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Old 07-01-2018, 02:11 PM   #1
papsimagoo
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Join Date: Jan 2007
Location: Portland, OR
Default not really Ben's 89' RSI 245

Flickr Album in no order: https://flic.kr/s/aHsksF7ygk
1989 Volvo 245
First things first. I didn't build the car into it's current form. That was done under the ownership of stereophile33/Johnathan/old RSI shop owner. It was originally built up between 2010-2012 ish...built and used as a product research/demo car for many fab jobs by Eric M/fab guys at RSI. Mainly it was Johnathan's DD.
Car was sold in 2013, used, clutch issue came and fixed around 2015 time-frame (265 Hydro clutch/spec stageV)
Hopped around a few owners in mid west between 2014-2016 - then sold to a guy in Chicago by his buddy....none of this really matters.
Fast forward to July 2017. I was living and working overseas in Oman, which is to the east of Saudi Arabia/Yemen. Car came up for sale on bringatrailer.com after months of searching for the SAME wagon. I'd put up a wanted ad for a built up wagon and had been checking prospects out for around 9 months. Won the car, flew to Chicago, drove car from Chicago to Portland, Oregon.
BringatrailerWagonRoadTrip
Walmart mattress instead of hotels along the way obviously....looking back this was a great opportunity to purchase a nice camping/portable sleeping solution....live and learn.
20170827_120046
Road Trip Volvo 240

It barely made it due to sitting with E85 in it's system at some point (gummed injectors, took 6 cleaning cycles). This also led to some wonderful fuel spray experiences, many O rings and a disposition towards E85.
Poly Strut mount degredation

Made this face a lot along the way due to all the fun clogged injectors
20180621_170530
So the car came home and sat both outside and in storage while I visited Portland a few times over this last year.

Specs upon build


Engine:
2.5l B230F + T by RSI
RSI 86mm Billet Stroker Crank
RSI 158mm H-Beam Connecting Rods
RSI Waveguide 8v Turbo Pistons
Cometic MLS Head Gasket
RSI Stage 2+ Cylinder Head Prototype
RSI Race Valvetrain Kit
RSI Stage 3 Turbo Cam Prototype
RSI Square Tooth Adjustable Cam Gear
RSI Twin Scrool SS Turbo Header
RSI Poly Engine Mounts
Twin Tial MVS 38mm External Wastegates
Greddy Type S Blowoff Valve
Holset HX40/Garrett Hybrid Turbo
Isuzu NPR Intercooler
NIW Motoring Intake Manifold
Megasquirt 2 EMS
Mitsubishi Coils
Injector Dynamics 1600cc Fuel Injectors
Drivetrain:
RSI Lightened Flat Flywheel 14 lbs
Clutchnet Stage V Clutch
RSI Bellhousing Adapter Plate
BMW Getrag 264 Transmission
RSI Getrag Shifter for 240
RSI Bronze Shifter Bushing Kit
RSI Dual Poly Mount Getrag Crossmember
Detroit Truetrac LSD
Suspension/Brakes:
RSI Short Strut Coilovers
RSI Adjustable Rear Spring Perch Kit
Koni Adjustable Shocks
IPD 28mm Front Sway Bar
Noltec Street Camber Plates
RSI Superpro Poly Bushing Kit
RSI R-Brake Kit 13" Front Brakes
RSI 240 Strut Tower Brace
Exterior:
E-Code Glass Headlights
3k 55w Raptor HID Kit
European "Eggcrate" Flathood Grill
90+ Flush Glass Tailgate
90+ Windshield w/ Flush Molding
ESM-002 17"x7.5" Silver Mesh Wheels
RSI 32mm Wheel Spacers
Custom Flared/Rolled Fenders
Interior:
Sparco Torino Seats
Sparco 383 Suede Steering Wheel
Sparco 4-point Street Belts
PLX Devices DM6 Touch Screen Wideband
VDO Boost Guage



May 2018- I finally quit job overseas. Come home to 245 awaiting...many fixes and parts.
Awaiting Parts
More Parts

Basically the car had minimal maintenance done over the last few years and I have been working on the car over the last month getting her back to snuff as well as personalizing.

