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Old 09-01-2009, 01:55 PM   #51
Wagner
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What will come out of this?
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Old 09-01-2009, 02:27 PM   #52
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Originally Posted by Wagner View Post


What will come out of this?
maybe a spacer for the driveshaft (and maybe some other parts from the leftovers, think underdrive pulley etc if i find the time ). depending on how expensive it is to have a driveshaft adapted (i have a 940 M47 front piece that i'd like to get shortened and balanced to work with the beefy rear driveshaft part that my 240 has).
only problem with this chunk of aluminium is that the chuck of my lathe cant hold it, it is missing the jaws for clamping stuff from the outside (like this one can).

The tips/tricks you told me about 2 years ago (I think) were very handy when i adapted the x-member and working on the M90. I didnt weld the 3rd gear synchro, didnt feel like taking apart a perfectly good gearbox. I tried to get it apart but after an hour and various removed things i gave up haha.

I can only work on the 240 in the weekends now (school), the annual checkup (APK = emissions, safety etc) expired a few days ago. need to get it running asap.
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Old 09-01-2009, 02:29 PM   #53
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Ouch, good luck fixing that i have some bad experiences with expired APK
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Old 09-01-2009, 03:25 PM   #54
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Originally Posted by JW240 View Post
depending on how expensive it is to have a driveshaft adapted (i have a 940 M47 front piece that i'd like to get shortened and balanced to work with the beefy rear driveshaft part that my 240 has
Do you already have quotes on that? I'll check first thing tomorrow.

Curious to see/hear how you adapted stuff to fit that M90 in your 240. Try to remember how you did all of that so you can help me fit mine.
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Old 09-01-2009, 03:32 PM   #55
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Originally Posted by JW240 View Post
. I tried to get it apart but after an hour and various removed things i gave up haha.

I can only work on the 240 in the weekends now (school), the annual checkup (APK = emissions, safety etc) expired a few days ago. need to get it running asap.
Yeah, those spring pins are really annoying and time consuming to remove and install. It is possible to weld it without too much dismantling though. That's how they did in the Bilsport article. There is one gear connecting ring is on the way, but apparently it is possible to remove that without taking the whole gearbox apart.

But you'll be fine as long as you use one full minute every time when you change to third gear to make sure that you are in gear.

Fast shifting to 3rd is what kills it.

While the aluminum adapter might be perfectly acceptable and work fine, i'm sure that the engineer in you wants to do it right and have the drive shaft shortened and balanced. And if you use the rubber quibo, use the BMW M5 one. (heh, it was you who originally mentioned it to me )

When i had a front piece made out new material (old flanges) at a qualified drive line shop (you need a certificate here for a modified drive shaft for the annual safety/emission inspection) it was approximately 200 euros, including the balancing of the whole drive shaft. I kind of had to do it that way, the spacer system, or the dual quibos you see in some builds, would not fly here in the annual inspection.

Anyway, inspirational stuff there again, it seems to become quite a desirable wagon.

And yeah, i know how the weekends-only thing goes. It's annoying when life gets in the way of wrenching on cars.
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Old 09-01-2009, 05:23 PM   #56
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Originally Posted by Mr.Borrie View Post
Ouch, good luck fixing that i have some bad experiences with expired APK
yeah im hoping there is some leeway, would be nice to have a few weeks extra before they start to spam me fines for the expired apk...

Quote:
Originally Posted by volvo78244 View Post
Do you already have quotes on that? I'll check first thing tomorrow.

Curious to see/hear how you adapted stuff to fit that M90 in your 240. Try to remember how you did all of that so you can help me fit mine.
Last weekend i didnt had any time left to check the length of the driveshaft, so i haven't contacted any companies yet. Jan(speed) sent me the address of a company as well.
I'll document everything about the swap so we can make/adapt the parts for your 242 of course

Quote:
Originally Posted by Wagner View Post
Yeah, those spring pins are really annoying and time consuming to remove and install. It is possible to weld it without too much dismantling though. That's how they did in the Bilsport article. There is one gear connecting ring is on the way, but apparently it is possible to remove that without taking the whole gearbox apart.
I tried to remove the gear found under the mess with the 3 springs/ball bearings but it was very stuck. Removed part of the shifting mechanism plates, put a bearing puller on there, hammered the locking pins, it was very stuck in there. It was curious to see that my M90 had steel blocks/holders for the springs, some have some kind of plastic there. The prices of M90's have dropped, so if i really want a welded one for true hooligan use in the future i can always prepare one

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But you'll be fine as long as you use one full minute every time when you change to third gear to make sure that you are in gear.

Fast shifting to 3rd is what kills it.
i'll be careful with that yeah, but if i can get a M46/47 to live on various cars around here with my shifting, im not that worried

Quote:
Originally Posted by Wagner View Post
Yeah, those spring pins are really annoying and time consuming to remove and install. It is possible to weld it without too much dismantling though. That's how they did in the Bilsport article. There is one gear connecting ring is on the way, but apparently it is possible to remove that without taking the whole gearbox apart.

But you'll be fine as long as you use one full minute every time when you change to third gear to make sure that you are in gear.

Fast shifting to 3rd is what kills it.

While the aluminum adapter might be perfectly acceptable and work fine, i'm sure that the engineer in you wants to do it right and have the drive shaft shortened and balanced. And if you use the rubber quibo, use the BMW M5 one. (heh, it was you who originally mentioned it to me )

When i had a front piece made out new material (old flanges) at a qualified drive line shop (you need a certificate here for a modified drive shaft for the annual safety/emission inspection) it was approximately 200 euros, including the balancing of the whole drive shaft. I kind of had to do it that way, the spacer system, or the dual quibos you see in some builds, would not fly here in the annual inspection.
Yeah the driveshaft modification would be the best, true. the BMW guibo is too expensive for me now, will have to save up for one hehe. I'll check if Meyle makes a HD version of the BMW one. The gearbox mount on my M90 is a Meyle heavy duty version, they claim it is stronger than the original one. does the driveshaft need to be shorter with the slightly thicker guibo? (I can imagine that the driveshaft gets to full compression with full suspension travel maybe, like the 7/900 series like to do?)

Quote:
Originally Posted by Wagner View Post
Anyway, inspirational stuff there again, it seems to become quite a desirable wagon.

And yeah, i know how the weekends-only thing goes. It's annoying when life gets in the way of wrenching on cars.
Life sometimes gets in the way of the fun stuff yeah... oh well, it could be worse
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Old 09-01-2009, 06:02 PM   #57
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I hope so too for you, offcource i was pulled over when i was driving like a cock when they checked my tags
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Old 09-02-2009, 01:03 PM   #58
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Quote:
Originally Posted by JW240 View Post
I'll check if Meyle makes a HD version of the BMW one. The gearbox mount on my M90 is a Meyle heavy duty version, they claim it is stronger than the original one. does the driveshaft need to be shorter with the slightly thicker guibo?
I think it might be a good idea to have the drive shaft made for the thicker guibo if you're going to go with that.

What is this Meyle you speak of? How much was the transmission mount and where did you buy it from? I might be putting a M90 in the 740, and it migt be a good idea to use a new mount.
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Old 09-02-2009, 05:16 PM   #59
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Quote:
Originally Posted by Wagner View Post
I think it might be a good idea to have the drive shaft made for the thicker guibo if you're going to go with that.

What is this Meyle you speak of? How much was the transmission mount and where did you buy it from? I might be putting a M90 in the 740, and it migt be a good idea to use a new mount.
i am going to adapt the center support to be like the grp A 242's had, 740 center support rubber piece, so i can make it slightly adjustable. No problems then if i get the driveshaft shortened 5 mm extra for a thicker guibo then.

