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Old 11-26-2018, 04:47 PM   #1
SjefkeHuppelkei
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Default Sjefke's 1972 P1800ES T5 Project

Hello everybody!
Picked up this project about half a year ago and it is finally time to share it with you guys!

The history of the car probably goes way back, but the things I know about it are limited to the last 10 years. It's originally an English P1800ES and therefore RHD. The guy I bought it from brought it from England to the Netherlands around 10 years ago and since then took all the things he needed for restoring his ES. He kept the remainings in his shed ever since and that's where I came in and bought it as my project.

The love for Volvo's has only begun a couple of years ago when I first bought a C30, which was chipped and slightly modified (Bilstein B6's, PUR bushings all around etc). A really nice looking and fun to drive car. Too bad it didn't last long, after a year the timing belt shattered and the engine was gone. After this I bought a '66 Amazon 2 door, '99 V70 T5 (daily) and then the ES. For this project, a dirt-cheap totalled 2001 S60 T5 was purchased.

The main goal for the project is to get a nice (LHD) sleeper with enough torque to get around in traffic. And maybe win a couple of traffic light sprints .

Some of the things I definitely wanted was to keep it all Volvo parts, to start with a B5234t with an M90, drive shaft from a 960, brakes from the S60 etc.

Enough talking, here are the pictures of the day I purchased the ES:

Found like this:


Fresh out of the barn, seeing sunlight for the first time in years:



Together with the V70:



Donor car:


Check also instagram for small updates and pictures: https://www.instagram.com/volvo_p1800es_t5/
Hope you guys will appreciate this project and will keep you posted! Cheers

Last edited by SjefkeHuppelkei; 11-26-2018 at 05:37 PM..
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Old 11-27-2018, 06:38 AM   #2
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Work faster! I want to see it run!
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Quote:
Originally Posted by Captain Bondo View Post
cuz on turbobricks, posting about something and not doing it counts as quitting a project halfway through. Quitting a project halfway through counts as finishing it.

Yay you finished it!
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Old 11-27-2018, 03:51 PM   #3
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Nice plan.
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Old 11-28-2018, 12:23 AM   #4
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By all means, keep the Playboy Bunny sticker on the rear valence! Priceless......

Goodluck, looking forward to seeing a whiteblock in that 1800ES.
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Old 11-28-2018, 04:00 PM   #5
SjefkeHuppelkei
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Will try to keep the sticker as long as possible, but it will get a paint job in the end so maybe it has to go one day.

First of all I cleaned the car from it's dust.
Slowly started to take apart the whole car and tried to not touch the grinder for a couple of stuck bolts. In the end, only one bolt broke and had to be drilled.

This was during the summer when I had the chance to cheaply rent a huge garage at a friends place. It was an old school building where in the past the students were taking apart cars. Ideal for disassembling my ES and S60. Unfortunately, he had to move out due to a new owner and I had to take the cars with me to a new place.






This is the new home of the car:




Cheers!
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Old 12-02-2018, 12:52 PM   #6
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Nice project, i'm following
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Old 12-13-2018, 03:37 PM   #7
SjefkeHuppelkei
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Cleaned the rear axle, front cross member and got the shortened oil pan back from the workshop. In order to fit everything under the hood and clearing the inner fenders, the turbo is relocated. The turbo is flipped 180 degrees so it faces forward and a little (very professional) mockup for a spacer is created to see if it all fits. Results will be clear in this weekend since I haven't had the time to do it anymore.













Cheers!
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Old 01-09-2019, 03:59 PM   #8
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First of all, happy new year everybody!

I've made little progress over the last couple of weeks. Lots of christmas holiday drinks and food, so only little time to work on the car.

In the mean time decided to not take the stock rear axle and go for the inevitable choice of a more durable rear axle. This weekend I can pick up one from a '90 240. Not exactly sure if this is the 1030 or 1031 by the pictures the seller send me but it will either way be a lot better than the original P1800's.

Anybody that nows more of these rear axles? These are the pictures he send me:



The sump is back after another trip to the workshop in Poland where the first time the welding wasn't done perfect. The sump didn't fit so I had to send it back and wait again. This time they did their job quick and the sump fits nicely!



Removed the flywheel, since the DMF had a lot of play and I want to swap it for a single mass version. With the very professional locking method:




Drilled out the extra holes in the turbo cooling feed lines for mounting it upside down. This way the supply and return of the oil lines are in the same position. Still have to make thread for the banjo fittings. And of course plug the other side.




After fitting in the original radiator, it becomes clear that the available space is very limited and I have to think of another position for the alternator since it will interfere with the steering box. This is what it will be like under the hood:


Cheers!
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Old 01-09-2019, 11:01 PM   #9
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That rear axle is a 1030. It's no stronger than the 1800E rear axle. The only thing worth using would be the 3.54 ring and pinion.

Edit:

The late 240 parts catalog does show 1216341 as a 1031. Remove the rear cover and see if there are notches for the ring gear in the case.



Left - 1031 with casting cutouts in outer case---Right 1031 without cutout.

Last edited by hiperfauto; 01-09-2019 at 11:35 PM..
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Old 01-10-2019, 06:08 AM   #10
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Hi Eric (or Ian?), both have the notches. Remove the gasket and.... tata
Wrong from the ANU website
1030 and 1031 did share the same housing at that time (don't know the time precise)
still the right is a 1030 with 41:11, which will be a 3.73:1 (really common)
the left is a 1031 with 41:13, which will be a 3.15:1 (the longest standart Volvo 140/160/200/700/900 rear end I know)

All from storage at my brain, not 100% shure it matches with the reality

first time I noticed something not 100% right from you

have a nice day, Kay

the rear end Sjefke will pick up is a 1031, very shure . With 3.54:1 ratio, like on the sticker noticed.
No ABS and No diff lock

Last edited by mocambique-amazone; 01-10-2019 at 06:31 AM..
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Old 01-10-2019, 08:19 AM   #11
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Quote:
Originally Posted by mocambique-amazone View Post
the rear end Sjefke will pick up is a 1031, very shure . With 3.54:1 ratio, like on the sticker noticed.
No ABS and No diff lock
Thanks for the information, guys! This is something very confusing, since there are a lot of contradictions on various websites.

The 3,54 ratio is definitely the one I wanted in combination with the whiteblock and the M90 gearbox. This way I come close to the overall gear ratio of the S60.

Cheers!
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Old 01-10-2019, 10:16 AM   #12
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I like where this is headed, keep it up.
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Old 01-10-2019, 05:06 PM   #13
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Nice to see another T5 swap in the works!
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Old 03-08-2019, 07:14 AM   #14
SjefkeHuppelkei
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It's been a while since I updated this thread.
A lot is been done, picked up the rear axle and chopped off the original 240 supports.

I've made cutouts in the oil pan and had it welded by a colleague. It passed the 'water-leakage test' the second time. First time some little droplets leaked through.

Further I'm sandblasting all the front suspension parts after work whenever I have time and get them ready for powdercoating. I want the complete rear axle to be powdercoated as well after I've mounted the P1800 brackets on there.

Also removed the PCV system and discovered some gunk...













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Old 03-08-2019, 09:29 AM   #15
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Those oil pan cuts look similar to what I did. I imagine that's what we can expect needing at this point to clearance the control arms. That level of gunk in the pcv system is normal honestly. I generally just clean it out and move on, I've only seen it be an issue when the port is clogged up.
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Old 03-23-2019, 12:08 PM   #16
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Nice!

I have a 73 ES I am very slowly doing the same thing to.
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