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Old 05-02-2018, 09:29 PM   #126
oldschoolvolvo
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Been working on some things:

1) NVH reduction: I was tired of all the interior buzz / rattle that turned up after the T5 swap so I added some 40oz jute carpet padding in the cabin / trunk. This helped to lessen the idle noise of the transmission and the general road noise while driving. I systematically replaced all solid / poly bushings in the rear with rubber (except for the panhard rod). The most noticeable improvement came from replacing the BNE solid torque rods with the BNE Hybrid version which resulted in a major reduction in cabin noise. The car is much nicer to drive now. It still has the “decel rattle” on hard engine braking in the same rpm band as before, but the noise level has dropped significantly. I considered adding the Aerostar dampened slip yoke to my driveshaft, but IMO there is not enough slip yoke engagement with that unit (it is shorter than the normal T5 slip yoke). If I had my ds lengthened by 1.5-2” then I would run it and the decel rattel would probably be cured, but I’m ok with it as-is for now.




2) Turbo upgrade: I rebuilt a used 16T and paired that with a TD04HL conical turbine housing so I could use it with my current exhaust setup. I used a piece of 1/4" steel plate I had laying around to fabricate a re-clocked wastegate bracket. It's not pretty, but very functional. I also reused the 13C wastegate actuator. With my MBC I have the boost set at 10psi, AFR is ~11.8-12.0 in boost. I needed to reduce the preload on the wastegate a little bit to prevent boost spiking. With the same preload as the 13C it would spike to 12 and settle to 10. From a drivability standpoint, the 16T has a much smoother response than the 13C. In other words, the 13C had a noticeable "torque bump" when rolling onto the throttle. The 16T does not have this characteristic but has a more progressive power increase and the car feels like it has stronger acceleration than before and is more responsive at higher rpms. I know there is more benefit to be had by doing a 3" downpipe / exhaust / straight-exit turbine housing, but I'm pretty happy with the improvement as-is for now.



Wastegate opening comparison.


3) Headlight relay upgrade: I followed the Daniel Stern method of adding a H and L relay for the headlights. I did this more out of principle than need...it is nice to know that the headlight current load is no longer being carried through the headlight switch and also some of the ~40 yr-old wiring connections were quite corroded.

4) Added a wooden shift knob and a leather shift boot for a little class in the interior.



5) When I have 1/3 tank or less of fuel and the temp is 75*F or higher my fuel pumps get loud and the main pump sounds like it's pumping a bit of air. The fuel lines also get hot to the touch after driving for a while. If I fill up, the pumps are nice and quiet. I wonder if with the Kjet pump setup, the pumps are moving a lot more fuel than I really need and are heating/aerating the fuel at lower fuel levels. I am considering converting to a single DW in-tank pump and getting rid of the Kjet pumps.
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Last edited by oldschoolvolvo; 05-02-2018 at 09:35 PM..
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Old 05-02-2018, 10:51 PM   #127
Uncleknucklez
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Great update on this one Mike, I plan to finally slap on my 16T 3” DP this weekend, looking forward to it!

The fuel thing could be the rubber hose between the in tank and the pickup could be deteriorating or cracked. Below a certain fuel level the hose will be exposed and suck air and make the main fuel pump noisy. I’d check it if you haven’t replaced it.
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Old 05-03-2018, 04:52 AM   #128
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You might want to check out these roto joints. "The Roto-Joint is designed to work like a spherical rod end while maintaining streetable qualities of a softer bushing"

https://umiperformance.com/catalog/images/rotojoint.jpg

Either way great write-up on your project.
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Old 05-03-2018, 06:37 AM   #129
oldschoolvolvo
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Quote:
Originally Posted by Uncleknucklez View Post
The fuel thing could be the rubber hose between the in tank and the pickup could be deteriorating or cracked. Below a certain fuel level the hose will be exposed and suck air and make the main fuel pump noisy. I’d check it if you haven’t replaced it.
Good point..that hose should be ok b/c I replaced the in-tank pump a few years ago w/ the ipd "upgrade" pump and the hose supplied with the kit seemed stout and of good quality (and the proper fuel-submersible type), but it's worth checking I guess.
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Old 05-05-2018, 10:18 AM   #130
JW240
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Nice, lookin good!
Those tq rods are nice. I have similar but homemade and its very noticeable how the rear suspension works better for going fast and is still quite comfy at the same time.
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Old 05-09-2018, 11:25 AM   #131
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Great write up.
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Old 05-09-2018, 09:11 PM   #132
oldschoolvolvo
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Another comment about the 16T...the overall drivability is improved, seems like it has more torque out of boost as well. To me it is noticeable during hwy cruising. With the 0.68 5th gear, 70mph is ~2700rpm and previously small throttle inputs / hills were enough to start spooling the 13C, but now it generally stays out of boost but still feels torquey...if that makes sense.
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