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Project 755 - ErrnRRR

YellowT5-r

New member
Joined
Dec 7, 2004
Location
Portland, OR
So I've had this 1991 745ti since about 1997. Love the car madly. I'd done most of the usual mods, IPD suspension, 15g, MBC, Thelostartof chips, RSI Stage II cam and adjustable cam gear, Unorthodox Racing aluminum crank pulley, etc. Finally put an M90 in the car about 5 months ago and loved that, then my trusty old B230FT went all soft and squishy (read: leak down that would make a porn star blush). Now our other car is a yellow T5-R, and I LOVE that motor, but just don't like the FWD platform. I have been threatening this conversion for years, but as life works, I had the time, but never the $$ to get the job done right. Peter Lissens has been mocking my progress towards this goal for at least the last 2-3 years. Well, I'm finally in a place where I have the $$, but absolutely 0 time (I work between 80-120 hours per week), so enter RSI. Jonathan, the unassuming evil genius, Eric, the only guy with dirty hands in the shop, Pat, who I'm sure does something there, and Mitch, who BBQ's a mean weenie and accepts payments, and tolerates abuse admirable.

The requirements:
A reliable DD that uses as many OEM Volvo parts as possible (ancillary bits at least, hoses, motor mounts, etc.)
With the hood down, the car should look like something a sporty grandpa would drive
Power under the curve before peak - it's a daily driver after all
As much power and torque as we can possibly stuff under the 400 WHP Curve

The plan:

Stage I - Mule motor phase
Transplant a stock, running 5-Cylinder white block into said '91 745
For convenience and cost, we're using a white block M90
New header, turbo, IC, intake, fuel rail, injectors, COP ignition (all being set up for a later built motor), 960 cooling system
MSnS
See what breaks/fix

Stage II - Stupid slick stuff and catchup phase

Slick Stuff:
Teach MSnS how to run Volvo's variable cam timing (I got your V-Tec right here, yo!)
Run the variable exhaust from a +T car and the variable intake from an N/A car (if you're gonna do stupid stuff, you should be really stupid)
Set up MSnS to run a Ford Flex Fuel sensor (hey, E85 is green fuel and lets you build really really stupid motors)
See what breaks/fix

Catch up:
Need better suspension - convert the car to RSI coil overs
Need Moar brakes (most likely an R conversion)
Starch and press drive line - as soon as the car has more than 225 rubber under it, PARTS WILL FLY - not sure what rout we're taking here yet
Daily driver style cage to remove flexy-flier quotient and add safety
Subtle first gen M3 style flares so we can actually put some rubber under a grandpa series
Paint?
See what breaks/fix

Stage III - Stupid motor build
RSI internals
Head work
Custom cams
Balanced within an inch of its life
Dry-sump oiling - cause we can, and if you can, shouldn't you?
Richmond Gear 5 or 6 speed
Relocate motor even further down and back as possible
See what breaks/fix

That's the nickel tour of the project that's only been in the works for about the last 12 years :D.

The following images may be inappropriate for younger viewers, however, be assured that the vehicle in question is over 18 years of age, and is subsequently a legal, consenting adult.
 
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What it is:

brick.jpg


What it was:

011.jpg


What it shall be:

aaronst5swap025-1.jpg


Step 1 - Remove defunkt Soviet-era tractor motor:

aaronst5swap005.jpg


Step 2 - Start with a good boneyard white block - Sexxay Part A:

aaronst5swap043.jpg


Step 3 - Select additional sexxay parts: .60 A/R GT30-R with a new ubersexxay Tial cast stainless hot section capable of efficiently supporting 500HP and sexy enough to give the dead wood. Yes, that's V-band everywhere since there's no pulse pairing joy with a 5-lunger.

aaronst5swap015-1.jpg


Step 4 - Use protection to keep love stains out of said sexxay turbo (Pat is no longer allowed to take this turbo into the bathroom with him :shock: ):

a034.jpg


Step 5 - Insert sexxay part A into Brick:

aaronst5swap026-1.jpg


Step 6 - Enjoy convenience of weak-sauce OEM transmission and chassis that has mounting points for EVERY transmission option, even if Volvo never put in the car:

aaronst5swap022.jpg


Step 7 - Employ highly skilled fabricator to channel the Fab-fu of Jah hisself:

a035.jpg


Step 8 - Figure out a nice way to introduce sexxay part A to sexxay part B - tacked together at this point, some minor tweaks still to be done, but you get the idea:

a036.jpg


Step 9 - Introduce sexxay parts A, B, and C to brick to see if they like each other - its love at first sight:

a031.jpg


030.jpg


Step 10 - Realize that this intercooler (invisible in this picture cause it's too smaaallll) won't fit around new-ish 960 radiator - order bigger intercooler, 'cause hey! (Observe that 5-cylinder goodness only hangs 1-1/2 cylinders ahead of front axle line - so close to front-mid engine goodness!):

a037.jpg


Step 11 - Decide that even though the 5-cylinder is only .2 liters bigger than the old red block, it needs a 75mm throttle body:

a038.jpg


Step 12 - Tune in next week!
 
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Kick ass.

One thing though, that whiteblock doesn't have a timing belt on it... Are the valves still good?!?!!?
 
WANT!!!

It will be nice driving a car with parts making sexaay time with each other as they go.
 
Looks tasty.

Make a heat shield for that exhaust side motor mount though or that sucker is done for.


Ready for IPd?

:cheers:
 
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