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Old 10-10-2016, 05:23 AM   #1
Estoque
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Default Going broke and lovin' it - 242 Turbo build

Hi fellow Turbobrickers!

As a long time reader on the Forums and the Facebookpage, i'd like to share my Volvo obsession with all of you. This thread will be about the '77 242 Turbo that me and my brother share and my Daily Driver 245 Turbo, which currently is out of his DD duty because i drive a VW Diesel at the moment.

First Volvo i ever owned was this hooptie, a 500,- car for a Rally through Europe:

I still think that mustache is the best addition i ever did to a 240.. So classy!

We installed some extra cargosprings on that thing and drove the wheel of it. Every time you'd take a right turn the thing would just bounce and skip across the road. Awesome car!

After that car, my DD Golf 4, wasn't any good anymore to me and i sold it to some guy in Poland.

After a lot of searching i found the perfect 245 Turbo. It looked sporty, had the Polaris rims on it(which i didn't care for at that moment) and had a Wilwood BBK in the front. Aswell as a B230FK swap (it's a original 2.1 Turbo, but one of the previous owners wanted more reliability), M46 + OD, 3" Ferrita, 15g Turbo, IPD Turbo Cam, Chipped LH2.4 and lowering springs.

So after 2 visits and a lowball offer on that car, i'd call myself the owner of a true Turbobrick.

This is how it looked when i bought it.


Loved it from the start! and my 240 addiction was born.

After 2 blown M46's, a bit of welding, new PU-Bushes all around, rebuilding the hydraulic steering rack, a few coats of paint and plastidip, rebuilding E-codes, custom skidplate, complete brake revision front and back, 2 failed MOT's, and 2 sets of tires. The 245 looks like this:

Yes, it's purple!




Haulin' junk:



Aside from Carbon mirrors that come in next week, no big changes done to it over the last 6 months.


But this thread says 242, so let me show that thing!



Bought it, 2,5 years ago together with my brother from the son of the First owner. The poor man died 5 years prior to our purchase and his son didn't know what to do with it and decided he wanted to sell it after 5 years. In the 5 years after the passing away of his father, he had the car serviced and MOT'ed every year, but failed to drive it anywhere.

The old 2.1 engine and carb where junk, but the car is in mint condition. So me and my brother decided to buy it and do a quick turboswap. ooh boy, where did we go wrong?!

after the acquisition of the 242, we bought a '95 940 Manual Turbo and started swapping out all the parts. After a month of building, the car was ready but wouldn't start.

the Fugly 940 with the worst paintjob ever:


bought a extra FK:


Stuffed a M46 in the 242 instead of the M90 that came with the 940.
Had still 3 laying around because of my 245 having the habit of eating them.






After 4 months of ****ing around getting that POS to start, we had enough of it and bought a Megasquirt kit.


It stood on this lift for over 4 months..

Wired in the Megasquirt:


Done:


new rims, Zender 15":


together with the sidepipe (no silencers)


took it to the dyno-dude for mapping, 3 days prior to a 5 day roadtrip to the UK and scotland:


And then, it ran for the first time. Sound was ****ing loud! Hear that gearbox squeel when we put it into gear.. 1 day before our roadtrip (with this car) to Scotland.

https://www.youtube.com/watch?v=fakI...ature=youtu.be

No testdrive, just go! and our roadtrip/rally to the UK started with with our first drive in the car which was a 800km trip to London. The gearbox squeeled every time we engaged a gear and after 3 days of torturing that poor old M46, we decided to give it a desperate needed oil-change. Instead of the recommended ATF that Volvo says we needed to run in this gearbox, we opted for a tradition gearbox oil and it never squeeled again! (until it blew up 1 year later)



Gearbox oil change! - one of the nicest chaps i've ever encountered in my life. Guy wasn't thrilled when we walked into his volvo shop because he was busy. Untill we mentioned we needed a gearoil change in our 242 Turbo and we just needed his pit to do it. We used his tools, his workshop and his gearoil and he wouldn't take a dime, so then we bought his whole crew a beer.. Awesome guy!



Then we found out our fueltank was leaking (i took the photo and 6hours later in the hotel i showed my brother the picture, we then noticed the liquid behind the rear wheel :P)


During this rally, the obvious became really clear. This thing corners like poo! The stock springs, the 160hp we had on tap and the 4.11 rear end weren't a good combination to throw around all the small and tight corners in Scotland. But still, had a blast!

here we encountered a 142 with FK Turbo which was much better suited for these roads (scrapin' his tailhook on every bump!)



Then the 142 broke down (weld on the Oil return from the turbo shat itself)

Then we became Facebook-famous:


After this adventure, we decided the car needed a bit of extra love and parts to make it more fun. build continues in the next post.




