not really Ben's 89' RSI 245

[papsimagoo]

Flickr Album in no order: https://flic.kr/s/aHsksF7ygk

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.

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.



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.


Made this face a lot along the way due to all the fun clogged injectors

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.



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


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


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


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


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


So now I can have it pretty quiet for cruising or.......VIDEO


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.



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.




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

[dl242gt]

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.

[reiernumans]

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.

[t8fanning]

Looks good. You should be making some power when it's back together. Can't wait to see it.

[122power]

gonna register it down here or no? The roads here suck fyi

[papsimagoo]

Originally Posted by 122power

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.

[122power]

Umm better keep your plates. 89 240's never had turbo.

[Jack]

make it a diesel title

[122power]

Shhhh. Giant tank in back. Runs on Propane.

[Vol242vo]

Awesome wagon, I've seen it here before and always thought it was tastefully built!

[swedishiron.com]

Is there something actually wrong with the turbo?

[papsimagoo]

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.

[John242Ti]

Better yet, register it in Washington. Yearly tabs yes, but no emissions at all for the car.

[122power]

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.

[slow240]

Originally Posted by dl242gt

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

[dl242gt]

Originally Posted by slow240

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.

[papsimagoo]

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.


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.


VIDEO ^^

I also put on some fogs, silly since I'm moving to LA, but I've always liked the look and just in case part of me excuses it. A skidplate with PO masterful art, and a 16" SPAL pusher fan I'm still deciding what to wire to for LA. Thinking dash switch and wired to the high pressure AC switch (This has a 93' AC system)

[John242Ti]

Might be a noisy shim bucket. In person, does it sound like a loud "TAKKA-TAKKA" noise?

[papsimagoo]

Watch the video if you can, yes it's harmonics sound like a "tak" but I've been told that can totally be skewed internally...I got down low but not ear to oil pan.. I'm by myself so I might grab a neighbor to listen while underneath, usually doesn't "tak" until rpm get about 1500 and above, aka need helper or grabber arm for throttle from under car. Gonna go fondle valves with my feelers now.

Update:
Valve clearances
Starting from front of car.
1- .002-.003”
2- .009- .010
3- .006
4- .006-.007
5- .007
6- .007
7- .009- .010
8- .007

[papsimagoo]

Pulled the head again today, got stainless valves 40/48. Got lucky with some local KL racing 40mm exhaust, though I will for sure go inconel next time. Measured the cam... 47mm lift and ~36mm base circle. So I'm excited the cam is not a larger base circle and I can sell cam. Gonna go for something more tame like an IPD turbo cam for a stronger idle as well. Mine dies easy with no IAC and trying to regain some fuel economy.

[stick70]

Badass. This is a nice car dude.

[t8fanning]

Originally Posted by papsimagoo

Pulled the head again today, got stainless valves 40/48. Got lucky with some local KL racing 40mm exhaust, though I will for sure go inconel next time. Measured the cam... 47mm lift and ~36mm base circle. So I'm excited the cam is not a larger base circle and I can sell cam. Gonna go for something more tame like an IPD turbo cam for a stronger idle as well. Mine dies easy with no IAC and trying to regain some fuel economy.

Looking good! You really should use a bigger cam than the IPD turbo. You'll want the power eventually. My idle varied very little between the IPD turbo and RSI stage 3. Idle quality and fuel economy are all in the tune.

Also, what's the reason for no IAC?

[papsimagoo]

Cam profile, large base circle, the plenum intake, overlap and the car didn't have one put in. I'll drive both, and be dealing with LA traffic so an IAC might turn into a must. I still have the stage 3 if I'm not a fan.

[77volvo245]

ipd cam kinda small for your set-up i wouldn't change the cam imo

[t8fanning]

I agree. Just keep the stage 3 in. You won't regret it. That's what I use and our setups are pretty similar. You really should put in an IAC. It helps a ton.