2/DSC01672.jpg

painted bay
http://i52.photobucket.com/albums/g1...2/DSC01717.jpg

preparing to drop in the motor
http://i52.photobucket.com/albums/g1...2/DSC01709.jpg
http://i52.photobucket.com/albums/g1...2/DSC01713.jpg
http://i52.photobucket.com/albums/g1...2/DSC01718.jpg

ready to go in
http://i52.photobucket.com/albums/g1...2/DSC01725.jpg

motor in, test fitting header with junk headhttp://i52.photobucket.com/albums/g1...2/DSC01747.jpg

body still needs a lot of work
http://i52.photobucket.com/albums/g1...7/DSC06614.jpg
http://i52.photobucket.com/albums/g1...7/DSC06615.jpg

engine bay
http://i52.photobucket.com/albums/g1...7/DSC06627.jpg
http://i52.photobucket.com/albums/g1...7/DSC06628.jpg
http://i52.photobucket.com/albums/g1...7/DSC06626.jpg

The new motor has been run through 3 sessions of stealth's run in procedure. When I was almost finished with the 3rd session I blew a freeze plug. I wasn't sure if this was due to the coolant system getting pressurized from a slight leak in the headgasket or if the machine shop installed the freeze plugs incorrectly. The blown freeze plug was replaced with one of the rubber expandable plugs and the head gasket replaced. If another one blows the motor is coming out and all of the plugs are going to be replaced(JB will be involved). The motor did sound great and sounded really smooth after the 2nd session.
I'm heading back to Colorado tomorrow, so I won't see the car for a few months. The plan is to get a bunch of little parts needed while I'm away. Hopefully get the car painted over springbreak or the beginning of summer. Once the body is painted the 93 block cloth interior(that's sitting in the basement) is going in the car. Then a few test drives (I smell Missouri) and if all goes well it'll get registered.

Delfosse 01-15-2007 01:01 AM

OMG I wet myself!.. that is killer! good lighting on the engine bay pic's!

Nick 01-15-2007 01:03 AM

Gorgeous car! Very nice work!

Tom Wiley 01-15-2007 01:06 AM

DOnt do anything to the outside!

SLEEPA POWA!

EDIT: I spy Eikers! What rubber are you gonna put on them?

blkaplan 01-15-2007 01:25 AM

Quote:

Originally Posted by Yeliwmots (Post 1042611)
DOnt do anything to the outside!

SLEEPA POWA!

EDIT: I spy Eikers! What rubber are you gonna put on them?


Those aren't crappy eikers, they are the real things.

BTW, way to go davo!

DavoS40 01-15-2007 01:56 AM

Thanks for all the complements guys!

Quote:

Originally Posted by Yeliwmots (Post 1042611)
DOnt do anything to the outside!

SLEEPA POWA!

Originally that's the attitude the project took on, screw all the looks and just make it fast. Now I'm going for just a great all around car: handles great, plenty of power, nice interior, clean factory looks on the outside but nothing that says look at me.

edicius 01-15-2007 02:06 AM

Just a thought, some after-market water pumps if not shaped like the oem blade can cause freeze plugs to pop. Not sure what it has on it but just in case you didn't know

DavoS40 01-15-2007 02:15 AM

Quote:

Originally Posted by edicius (Post 1042678)
Just a thought, some after-market water pumps if not shaped like the oem blade can cause freeze plugs to pop. Not sure what it has on it but just in case you didn't know

I read the stories about the stamped impellers and made sure to get the one with cast impeller.

740ATL 01-15-2007 09:31 AM

I love everywhere this project is going. Well done.

VQ 01-15-2007 10:09 AM

Amazing, the work put into that is huge!

suterman 01-15-2007 10:16 AM

Now THATS what I'm talking about!

oldschoolvolvo 01-15-2007 12:31 PM

very nice work!

Homer 01-23-2007 12:56 AM

Very nice Dave. I've seen the car in person and "helped" a bit. I like where it is going and can't wait to ride around in it. This project is being done like it should, on a budget nonetheless.
The lighting is very high tech too! ;-)

str8krewzn 01-23-2007 01:02 AM

What did you do for a WG?

oxity 01-23-2007 01:09 AM

awesome awesome, yah im curious about the wastegate and manifold myself

stylngle2003 01-23-2007 01:15 AM

i see an internal flapper on the back of the turbo

impulse922 01-23-2007 01:18 AM

this project has been in the dark, this the first time you've posted anything on it?

DavoS40 01-23-2007 03:57 AM

Quote:

Originally Posted by Homer (Post 1054002)
Very nice Dave. I've seen the car in person and "helped" a bit. I like where it is going and can't wait to ride around in it. This project is being done like it should, on a budget nonetheless.
The lighting is very high tech too! ;-)

Without the parts hook up and the motivation to do it clean it wouldn't be where it is now man!

Quote:

Originally Posted by impulse922 (Post 1054039)
this project has been in the dark, this the first time you've posted anything on it?

I've made a few threads about it in the past, but not since last summer when I totally tore it down.

Quote:

Originally Posted by str8krewzn (Post 1054015)
What did you do for a WG?

Two summers ago I ran the stock wastegate and it held a consistent 19psi(which it was I think the original actuator opens up at). Now I ported the hell out of the wastegate, and I'm planning on fabricating something similiar to atp's ultimate wastegate over springbreak with an internal wastegate I can get different springs for. Eventually I'll get a the header setup for twin wastegates with a nice twin scroll turbo.

homer1300 01-23-2007 01:46 PM

is that block orange? or is that just a bad digital camera?

Hank Scorpio 01-23-2007 01:58 PM

You and Lee really make me miss 240's (and REALLY hate living in smog states)

amazing job man!

Blackbrick 01-23-2007 05:50 PM

Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.

Hank Scorpio 01-23-2007 06:06 PM

Quote:

Originally Posted by blackbrick82 (Post 1054904)
Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.

Not sure I am now :*( /thread jack

Chrisco 01-23-2007 06:21 PM

that engine bay looks godly

DavoS40 01-23-2007 06:26 PM

Quote:

Originally Posted by homer1300 (Post 1054574)
is that block orange? or is that just a bad digital camera?

It's chevy red-orange it turned out more orange than I wanted though.

Quote:

Originally Posted by Hank Scorpio (Post 1054577)
You and Lee really make me miss 240's (and REALLY hate living in smog states)

amazing job man!

Thanks dude, it was your old project that really got me motivated to take it this far!

Quote:

Originally Posted by blackbrick82 (Post 1054904)
Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.

Thanks, when are we going to get some updates on your 242?

Big Lan 01-23-2007 07:18 PM

Your engine gives me big wood.

Quote:

Originally Posted by DavoS40 (Post 1054951)
Thanks, when are we going to get some updates on your 242?

He's turned it into a 120 wagon :cries:
Quote:

Originally Posted by Hank Scorpio (Post 1054929)
Not sure I am now :*( /thread jack

Start new thread now! Must hear details! Can't wait month to talk! Unless you're still going to hooters...


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