Karl Buchka
Active member
- Joined
- Mar 25, 2007
- Location
- Los Angeles
The car is a 1979 242DL. I bought it in December of 2007 from the original owner. The car had been sitting in his Connecticut garage for the last 10 years, so it was purchased as non-running for $500. For a lifetime New England car it had a surprisingly small amount of rust (along with 120'000 miles). After a nightmarish day of trailering it home I put fresh gas in it, cranked it for about 60 seconds, and it fired up. Granted, it ran like **** on three cylinders, but it ran. Here's what it looked like the day I got it home:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5165962256724126882"><img src="http://lh4.ggpht.com/kbuchka/R7EvTVMd7KI/AAAAAAAAHl4/wq64xW_Et78/s400/DSC00977.JPG" /></a>
And here's how it sounded:
<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/Lt3x03iJsRY&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><embed src="http://www.youtube.com/v/Lt3x03iJsRY&hl=en&fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="344"></embed></object>
When I initially checked out the car it seemed like it was decent mechanical condition for what it was, but as I started tearing in to it I realized the previous owner was a lying moron with no regard for workmanship or safety. Both buttcheeks were 100% fiberglass; all the factory bullet fuses had been replaced with Radioshack 30A glass fuses; the sheetmetal in the trunk around the sender unit had been sliced to **** with a pair of tin snips; the stereo wiring was an electrical fire waiting to happen; and the advertised "brand new fuel system" consisted of a dead in-tank pump, dead sender, swiss cheese fuel tank, and rusted out hard lines.
After a quick interior swap/refresh I put the car aside and started working on the engine.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5165962299673799906"><img src="http://lh6.ggpht.com/kbuchka/R7EvV1Md7OI/AAAAAAAAHmY/rCWUHIQIYyA/s400/DSC00985.JPG" /></a>
Take a megasquirt,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5148176515809690466"><img src="http://lh5.ggpht.com/kbuchka/R3H_Q9HYQ2I/AAAAAAAAGY8/Exu6Ok746d4/s400/DSC00991.JPG" /></a>
a T5 World Class,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5151807068844868930"><img src="http://lh6.ggpht.com/kbuchka/R37lO9HYRUI/AAAAAAAAGmQ/vaUhFfwdcR4/s400/DSC01019.JPG" /></a>
shortened 960 pan,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5154423803439761154"><img src="http://lh4.ggpht.com/kbuchka/R4gxI9HYRwI/AAAAAAAAGxc/Y4jH30DAuRo/s400/DSC01043.JPG" /></a>
transmission adapter plate,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5163310920711503042"><img src="http://lh4.ggpht.com/kbuchka/R6fD7Q3nfMI/AAAAAAAAHcg/R97oFwJJFrY/s400/DSC01124.JPG" /></a>
and some other fun parts, along with 30 straight 12 hour days (for both my brother and I), and you end up with something like this:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5164853102894771314"><img src="http://lh3.ggpht.com/kbuchka/R60-iFMd7HI/AAAAAAAAHiU/VfETdbQ2Tjk/s400/PICT0761.JPG" /></a>
<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/fy7Zl7ei2v0&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><embed src="http://www.youtube.com/v/fy7Zl7ei2v0&hl=en&fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="344"></embed></object>
This is obviously a somewhat abridged history, but I'm sure you get the idea.
While chasing an elusive electrical gremlin I decided the old harness needed to go. After $160 on an eBay universal harness and four solid days of work, my brother and I had a brand new electrical system, complete with all 850 solid state relays for headlights and flashers.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196371612214084674"><img src="http://lh6.ggpht.com/kbuchka/SB04cyLxxEI/AAAAAAAAIW0/9wPDWWALF3Y/s400/DSC01171.JPG" /></a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196371620804019298"><img src="http://lh4.ggpht.com/kbuchka/SB04dSLxxGI/AAAAAAAAIW8/sDMCin7it0E/s400/DSC01174.JPG" /></a>
In the beginning of May '08 I brought it to a little car show held annually at my college, The University of Massachusetts Amherst. I won first place in the Volvo class and narrowly missed out on first place in the Exhaust Sound Off. The two-step set at 2900rpm was good enough to net 186.2dB at the tailpipe, along with 12" flames.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196371633688921218"><img src="http://lh3.ggpht.com/kbuchka/SB04eCLxxII/AAAAAAAAIWI/fjx9uJAaCkk/s400/DSC01180.JPG" /></a>
Following the show I did very little major work on the car, mostly fixing some odds and ends.