Next post i'll start with the build 2.0
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Old 10-10-2016, 05:24 AM   #2
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Few more pictures of the roadtrip:




after the Roadtrip and the 7000km testdrive, the 242 needed more power, a different gearbox and more lowzzz!

Bought parts to swap the M90 in:
940 Diesel pressure plate and clutch, together with 260 pedals for hydraulic clutch conversion:



Clutch thingie from a 262.


M47 to M90 Driveshaft adapter:


Had a mental brakedown on my birthday because of this:

Not because of the cluster, but because i realised (after the purchase) that i'd would work with the M90 and Megasquirt.
But hey! now it's a cool piece in my room together with all the other (rare) parts i've collected over the years.


made the M90 fit:




**** that weird aluminium pin on the end that holds the gearlever up:


Went all "Bruce Jenner" on the crossmember!:



Mounted:


Together with a 140 wooden gearknob that came out of the R-sport catalogue:


Hydraulic Clutch setup complete:


Then we discovered the rear-axle had tried to break free!



Since i'm not a fan of cut coils (i'm sorry!) we needed loweringsprings and bilsteins/Koni shocks. After coming to a conclusion that 60mm drop wouldn't cut (pun intended!) it, we opted for GAZ coilovers.

Christmas feeling!



Out with the old, in with the new:



Much better: Not even on the lowest setting!


Another reason why the 242 needed more lows:

When we're Stackin' bricks, it required the front wheels of my 245 to be removed.

All the previous work was done in the winterseason of 2015/2016. So when my 245 came out of storage, i needed to make a photo with both the 240's (and my Sisters mini)



Then took the 242 for some offroad abuse, she likes that!





Beginning of the real build!:
The old FK engine used a lot of oil (1l every 200km). Because of the spare engine we had still laying around, we opted for rebuilding that one and swapping out the old one with the fresh FK.

Old engine before teardown:


Mint!:


Done:


Parts:


Turned a Redblock into a Whiteblok, easiest conversion ever!:

gone back red:

Last edited by Estoque; 10-10-2016 at 06:22 AM..
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Old 10-10-2016, 06:22 AM   #3
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Decided that a fresh engine wouldn't feel right without a little bit more power. So smashed the piggybank again and orderd these:
New Holset HX35 and DW200 pump:



New stainless-steel Topmount exhaustheader with external WG.


Extra stoppingpower and a lousy reason to upgrade to 17" wheels.


Seats with extra hugging power, because i need hugs. (will be reupholstered with red fabric)


Car was dead, so towed it to the garage.. Low cars = creative sollutions for unloading!


Mocking up the brakes:


Old junk is helping me out with mocking up a spacer/adapter:


More parts:








Out with the old junk:



Needed a few seals, but almost done:


cleaning and painting:




Scored a NOS Flathood:




Next steps:
- Design Brake adapters in Solidworks
- Clean/paint the enginebay
- decide on Wastegate setup (48mm flange)
- Get bigger injectors
- Mount tires
- Build custom sidepipe exhaust and downpipe (2,5" or 3")
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Old 10-10-2016, 08:32 PM   #4
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damn those are some nice cars. i'm really digging the 17"s for the 242. just one question; do you only have one wastegate flange? the hx35 is a twin scroll and if you have a twin scroll manifold, you should have 2 wastegates.
keep up the good work! we really need a TB meet in the netherlands!
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Old 10-11-2016, 01:31 AM   #5
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Nice to see your project condensed like this. You went Bruce Jenner on the x-member wtf?! :P
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Old 10-11-2016, 03:09 AM   #6
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Quote:
Originally Posted by tjek View Post
damn those are some nice cars. i'm really digging the 17"s for the 242. just one question; do you only have one wastegate flange? the hx35 is a twin scroll and if you have a twin scroll manifold, you should have 2 wastegates.
keep up the good work! we really need a TB meet in the netherlands!
It's not a twinscroll manifold. It uses a 4 to 1 collector. So that's why there is only one WG-flange. But the flange is 48mm, so that is a weird size flange. mayby welding it up to a 50mm flange.

