My 242, Now What Do I Do?

[B2fkb0]

Well finally got back at it today. Got the engine and tranny pulled and the engine bay washed.

[B2fkb0]

Pulled the rack and cleaned it up; pulled the interior and extracted (cleaned) all the seats, mats and carpet. Found the sound deadener foam was wet on both sides of the tunnel under the dash. Pulled out all the non-stock wiring. Vacuumed everything. The musty smell is gone!

[B2fkb0]

The two wire bundles that exit out of the firewall next to the brake booster; how do they come out?

[LC4CARL]

Busy, busy!

[B2fkb0]

Gutted the engine bay and interior


Built the paint booth


Working on the motor- intake resto
https://youtu.be/KTtxZSGrknM

[B2fkb0]

Interior is awesome!


Removed excess wire


Getting there; engine bay is ready for primer. Brake booster/master/lines detailed.
Interior was extracted, vacuumed sprayed and wiped down and set in the sun the dry. They're ready for re-insertion!!

[B2fkb0]

My good friend Robert Spinner came by on his way East.



He helped me out by bringing the louvers I got from Steve (stove)! Oh yeah!

[B2fkb0]

Started on the intake


Shiny parts!

[B2fkb0]

Worked on the intake and exhaust/turbo








Start exhaust w 90+ manifold





Add in angle flange hot side from an 01 s60



Add in the rest of the 16T



Getting there! No comments?!

[okoye]

seems like you've got an attention to detail!

[B2fkb0]

It's that or ocd; but thanks! Re-clocking the turbo and figuring out all the lines is taking a bit of work but it's a fun adventure. Drilling the turbo mounting holes proved to be challenging!

[SquareD]

I admire folks that have the passion and persistence to tackle projects like this. Great work, looking forward to following your progress.

[cwdodson88]

looks good! The angled flange downpipe should be nice, planning to run 3" all the way back?

[DD Ranch]

*

[B2fkb0]

Thanks Square D, your car is definitely an inspiration!
Hi CW Plan is 3" for 3' then transition to 2.5" TME system that came with the car.
Hey DD, I used por15 engine enamel on the intake; the 90+ came to me already coated with something unknown. It was in the trunk of a 244 my friend Slicknerd and I bought for $75 and drove home. I saw that mani and noticed it was machined flat and redrilled/tapped and coated so I grabbed it!

[blkaplan]

Why did you mill your exhaust manifold flat if you are using a volvo turbine housing?

[Matt86]

Awesome project! I wish I had the time and energy to tackle a project of this size. Also those Louvers are killer!

[AndrewNance]

Originally Posted by blkaplan

Why did you mill your exhaust manifold flat if you are using a volvo turbine housing?

So you don't have to do it later?

[B2fkb0]

Originally Posted by blkaplan

Why did you mill your exhaust manifold flat if you are using a volvo turbine housing?

Hi Ben
I got the 90+ manifold already milled. And it seems it was drilled and tapped as well (3/8-24 thread). I'm not sure as this is my first go around with redblocks! So much to learn.

Today I got a little more accomplished;
Removed the studs from the angle flange hot side and drilled the holes out (cobalt bit was a must, that high nickel cast is tough). Found that the upper rear stud and the hot side had a clearance issue





So I had to trim the flange to accommodate...



That was raw and it has now been smoothed out. Then a nice coat of cast iron grey from por 15



Next up is reclocking; the pins are out, the cchra is cleaned and I'll tig weld some mounting studs on the housing for the fasteners. Then the oil and water lines. Whew! I hope the 16T is worth it!

[B2fkb0]

Also, thanks Matt for the kind words! Time is always an issue; I'm fortunate to have this summer off.

Robert is a great friend (transported those louvers from CA to MI) and we're lucky to have him in the Volvo community. He also has a 740 that he is building for his brother as a gift. So he likes all of them!

[B2fkb0]

Mock up with the angle flange/90+/530 head with downpipe



And going to un-shroud the exhaust valves and lower the compression a bit.



Just a bit! Also gasket match the intakes and exhaust manifolds to the head.

[B2fkb0]

[DanMarino]

I love me some Robert DIY Spinner videos! Cool that you guys are buddies. I love your project. I don't have the cash or space to do something like this.

[LC4CARL]

Unshroud = remove material at the gasket surface around the valve? And the larger chamber volume will lower the compression a bit?

[cwdodson88]

Originally Posted by LC4CARL

Unshroud = remove material at the gasket surface around the valve? And the larger chamber volume will lower the compression a bit?

Yes, you remove material from inside the combustion chamber around the valves increasing the CC of the chamber, lowering the compression.