Having some fun:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196662926960870866"><img src="http://lh6.ggpht.com/kbuchka/SB5BZiLxxdI/AAAAAAAAIcM/VFXnEKYTTcI/s400/IMG_1101.jpg" /></a>
Mockup for the new wheels:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5214322745827656338"><img src="http://lh6.ggpht.com/kbuchka/SFz-6SFMApI/AAAAAAAAKF8/Y-9Zet2NDtk/s400/IMG_1695.jpg" /></a>
Came back from the Motherland with some Euro spec 5-panels:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5215646700003532098"><img src="http://lh6.ggpht.com/kbuchka/SGGzCjumHUI/AAAAAAAAKKA/VXnpQjqDktk/s400/DSC01204.JPG" /></a>
<a href="http://forums.turbobricks.com/showthread.php?t=135058">I was having vicious boost creep issues</a>, so I pulled the turbo and ported the wastegate:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218245737257130834"><img src="http://lh4.ggpht.com/kbuchka/SGru2b_oW1I/AAAAAAAAKZ4/wsMPX-QSSCQ/s400/DSC01205.JPG" /></a>
The Walbro 255lph pump I had bought turned out to be a cheap knock-off when it outright failed one day. I was forced to buy a new one, but at least I knew this one was real. <a href="http://forums.turbobricks.com/showthread.php?t=140796">Can you spot the fake?</a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218464375441378210"><img src="http://lh5.ggpht.com/kbuchka/SGu1s2s2y6I/AAAAAAAAKcI/MRQat9U3PWU/s400/DSC01216.JPG" /></a>
Made a new dashplate using 240 gauges, Porsche 924 gauges, and a glycerin filled industrial compound pressure gauge (for boost):
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218605359769262722"><img src="http://lh4.ggpht.com/kbuchka/SGw17OP_GoI/AAAAAAAAKdY/H9w-WZy7W_A/s400/DSC01220.JPG" /></a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218605363764596818"><img src="http://lh5.ggpht.com/kbuchka/SGw17dIjEFI/AAAAAAAAKdg/cqRqCXfcUsA/s400/DSC01221.JPG" /></a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218605364893070674"><img src="http://lh5.ggpht.com/kbuchka/SGw17hVmNVI/AAAAAAAAKdo/zBK9Bagcqo8/s400/DSC01222.JPG" /></a>
So here's how it stands today:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196662664967865586"><img src="http://lh5.ggpht.com/kbuchka/SB5BKSLxxPI/AAAAAAAAIZg/RAuknNLi0LM/s800/IMG_1087.jpg" /></a>
And a detailed spec list because I happened to have one typed up already:
The mechanicals:
x B5234T (gasoline, 5 cylinders, 2.3 liters, 4 valves per cylinder, turbo) engine
x Intake manifold from a 2003 Volvo S60T5
x Modified oil pan (cut and shortened), upper engine mounts, dip-stick
tube, and water transfer tube from a Volvo 960
x Mitsubishi TD04L-15G turbo with a ported turbine housing (running 20psi)
x 3" downpipe to 2.5" catback
x ClutchNet sprung-hub 6-puck clutch disk
x Borg-Warner T5 World Class transmission
x Custom one-piece driveshaft from The Driveshaft Shop
Electronics:
x Megasquirt V3 PCB running the latest Megasquirt'n'Spark-Extra firmware
x Sequential coil-on-plug with a 60-2 crank wheel and cam sync
x Boost control, fan control, and two-step launch control
x JAW wideband controller.