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Nice to see your project condensed like this. You went Bruce Jenner on the x-member wtf?! :P
I hacked all the bits off and made a hole in it :P
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Old 10-11-2016, 04:55 AM   #7
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it looks like an easy fix to make it a twin scroll manifold. just weld a plate in the middle dividing the 1-2 and 3-4 runners. that would help spool up time a bit.
what is your power goal? a 50mm might be a bit overkill. i'm guessing you did your homework on it? high boost small wastegate, low boost big wastegate. 50mm would be in the big wastegate area
and make sure to measure the v-band flange on the exhaust housing, as holset tends to use sizes that are just off from the normal 2.5 or 3 inch. just a heads up. ask me how i know
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Old 10-11-2016, 06:18 AM   #8
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It's going to be a trial and error build. We'll see how easy it's spools with the new IPD Turbo cam.
I don't see the need for a Twin-scroll for now. A powerband between 3k and 5,5k rpm's would be fine for me. Powergoal is anything over 350hp.

i have no experience with external wastegates, so i'll go around and order a 50mm one with different springs. We'll see how it works out.

Exhaust V-band flange: 73mm
https://goo.gl/photos/RjkGatms4tThbf6X6

Wastegate flange: 48mm
https://goo.gl/photos/K5Cr5dCMGdfenmRf9
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Old 10-11-2016, 09:08 AM   #9
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Theres never a need for going TwinScroll... just a "always better" ;)

Very nice build for europe
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Old 10-11-2016, 09:35 AM   #10
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I know, but i lack the skill of designing my own header. (or i'm just a lazy ****)..
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Old 10-12-2016, 01:55 AM   #11
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meh.. why do the cool kids in europe live that damn much away from each other.. we could put our lazyness together to create uberlazyness to get cool **** done :D
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Old 10-12-2016, 02:11 AM   #12
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Quote:
Originally Posted by MadDog_945 View Post
meh.. why do the cool kids in europe live that damn much away from each other.. we could put our lazyness together to create uberlazyness to get cool **** done :D
Yeah lucky yanks. The US is like the Luxemburg of North-America.
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Old 10-12-2016, 03:33 AM   #13
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Quote:
Originally Posted by MadDog_945 View Post
meh.. why do the cool kids in europe live that damn much away from each other.. we could put our lazyness together to create uberlazyness to get cool **** done :D
If you're a smart kid, you probably won't be wrenching on old volvo's :P
My parents made the mistake to let me get 2 Volvo's, i'm now ruined for life :P
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Old 10-12-2016, 01:21 PM   #14
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I do love the way this thread is going!!

I got a 1981 242 DL myself, and can't wait to start playing with it lol. Many sleepless nights ahead.

Keep it up!!

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Old 10-13-2016, 12:53 AM   #15
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Going to be sweet!
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Old 10-13-2016, 12:58 AM   #16
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Quote:
Originally Posted by Estoque View Post
If you're a smart kid, you probably won't be wrenching on old volvo's :P
My parents made the mistake to let me get 2 Volvo's, i'm now ruined for life :P
If my parents havent indoctrined me into volvos that bad ;) i would have had a skyline bnr32 and call it a day ;)
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Old 10-13-2016, 01:08 AM   #17
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Is your sister single?
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Old 10-13-2016, 02:49 AM   #18
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Quote:
Originally Posted by adomz View Post
I do love the way this thread is going!!

I got a 1981 242 DL myself, and can't wait to start playing with it lol. Many sleepless nights ahead.

Keep it up!!

ADam
Thank you my soon to be Sleep Deprived Brother :P

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Going to be sweet!
That's the plan :D

Quote:
Originally Posted by MadDog_945 View Post
If my parents havent indoctrined me into volvos that bad ;) i would have had a skyline bnr32 and call it a day ;)
My parents told me to save money and only buy one car, see where it got me :P
i'm hopeless.

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Is your sister single?
Not yet, make me an offer and i'll help you :P
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Old 10-13-2016, 03:04 AM   #19
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I received my custom Carbon mirrors yesterday!
Not because i want to save weight, but because of the good looks.

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Old 10-13-2016, 11:38 AM   #20
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So you keep the stock internals of the FK? Nice build, taking ideas for my project
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Old 10-13-2016, 11:41 AM   #21
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Yes, stock internals but all new bearings, rings etc.

If this one blows up, i have a spare FK laying around! :D
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Old 10-13-2016, 11:47 AM   #22
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Quote:
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Not yet, make me an offer and i'll help you :P
That's a weird answer. Lmao.
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Old 10-14-2016, 02:58 AM   #23
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That's a weird answer. Lmao.
I meant, if there is a posibility for me to get a Volvo-minded brother in law, it's worth a push in the "right" direction for her current partner :P
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Old 10-14-2016, 04:03 AM   #24
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those mirrors are +20hp at minimum !
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Old 10-14-2016, 06:01 AM   #25
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Originally Posted by MadDog_945 View Post
those mirrors are +20hp at minimum !
I'm worried that after installing these mirrors, the aluminium skidplate will fall of and my cluster will read a "Danger to Manifold" error..

Better go Gallo 12 or Gallo 24!!
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