I installed some stereo hardware. A minimal but effective sound system in my book. I also installed a 45wx4 alpine KTPU445 headunit amp for some compact power. 4 speakers and a sub with most of the Hz range covered decent enough. Up front I installed a newer media alpine deck. HD149BT
Alpine HD149BT

I installed some 5.25" Component type R's, been waiting over 6 months on Kaplhenke to push out their aluminum speaker grills/brackets...
Alpine Type R

Then some Focal PS 165's for the rear doors, still unsure about the functionality/long term placement of the external tweeters.
Focal PS 165

Then finally an Alpine PWE-S8-if you can find it.
CarChest

Exhaust was also an issue for me as it was too loud to hear any music at speed, which is huge for me....so it started with 3" turbo back with a single resonator which had blown out its material...went through two trials before ending up with this= DOWNPIPE--> SMALL RESONATOR --> QTP EXHAUST CUTOUT/ACTUATOR --> HIGH FLOW 200 CELL CAT --> LONG RESONATOR --> LARGE MAGNAFLOW
Exhaust 3 Volvo 240Exhaust 2 Volvo 240Exhaust 1 Volvo 240Switchie

So now I can have it pretty quiet for cruising or.......VIDEO
Volvo 240 Oregon Coast WOT

June 2018 - A/C compressor replaced, All new V belts, new custom oil cooler lines, ipd skid plate install, ipd strut-firewall braces, winter mats, air filter, timing belt, water pump, FPR bracket, dash mat.
Fast Specialties/Travis


July 01 2018-
The car currently sits in the street while the head and turbo are in the shop. Ever since I bought the car, it has had a loud valvetrain, and the engine's seen about 50k so far. Good time for a turbo rebuild and to head servicing.
Exhaust parts buildupHead off 2
Oil Cooler/skidplateDriveway Durham


My plans are to move to LA in the next week or two depending on when I get the head/turbo back and can get the car back on the road. Still have some kinks to work out listed below...but I'll discuss those in the appropriate threads.


Issues/projects:
Fog light install
Reinstall head/turbo/tune
fix erratic cluster issues - gas, rpm, speedo
Install a/c pusher fan to high pressure switch
Engine bay heat- wrap header/turbo blanket?
Purchase/install better headlight wiring kit for HID's
Figure out turbo controller issues
install alarm system/2 way

Ben
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89' RSI 245
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Last edited by papsimagoo; 07-01-2018 at 02:43 PM..
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Old 07-01-2018, 04:09 PM   #2
dl242gt
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Good find Ben. Looks like it's in great condition even with the needs. My noltec camber plates separated the same way. I want to get a set from Kaplhenke.
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Old 07-02-2018, 03:43 PM   #3
reiernumans
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AWESOME car. Going to follow this one.

