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Old 08-18-2012, 11:13 AM   #51
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I am determined to bring my mostly-stock/lightly-modified 242 down to your shop next summer.
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Old 08-18-2012, 11:40 AM   #52
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a rare FTFY from me.
I'm sure his car will still be running before mine, and my build is way less ambitious

That shop space is to die for, hard to get motivated to work on a car when it's outside on an sloping driveway :(
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Old 08-20-2012, 12:51 PM   #53
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Where about on the Cape? I have family in Falmouth, and Yarmouth Port.

You guys did a nice job on the shop, hope he got a deal on it being left in such condition.
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Old 08-20-2012, 10:07 PM   #54
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I still dig on whiteblocks (and technically this is still a whiteblock), but the V8 is a pretty rad motor that was just too cheap to turn down. And 300hp+ NA should provide for tons of fun.
why not go to an all aluminum ls motor? want to stay volvo powered? just was thinking about the vette tranny and how it would mate up to a ls motor... im sure the torq tube length would be wrong? maybe not?
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Old 08-20-2012, 10:58 PM   #55
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why not go to an all aluminum ls motor?
Where's the fun in that?
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Old 08-21-2012, 09:11 AM   #56
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It's a great looking shop and a great project, guys.
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Old 08-21-2012, 09:19 AM   #57
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Mesoam, the shop is in Yarmouth.

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why not go to an all aluminum ls motor? want to stay volvo powered? just was thinking about the vette tranny and how it would mate up to a ls motor... im sure the torq tube length would be wrong? maybe not?
Kildea pretty much nailed it. Could go LS1, but at that point we might as well just get a Corvette, and where's the fun in that?

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It's a great looking shop and a great project, guys.
Thanks!
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Old 08-22-2012, 04:48 PM   #58
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with an xc90 motor might as well get an xc90? no? im just pulling your strings. just seems like the ls motor would be a great candidate for this and make power easier.
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Old 08-22-2012, 05:11 PM   #59
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I'm definitely a fan of the LS1, but when 'different' is the name of the game it doesn't quite hold water. I'm also a fan of keeping it Volvo powered.
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Old 08-22-2012, 06:30 PM   #60
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Or Yamaha powered - even differenter!
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Old 08-22-2012, 07:31 PM   #61
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Nice work. I too have a Syncrowave of that vintage. Fan is hella noisy. Now that Bondo mentioned it, Ill look into the retro fit kit. Sitting idle, mine pulls 5 amps, so I just dont leave it on for the sake of fabbing!
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Old 09-04-2012, 05:56 PM   #62
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Alex just put the finishing touches on the button flywheel today. It came out beautifully.



Unfortunately I wasn't around to snap any pics of the turning operations, but the basic procedure was the following: Rough cut a circle out of 20mm plate with the oxy/acetylene torch, weld a scrap slug to the center of the plate for the chuck jaws to grab, then turn the front and the back profiles.

After the turning and drilling the bolt patterns, he milled recess slots for the clutch cover bolts:


Adding some chamfers:


Final weight:


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Old 09-04-2012, 05:58 PM   #63
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8lbs? Holy caca
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Old 09-04-2012, 06:08 PM   #64
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Cool! What happens for a crank sensor? Something on the crank pulley I imagine?
Does that motor have some sort of evil crank damper?
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Old 09-04-2012, 06:35 PM   #65
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I sure as hell didn't sign off on those drawings.
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Old 09-04-2012, 06:44 PM   #66
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That was intentional. Homer's Quality Assurance methods are merciless.

The crank sensor will be mounted on the bellhousing and trigger off a 60-2 mounted on the starter ring gear. The drawings are all done and it will probably be the next thing I make. Since the bellhousing is being made up from scratch it's not a big deal to add a mount for a sensor on it. The engine has a reasonably sized crank damper on it that we'd like to keep stock and unmodified.
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Old 09-04-2012, 07:00 PM   #67
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...we might as well just get a Corvette, and where's the fun in that?
You'd get to grow a mullet though - and what's not fun about a Mississippi Compromise???

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Old 09-04-2012, 11:00 PM   #68
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So jealous of the designing, drawing, and manufacturing you guys do. Good work!
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Old 09-05-2012, 11:57 AM   #69
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Just did a rough calculation, and the rotating mass of all the clutch components comes in around 30lbs. That's flywheel, clutch cover, discs, floaters, ring gear, trigger wheel, torque tube prop shaft, and all associated fasteners. Hopefully we don't need to add any ballast.
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Old 09-05-2012, 12:25 PM   #70
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How easy will it be to drive?
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Old 09-05-2012, 12:26 PM   #71
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Sitting in the shell making engine noises is very easy.
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Old 09-05-2012, 12:27 PM   #72
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Old 09-05-2012, 01:07 PM   #73
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How easy will it be to drive?
My flywheel weighs just a shade over 9 lbs. You have to think about it all the time when starting off from stop. Otherwise works fine.
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Old 09-05-2012, 02:50 PM   #74
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My flywheel weighs just a shade over 9 lbs. You have to think about it all the time when starting off from stop. Otherwise works fine.
Mine is 9lb too. I run a light pressure plate and it's still prone to stalling if I don't get it right. I'd rather have a flywheel that was a little heavier for street driving. But I drove Ian's car and that clutch is tougher than mine because the pedal is so light, yet it grabs so hard and sudden. Very weird, very different from any 240 I've driven. Usually heavy clutch grab = heavy pedal.
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Old 09-05-2012, 07:23 PM   #75
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In progress photos:











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