We ordered new engine mounts for my brothers 760 with B28E and we got 2 Meyle M90/AW71/B28 mounts (Meyle p/n 514 132 8900/HD afaik, i found that via google but will check later if its correct).
I just noticed it last week that they were the HD version
I got them for a very friendly price, 20€ each. Maybe you have to order them as the V6 mounts to get the HD ones.
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Old 09-03-2009, 09:25 AM   #60
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Default Driveshaft shortening

Hey JW,

Just called the shop who shortens driveshafts, they gave me a quote of 218€ (including 21%VAT), not too bad I think? Let me know if you want the address...
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Old 09-21-2009, 03:01 PM   #61
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The engine shot:


Downpipe:

Made from 321 stainless steel (bling). 76.1x2mm tubing. home made V-band flange. I still have a flex section, 200 cpi metallic racecat and a support bracket that need to be added to this downpipe. The rest of the exhaust will be a 3" JT superflow system with 2 straight through mufflers.
Aircleaner is from some Volvo construction equipment thingie, maybe i can get it to fit. it is pretty hugee (occupies space of windshield washer tank+coolant reservoir if i were to use it).


sneaks past the firewall. inspired by Kaplhenkeee.

Interior back, seat heater connected, central locking installed, power mirrors. M90 shifter fits nicely. The seat looks more gray than it is in the pic, the flash makes it look that way.


The M90 shifter installed together with the sound insulating stuff:

Fits good, no extra holes needed to be drilled in the transmission tunnel. stupid me uploaded it in lower res... see gallery for much more M90 install pics.
The hydraulic clutch has been installed/bled as well. 260 pedal+mc, 940 line+sc. Seems to work good.

Last edited by JW240; 09-21-2009 at 03:08 PM..
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Old 09-21-2009, 03:59 PM   #62
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Wow, very very nice. I like this build its clean and simple. Keep it up!
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Old 09-21-2009, 04:19 PM   #63
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Yes that looks more like it, not sure about the 850 seats look, then again they will be much better for track like driving but they do ruin the grandpa 245 look that i loved on your car.

btw that "sound insulating stuff" i need to install that on my car there is now kind of a hole to the outside of the car.. i dont like that .. should fix that.. anyway looking good
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Old 09-22-2009, 10:10 AM   #64
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I like your approach with this project. It's very factory-like, and not over-complicated for the sake of being over-complicated.

But will it outrun the 760 ?
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Old 09-22-2009, 02:17 PM   #65
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Quote:
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But will it outrun the 760 ?

The 240 has better suspension, but in terms of power the 760 will give it a good run for its money
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Old 09-22-2009, 02:51 PM   #66
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I think the 240 needs a V8 You know it does.
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Old 09-22-2009, 02:54 PM   #67
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I think the 240 needs a V8


I do know what you need, a signature that's not that annoyingly long
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Old 09-22-2009, 03:06 PM   #68
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Your wish is my command...
I changed my sig, now you should get some springs on the back of the 760
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Old 09-22-2009, 03:38 PM   #69
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Looks nice m8 !
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Old 12-01-2009, 08:42 AM   #70
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It runs!



some pics:

Finished DP with 2 O2 bungs, flex, v-band and cat.


DP support, extra HD, stainless steel.


Welding


Intake/IC piping made from exhaust tubing. I brazed the joints and the beads for the hose, worked great. Still need to add the CBV ports and the port for the crankcase ventilation hose. Aircleaner is a used K&N one from a Subaru or Mitsubishi, i forgot. I tried to fit the 240 diesel box or 7/900 turbo box but those take up so much space....


Got negative camber?
Still need to adjust the passenger side wheel bearing (has play), adjust toe-in and chase down a small noise. Solid endlinks fitted as well (will dig up some pics of my creation)

Next up is the exhaust, some wiring work, some finishing touch etc. Maybe some rust removal in the rear wheel arches as well. Almost ready for the street again
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Old 12-01-2009, 09:13 AM   #71
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I love the intake and the M90 DP clamp! Jealous!
Good work there, so your pretty much done now aren't you
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Old 12-01-2009, 10:15 AM   #72
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Hey, put ©Turbosteen in that video
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Old 12-01-2009, 10:21 AM   #73
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Hey, put ©Turbosteen in that video
with that logic you need to paint your car in Group A style and put JW240 as sponsor in every spot
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Old 12-01-2009, 02:22 PM   #74
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HOORAY. Awesome!
Do you still want my old K&N cone?
Next step, install the christmas present im sending you.
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Old 12-01-2009, 02:25 PM   #75
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with that logic you need to paint your car in Group A style and put JW240 as sponsor in every spot
And White Rice is for 10% property of JW, since that's the amount of metal he welded into it j/k
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