x From-scratch engine harness
x 21-Circuit universal chassis harness
x Walbro 255LPH in-tank fuel pump
Other stuff:
x Volvo branded Momo Alpine steering wheel
x 250km/h speedo and 8k rpm tach from a European spec. Porsche 924
x Industrial glycerin filled compound pressure gauge (accurate to within 1%)
x VDO oil pressure, fuel pressure, oil temp, coolant temp, fuel level,
battery voltage, exhaust backpressure, and exterior temp gauges
Right now the car is parked for a complete overhaul, including rods, turbo, header, cams, injectors, EMS, and suspension.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5165962256724126882"><img src="http://lh4.ggpht.com/kbuchka/R7EvTVMd7KI/AAAAAAAAHl4/wq64xW_Et78/s400/DSC00977.JPG" /></a>
And here's how it sounded:
<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/Lt3x03iJsRY&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><embed src="http://www.youtube.com/v/Lt3x03iJsRY&hl=en&fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="344"></embed></object>
When I initially checked out the car it seemed like it was decent mechanical condition for what it was, but as I started tearing in to it I realized the previous owner was a lying moron with no regard for workmanship or safety. Both buttcheeks were 100% fiberglass; all the factory bullet fuses had been replaced with Radioshack 30A glass fuses; the sheetmetal in the trunk around the sender unit had been sliced to **** with a pair of tin snips; the stereo wiring was an electrical fire waiting to happen; and the advertised "brand new fuel system" consisted of a dead in-tank pump, dead sender, swiss cheese fuel tank, and rusted out hard lines.
After a quick interior swap/refresh I put the car aside and started working on the engine.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5165962299673799906"><img src="http://lh6.ggpht.com/kbuchka/R7EvV1Md7OI/AAAAAAAAHmY/rCWUHIQIYyA/s400/DSC00985.JPG" /></a>
Take a megasquirt,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5148176515809690466"><img src="http://lh5.ggpht.com/kbuchka/R3H_Q9HYQ2I/AAAAAAAAGY8/Exu6Ok746d4/s400/DSC00991.JPG" /></a>
a T5 World Class,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5151807068844868930"><img src="http://lh6.ggpht.com/kbuchka/R37lO9HYRUI/AAAAAAAAGmQ/vaUhFfwdcR4/s400/DSC01019.JPG" /></a>
shortened 960 pan,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5154423803439761154"><img src="http://lh4.ggpht.com/kbuchka/R4gxI9HYRwI/AAAAAAAAGxc/Y4jH30DAuRo/s400/DSC01043.JPG" /></a>
transmission adapter plate,
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5163310920711503042"><img src="http://lh4.ggpht.com/kbuchka/R6fD7Q3nfMI/AAAAAAAAHcg/R97oFwJJFrY/s400/DSC01124.JPG" /></a>
and some other fun parts, along with 30 straight 12 hour days (for both my brother and I), and you end up with something like this:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5164853102894771314"><img src="http://lh3.ggpht.com/kbuchka/R60-iFMd7HI/AAAAAAAAHiU/VfETdbQ2Tjk/s400/PICT0761.JPG" /></a>
<object width="425" height="344"><param name="movie" value="http://www.youtube.com/v/fy7Zl7ei2v0&hl=en&fs=1"></param><param name="allowFullScreen" value="true"></param><embed src="http://www.youtube.com/v/fy7Zl7ei2v0&hl=en&fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="344"></embed></object>
This is obviously a somewhat abridged history, but I'm sure you get the idea.
While chasing an elusive electrical gremlin I decided the old harness needed to go. After $160 on an eBay universal harness and four solid days of work, my brother and I had a brand new electrical system, complete with all 850 solid state relays for headlights and flashers.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196371612214084674"><img src="http://lh6.ggpht.com/kbuchka/SB04cyLxxEI/AAAAAAAAIW0/9wPDWWALF3Y/s400/DSC01171.JPG" /></a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196371620804019298"><img src="http://lh4.ggpht.com/kbuchka/SB04dSLxxGI/AAAAAAAAIW8/sDMCin7it0E/s400/DSC01174.JPG" /></a>
In the beginning of May '08 I brought it to a little car show held annually at my college, The University of Massachusetts Amherst. I won first place in the Volvo class and narrowly missed out on first place in the Exhaust Sound Off. The two-step set at 2900rpm was good enough to net 186.2dB at the tailpipe, along with 12" flames.
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196371633688921218"><img src="http://lh3.ggpht.com/kbuchka/SB04eCLxxII/AAAAAAAAIWI/fjx9uJAaCkk/s400/DSC01180.JPG" /></a>
Following the show I did very little major work on the car, mostly fixing some odds and ends.
