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Old 05-23-2008, 01:48 PM   #1
volvogeek
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Default Project 86 245

I didn't think I'd be making a project page for this car. It was *supposed* to go to the ex after she wrecked her R, but it's too nice for her. So it's mine now, and I've been upgrading it since the day I bought it. 270k, M46, 3rd Seat, Maroon with Tan interior.

Plans for this are to make it handle fairly well, get some interior stuff sorted to make it more creature-comforty, then add performance.

I made up a modlist/mission statement, so I thought I'd share that with you all right here on the first post.

Quote:
Originally Posted by volvogeek
1986 Volvo 245 DL (Project DD)

Mission Statement: To provide an enhanced driving experience while keeping creature comforts intact.

Modifications:
Suspension:
iPd 28/25 Swaybars
iPd Adjustable Panhard Rod
Kaplhenke Coilovers F/R
Kaplhenke Adjustable Endlinks
Bilstein HD Shocks/Struts
Avalanche Performance Wheel Spacers (5x108 32F/25R)
Volvo OEM 'Thor' 17x7.5 ET49 Wheels

Braking:
ATE Powerslot Rotors F/R

Engine:
Avalanche Performance Underdrive Pulley
*Avalanche Performance Cam Gear (advanced 2º)
Denso 100A Alternator (from 940T)
Volvo 'A' grind camshaft
550cc Dodge Neon SRT-4 Injectors
Innovate LC-1 Wideband O2 Sensor
Custom 3" Side-exit Exhaust
Billet Aluminum Oil Filter Relocation Kit
RX-7 Oil Cooler
940 E-Fan with 850 Relay and Saab Temp Sensor
Volvo 90+ Turbo Exhaust Manifold
Ebay 3" Plate/Bar Intercooler
Megasquirt II V3 EMS

Interior:
Summit Racing Seats
Volvo OEM 240 Turbo Gauge Cluster
Innovate XD-16 Wideband O2 Sensor Gauge

Exterior:
DJAuto European-code Headlights/Turn Signals
Ebay RCCR Taillights
Volvo OEM 400-series Sidemarker Lights
1990-93 Tailgate Hatch
Ventshade Window Visors
*OEM Antenna Delete
*VW-style Whip Antenna
1993 Volvo 850 Chin Spoiler
*Coroplast Underbody Tray

Audio:
Pioneer DEH-4000UB Reciever
Pioneer GEX-P10HD HD Module
Pioneer TS-A532P 5.25" Front Speakers
Pioneer TS-A943P 6"x9" Rear Speakers

* - To Be Installed
The day I bought it:


RARE 14" iPd Virgo Replicas!


First order of business, cleaning and new wheels ($150 Hydras with tires, whoop):


Side markers:


RCCR tails and debadging (in progress):


Not shown:
  • Big Tach/Small Clock
  • Fixed odo gear
  • New Pass-side turn signal lens
  • Red tinted cluster lighting
  • Lots of engine bay cleaning

More pics here. New stuff added frequently.

I may be pulling most of the suspension off of the 79 242 for this car. I'll definitely be +T'ing it in the very near future. I also see a set of ecodes being sourced and installed. This weekend it'll get a new clutch, rear tailgate harnesses, engine and tranny mounts, and a few other things I ordered from FCP last week.

Last edited by volvogeek; 12-09-2010 at 01:10 AM.. Reason: added modlist/mission statement
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Old 05-23-2008, 03:17 PM   #2
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That paint buffed up nice.
Great project Richard. I wanna wagon someday.
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Old 05-24-2008, 03:02 AM   #3
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Dude. Sweetness. Looks just like mine, only with really good paint and interior.

I really like the way the Redwood color picks up the light. And those RCCR tails are new to me. Will have to do some research on them. I've been considering an LED project for mine this summer, when I get the time to dive into this car.

Will be following this thread over time for sure.
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Old 05-25-2008, 09:19 PM   #4
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Got a lot of stuff done this weekend - tailgate wiring harnesses, radio relocation, turbo gauge installation, sidemarker wiring, and lots of cleaning.


Note that this pic was taken BEFORE the cleaning happened.


Took the chrome trim off the rear window and pressure-washed the debris underneath.

I also found out something pretty cool about this car. I was going through the stack of receipts I was given when I bought the car, and found this picture in an iPd envelope:



Turns out, that pic looks a LOT like THIS pic from the '94-95 iPd catalog:


Knowing that this was a former enthusiasts car definitely would account for the absolutely spectacular condition the car is in. Well, until they sold it, anyway. I'm thinking of calling them up after I get it all done and seeing if they'd like to take a look at it.

No clutch this weekend unfortunately, it started raining fairly hard and the stuff I have to displace in the garage to put the car inside isn't very weatherproof. Maybe next weekend.
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Old 05-26-2008, 02:25 PM   #5
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congrats on a nice wagon :-)
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Old 05-26-2008, 03:48 PM   #6
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That pic is cool, so was that your 245 in the picture?
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Old 05-26-2008, 04:21 PM   #7
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thats cool!
really sick looking 245.
wait a sec, ipd made virgo reps?
how come i never knew this?
but what the point in them? Used virgos are pretty cheap themselves...

btw, my car was featured YEARS AGO in the catalog. back when it wasnt mine. IT used to have GT style rims, all this i found out recently, when my parent s gave me an old album....
why the car had the rims switched out for steelies...i dont know.
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Old 05-26-2008, 05:12 PM   #8
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Yep, iPd sold replica Virgos made by a company named Sendel, IIRC. Had them in the 14x5.5 size and 15x6 sizes. Back when they sold them, a set of real Virgos were $400-$600 used.

-J
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Old 07-31-2008, 04:31 PM   #9
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Little update since I've done some stuff.

Added vortex generators (yes I know they probably won't do ****, but what the hell, they were only $20):


Underhood painting (in preparation for the cravingboost stuffs in *hopefully* the same color):



Foglights I had laying around that I decided to install rather than re-box up after I'd found them (again):


And then lowering goodness and new tires:


3 coils off the front, 2 from the rear. Kumho Ecsta ASX 205/55ZR16's.

Cutting the coils looks pretty cool, but with the stock struts and springs...they're just not up to the task. New dampers are in order, as well as a set of iPd sways. I'll be doing coilovers on an extra set of struts as well. A turbo will be added fairly soon - greentops are already installed - all of the parts I have except for the computer, and I may just gut one and install my MS3 box instead.


And then I put the roof rack on just to see how it'd look. And yes I realize that the fairing completely neutralizes any benefit that the VG's *might* provide. Heh.

Last edited by volvogeek; 07-31-2008 at 04:45 PM..
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Old 03-13-2009, 02:40 AM   #10
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Hmm, perhaps I should update this, since I've done a few things since this was last updated...

Cravingboost.com strut bar arrived, and was immediately installed:


I refinished the old 14" iPd Virgo replicas and put them on for the winter:



Picked up a 90+ tailgate in *almost* the same color (it's a shade or two off):


Installed Bilstein HD's Front and Rear:


Added some fancy-schmancy Ecodes (and 9004->H4 adapters):



The foglights got eaten by the ice ruts in downtown Beaverton this winter. I'll pick up a set of lower-profile ones here soon - the ecodes are FABULOUS but I like to light to drop under the fog too.

More updates to come, lots of fun things in the mail. +T and 3" exhaust should also happen before iPd this year. Yay!
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Old 03-13-2009, 03:58 PM   #11
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dude thats VERY nice...me likey the colour co-ordination is spot on

can i ask how you painted the pulley??? did you have to pull it off or did you just brush it on/mask of everything?

edit - looks like you took the pulley off...and i like the gold on the belt
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Old 03-14-2009, 01:47 PM   #12
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Quote:
Originally Posted by grim reaper View Post
dude thats VERY nice...me likey the colour co-ordination is spot on

can i ask how you painted the pulley??? did you have to pull it off or did you just brush it on/mask of everything?

edit - looks like you took the pulley off...and i like the gold on the belt
Thanks! I pulled everything off (at the time I was also chasing a problem and popped a front seal, so had to tear everything out anyway), cleaned it up and painted. Got the cam and intermediate gear, though the latter is hidden by the lower cover.
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Old 05-28-2009, 06:40 PM   #13
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Updates... (larger pics available on picasa.)


New sway bars...25mm rear bar


28mm front.


Some coilover type-stuff. (via Kaplhenke)


Turbo water resevoir and Avalanche timing gear (as well as A-grind cam behind it)


Avalanche underdrive pulley (and belt sizes for those interested)

Coilovers will be going in shortly - I have a whole MESS of stuff to install when I do them, so I'll probably have to take the entire weekend when I decide to tackle it. I ordered some new PS boots but looks like I'll have to order again, since they never showed up. Want to do everything I can while I'm under there, and those are toast. After the suspension is completely done, next is the turbo! May drill the block for oil return here shortly because that won't take TOO long (plus I've got a broken exhaust stud I need to extract) and then all I'll need to have is some exhaust piping laying around to finish the exhaust after the turbo is on. Whee!
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Old 05-29-2009, 12:08 PM   #14
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Looking good.

Quickly becoming one of my favorite projects.
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Old 07-07-2009, 04:13 PM   #15
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I overheated it due to a comedy of errors... Pass-side motor mount died, blew apart into 3 pieces. Which pulled on the head to firewall heater hoses. Which caused a slow leak that I couldn't track down until the leak had progressed to a stream of water which would spray up to the front of the car. After which I couldn't find a heater hose ANYWHERE - not even iPd had them. And then I decided I'd take a drive to St John's over a hilly, curvy road (Germantown). So now the head is at the shop, parts are arriving in spurts (kept forgetting something stupid) and I'm doing some upgrades while it's down. Though I really should work on the suspension and whatnot, it's parked in an odd spot and I can only really access half of the car plus the front end. So underhood work will get done first.

First order of business, efan:

$25 at the iPd swap meet, with 2-speed relay. I'll drill the block for oil return while I wait for the rest of the parts to arrive. Then I've got brakes to do, suspension to install, and a turbo to get ready for.

edit: installed these as well somewhere between this and the last post:

Last edited by volvogeek; 07-07-2009 at 04:41 PM..
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Old 07-13-2009, 09:17 PM   #16
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where are your thor's?
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Old 07-13-2009, 09:24 PM   #17
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I'd trade you a set of real Virgos for those 14" IPD reps if you are ever interested.
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Old 07-13-2009, 11:07 PM   #18
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Thors are being refinished, one had a bunch of rash on the lip and another had a spot on one of the spokes that needed some attention, the other two just need a little touch-up. They're all in various stages of JB-weld and sanding atm. Hope to get them done and tires on 'em by the end of the month.

I've got a real set of Virgos that I'd like to get rid of - no bends, no rash, powdercoated and very pretty with CRAP tires. I'd give you both sets for something interesting...
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Old 08-04-2009, 12:51 AM   #19
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Couple of updates. Got the Thors done!




Added some beige/tan seats from Summit (I want to keep the interior tan).


Wideband!



Little paint and a 5-bar oil pressure sender...


Also dropped a 100-amp alternator in there and recharged the AC (Envirosafe ROCKS!). However when I was fixing the other things I think I messed up the fan controls so while the AC works and blows air while I'm moving, the fan doesn't so when I'm stopped it gets HOT.

Todo list includes installing coilovers, new brake rotors/calipers (stock but painted gold like the rest of my ish) & bleeding with superblue, installing adj panhard bar, and of course fixing the blower fan controls. It's getting there!
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Old 08-04-2009, 12:57 AM   #20
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this thing is rad mate.. new wheels look the goods..


and i want your coilovers....!!! haha
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Old 08-15-2009, 12:09 PM   #21
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Figured since I've got the suspension pretty much sorted - though I have a bunch of stuff yet to install, I DO have the stuff - I'd work on the sound system.

So, new deck:


Rear 6x9's:



Have the 4" originally from the front doors slated to go into the shoulder area 'triangles', but I cut the holes too high up so I have to get new ones. 5.25" in the front doors:


I have to fab up some spacers for them so I can mount the grilles yet - I really just wanted to get them in the car to see how everything sounded. It's been too long since I've had a fairly decent system, so I'm excited.


Mmm, remote control and USB input. One of these days I'll clean the carpet or maybe just grab some newer stuff from a junkyard car.
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Old 08-15-2009, 12:11 PM   #22
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I've got the same head unit. Nice isn't it?
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Old 12-07-2009, 03:09 PM   #23
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After a few months hiatus from boards and generally doing anything to the car, I decided it was time to get off my lazy arse.

First order of business - injectors and turbo ECU:

These are SRT-4 injectors, 550cc high-z


They're slightly smaller than bosch, and have a different connector, thus the adapter and spacer.


Installed - though technically the spacer should be on the top, there were no clip reliefs on the spacer so in the interest of safety I opted for this route.


Everything installed and running.

With the stock LH2.2 ECU, near WOT it would pop and stutter. With turbo LH2.2 ECU, it ran fine. I'm not sure how well (or if at all) the ECU will adapt to the higher fuel rate of the new injectors, but I'm keeping track of mileage just to be sure. The main reason for doing this was because the stock injectors I had were woefully dirty and ran like crap, especially near idle. I didn't want to spend a bunch of money refurbing stock injectors when I had these laying around, especially since a +T and MS+S is on the books.

Not shown: Winter mode - Hydras back on, Thors in storage. :'(
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Old 12-07-2009, 11:02 PM   #24
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wow. This is like the super nice version of my car (see sig) the only history mine has is a lifetime of abuse and cheap paint. It's now a patched up rustbucket that refuses to die you have made a beautiful thing here. And it has motivated me to find a nice rustfree wagon in the same color. I didn't realize how nice it could look.
Good luck with the project, keep us updated and good work so far. PROPS!

EDIT: I only paid $500 for mine so I guess I cant complain
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Old 12-10-2009, 07:29 PM   #25
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updates?
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