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Andrewhans 240 LS Swap, Going for 8's

So I finally got around to getting the engine out.


This was an angle I couldnt easily find (probly just bad at searching) so I took it as a reference for me.
 
Then the very next day I stuck the new motor in temporarily. I was being lazy and without the flywheel on the 4.8 fits on the mounts fully with the old Volvo trans still in the car. The block is up against the bellhousing but she fits.



This is motor placement with the STS Machining mounts and the wrong Holley oil pan (302-2 instead of the 302-1)

Its a little tight in the backside of the subframe but Ill just need to bend the brake line a tiny bit for it to clear.
 
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Been working on placement for the turbo. I feel like its too far forward and need some ideas using truck manifolds. Been looking around a bit.

Dont worry the couplers are just for mockup haha
<a href="https://andrewwurdinger.smugmug.com/Volvo-Project/i-cTj99X7/A"><img src="https://photos.smugmug.com/Volvo-Project/i-cTj99X7/0/2d32ae6a/L/20170827_173815-L.jpg" alt=""></a>
<a href="https://andrewwurdinger.smugmug.com/Volvo-Project/i-dRXBS9v/A"><img src="https://photos.smugmug.com/Volvo-Project/i-dRXBS9v/0/be1763d4/L/20170827_214801-M.jpg" alt=""></a>
<a href="https://andrewwurdinger.smugmug.com/Volvo-Project/i-xm2wSwx/A"><img src="https://photos.smugmug.com/Volvo-Project/i-xm2wSwx/0/eae26292/L/20170827_214810-M.jpg" alt=""></a>
 
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This is where im at.
Need to grab a 2.5" sched 40 90.[br]The 2" is too small for the T4 flange. I think the 2.5" will be perfect and I can still weld the two together without issue. Still need my cutoff wheels and flap discs to keep going. I have my welder back though. Cant wait to hang this turbo.
 
Made some more progress.


Also got the turbo placement finalized! This was a lot more work than I expected but was worth it in the end.





Once I get the v bands I will build the crossover for it. For now the excitement of the turbo having a home is amazing.
 
And just to top it off I found some random K&N intake in my garage. Chopped it up and the 90 and the air filter both will work perfect!

As a bitchin side note I was able to keep the OEM reservoir in its factory location!

 
Made a tiny amount more progress before work today. It's ugly as ****, but it shouldn't leak and will make the fuel system easier to work with.

 
Ran the fuel line today. Used almost 100% of the factory clamps I pulled the old line out of. Maybe used 3 zipties for the whole length of the car lol. I know, they are rookie numbers.

Also got the fuel pump hanger completely set up. Went to drop it in the tank and it bottoms out hard about 1/2 before seating on the flange. The bottom of my tank is smashed in and I dont want to buy a new one yet because Im just going to be running a single 450 for now.

I'll probly just smash the tank back out with a sledge and a piece of wood.

BTW these things have the smallest fuel pump hanger opening I've ever seen. Absolutely rediculous.
 
Here's a photo of the single Walbro 450 on the factory hanger.

Worked pretty well. Its still a pain to get it all the way in.

Also attached the Volvo pedal clevis to the OEM 4.8 throttle cable. Used a wire butt connector and a set of good ratcheting crimpers.
Pulled on it pretty damn hard and smashed the pedal into the carpet a few times and it didnt come loose. There is a small amount of play at the pedal before the throttle blade starts moving but foot to the floor does give me 100% TPS so I'm going to call that a win.
 
that 450 on the 240 hanger looks familiar, mighta done that one myself on the blue car.

so it looks like you'll be bringing this to the mountain meet then, eh? :-D
 
Eventually I would love to bring it to meets but Im a few months away financially from being able to get this fully running and driving. Just making all the free progress I can right now.
 
Here's a photo of the single Walbro 450 on the factory hanger.

Worked pretty well. Its still a pain to get it all the way in.

Also attached the Volvo pedal clevis to the OEM 4.8 throttle cable. Used a wire butt connector and a set of good ratcheting crimpers.
Pulled on it pretty damn hard and smashed the pedal into the carpet a few times and it didnt come loose. There is a small amount of play at the pedal before the throttle blade starts moving but foot to the floor does give me 100% TPS so I'm going to call that a win.

Is that plug fuel rated?
 
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