Also, very nice inspiration on the audio and exhaust work. I did a similar functional but not too wild audio setup in my Saab c900, planning on doing a somewhat similar style exhaust too.
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Old 07-02-2018, 06:24 PM   #4
t8fanning
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Looks good. You should be making some power when it's back together. Can't wait to see it.
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Old 07-03-2018, 12:57 AM   #5
122power
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gonna register it down here or no? The roads here suck fyi
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Old 07-04-2018, 01:38 AM   #6
papsimagoo
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Originally Posted by 122power View Post
gonna register it down here or no? The roads here suck fyi
Gonna rock Oregon plates in socal until I either find a guy and way around vehicle visual inspection...or I'll man up and temporarily swap stock stuff back in... I'm just not able to tune with MS yet and don't want to to source all these stock parts and spend that time for a sticker.
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Old 07-04-2018, 02:33 AM   #7
122power
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Umm better keep your plates. 89 240's never had turbo.
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Old 07-04-2018, 02:36 AM   #8
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make it a diesel title
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Old 07-04-2018, 02:36 AM   #9
122power
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Shhhh. Giant tank in back. Runs on Propane.
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Old 07-04-2018, 11:07 AM   #10
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Awesome wagon, I've seen it here before and always thought it was tastefully built!
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Old 07-04-2018, 02:13 PM   #11
swedishiron.com
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Is there something actually wrong with the turbo?
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Old 07-05-2018, 01:14 PM   #12
papsimagoo
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Turbo had some play. Saw oil in dp, Johnathan told me turbo liked to leak a lil but this was a decent amount and like to be proactive ~50k on engine...saves me from another down time in the future.
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Old 07-05-2018, 03:07 PM   #13
John242Ti
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Better yet, register it in Washington. Yearly tabs yes, but no emissions at all for the car.
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1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
Formerly Blue245Ti, 245GT-Turbo, and, originally 242GT-Ti.
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Old 07-05-2018, 03:10 PM   #14
122power
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Prolly cheaper too. Its 120 a year here plus plate fee, inspection fee, title fee, value excise fee, tax for what you paid for it fee etc. Prolly be around 250 by the time you get done I bet. Plus gas is more and can only get 91.
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Old 07-06-2018, 08:14 AM   #15
slow240
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Quote:
Originally Posted by dl242gt View Post
Good find Ben. Looks like it's in great condition even with the needs. My noltec camber plates separated the same way. I want to get a set from Kaplhenke.
I had a set of noltecs back in the day and they did the same thing, I wound up cleaning all the poly off and welding the two pieces together. Then before I ever got to run them again they perished in a garage fire lol
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'81 242t, DD, project, epic funmobile.
build thread; http://forums.turbobricks.com/showthread.php?t=251729
'92 244. 601 red, stock, awesome.
http://forums.turbobricks.com/showthread.php?t=292524
'92 245. 601 red, stock, awesome.
'90 244. blue, tall, ghetto, fabulous.
http://forums.turbobricks.com/showthread.php?t=310740
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Old 07-07-2018, 02:27 PM   #16
dl242gt
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Quote:
Originally Posted by slow240 View Post
I had a set of noltecs back in the day and they did the same thing, I wound up cleaning all the poly off and welding the two pieces together. Then before I ever got to run them again they perished in a garage fire lol
We all should have known to buy the all metal race version. The suspension bushings I bought also had the poly fail turning into crumbled poly bits.
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Old Today, 03:36 PM   #17
papsimagoo
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July 17th 2018--

Head/turbo rebuilt and everything put back on and running well EXCEPT for this valvetrain (hopefully) noise. but part of me thinks it may be a wristpin/worn ring....VIDEO BELOW VV---The car was making "this" noise before the rebuild, though I think it seems more pronounced due to a lower noisefloor from the rebuild/exhaust wrap/rebuild. Hmmmm not happy scared to drive car.



Besides that though I wrapped the exhaust and had some small cracks seals beforehand. Used DEI titanium wrap, about 90 feet for the whole system. Impressive engine bay temp difference which is great for my inlet location.
20180715_072927

Had the turbo rebuilt by diesel fuel injection services here in Portland, (They do a ton of Portland's turbo work) with a new H1C cartridge.
Head "rebuilt" by M & B. Exhaust seals replaced, hot tanked, reused old valves as they looked good. Trimmed/reamed, shortened just a bit.

NOS shifter foam installed (dremel + foam for a good fit) I also installed a Revers 1st 3rd and 5th "neutral" safety switch. Only I drive the car and I'm leaving a switch to disable remote start functionality for whomever. Man oh man did that foam quiet down my interior! Could also be due to wrapping exhaust/manifold.
20180707_181843
20180707_182353
VIDEO ^^
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