Having some fun:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196662926960870866"><img src="http://lh6.ggpht.com/kbuchka/SB5BZiLxxdI/AAAAAAAAIcM/VFXnEKYTTcI/s400/IMG_1101.jpg" /></a>
Mockup for the new wheels:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5214322745827656338"><img src="http://lh6.ggpht.com/kbuchka/SFz-6SFMApI/AAAAAAAAKF8/Y-9Zet2NDtk/s400/IMG_1695.jpg" /></a>
Came back from the Motherland with some Euro spec 5-panels:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5215646700003532098"><img src="http://lh6.ggpht.com/kbuchka/SGGzCjumHUI/AAAAAAAAKKA/VXnpQjqDktk/s400/DSC01204.JPG" /></a>
<a href="http://forums.turbobricks.com/showthread.php?t=135058">I was having vicious boost creep issues</a>, so I pulled the turbo and ported the wastegate:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218245737257130834"><img src="http://lh4.ggpht.com/kbuchka/SGru2b_oW1I/AAAAAAAAKZ4/wsMPX-QSSCQ/s400/DSC01205.JPG" /></a>
The Walbro 255lph pump I had bought turned out to be a cheap knock-off when it outright failed one day. I was forced to buy a new one, but at least I knew this one was real. <a href="http://forums.turbobricks.com/showthread.php?t=140796">Can you spot the fake?</a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218464375441378210"><img src="http://lh5.ggpht.com/kbuchka/SGu1s2s2y6I/AAAAAAAAKcI/MRQat9U3PWU/s400/DSC01216.JPG" /></a>
Made a new dashplate using 240 gauges, Porsche 924 gauges, and a glycerin filled industrial compound pressure gauge (for boost):
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218605359769262722"><img src="http://lh4.ggpht.com/kbuchka/SGw17OP_GoI/AAAAAAAAKdY/H9w-WZy7W_A/s400/DSC01220.JPG" /></a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218605363764596818"><img src="http://lh5.ggpht.com/kbuchka/SGw17dIjEFI/AAAAAAAAKdg/cqRqCXfcUsA/s400/DSC01221.JPG" /></a>
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5218605364893070674"><img src="http://lh5.ggpht.com/kbuchka/SGw17hVmNVI/AAAAAAAAKdo/zBK9Bagcqo8/s400/DSC01222.JPG" /></a>
So here's how it stands today:
<a href="http://picasaweb.google.com/kbuchka/1979Volvo242/photo#5196662664967865586"><img src="http://lh5.ggpht.com/kbuchka/SB5BKSLxxPI/AAAAAAAAIZg/RAuknNLi0LM/s800/IMG_1087.jpg" /></a>
And a detailed spec list because I happened to have one typed up already:
The mechanicals:
x B5234T (gasoline, 5 cylinders, 2.3 liters, 4 valves per cylinder, turbo) engine
x Intake manifold from a 2003 Volvo S60T5
x Modified oil pan (cut and shortened), upper engine mounts, dip-stick
tube, and water transfer tube from a Volvo 960
x Mitsubishi TD04L-15G turbo with a ported turbine housing (running 20psi)
x 3" downpipe to 2.5" catback
x ClutchNet sprung-hub 6-puck clutch disk
x Borg-Warner T5 World Class transmission
x Custom one-piece driveshaft from The Driveshaft Shop
Electronics:
x Megasquirt V3 PCB running the latest Megasquirt'n'Spark-Extra firmware
x Sequential coil-on-plug with a 60-2 crank wheel and cam sync
x Boost control, fan control, and two-step launch control
x JAW wideband controller.
x From-scratch engine harness
x 21-Circuit universal chassis harness
x Walbro 255LPH in-tank fuel pump
Other stuff:
x Volvo branded Momo Alpine steering wheel
x 250km/h speedo and 8k rpm tach from a European spec. Porsche 924
x Industrial glycerin filled compound pressure gauge (accurate to within 1%)
x VDO oil pressure, fuel pressure, oil temp, coolant temp, fuel level,
battery voltage, exhaust backpressure, and exterior temp gauges
Right now the car is parked for a complete overhaul, including rods, turbo, header, cams, injectors, EMS, and suspension.
Last edited: