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Old 09-16-2013, 01:41 AM   #1
Karl Buchka
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Default The Buchka 242 Street Car

Alex and I have been talking about doing a simpler project for a while. Something closer to stock that we can screw around with and not be too serious with.

We've had an '83 242DL roller sitting around and when we came across a B234f with a T5 attached, it seemed like a good opportunity to realize the idea. Alex went to California in late June, so I've been solo on this one for most of the build. I've also been working in Boston. With the car down at the shop on Cape Cod I've only been able to work on the car itself during the weekends.

So here are the basic specs:

B234f
Yoshifab rods
Ported 90+, Yoshifab adapter
Yoshifab valve springs
Shortened B234f intake manifold, 960 tb
T5wc, 4-puck disc, flat flywheel machined for 60-2
HX35, hogged out divider, enlarged internal gate
VEMS
800cc injectors
4" downpipe, 3" exhaust
4" core ebay IC

The "subject" at the shop, ready for surgery. The '83 DL is my favorite year and trim of the 240s. You get skinny bumpers, 5-panels, and no sunroof. This was originally a California car, so it's largely rust free.


B234f, as received. We were led to believe it was a solid engine that was ready to run. That turned out not to be the case. The valve cover was cracked and it was probably left outside for a number of months, which led to water ingress and rust on the cams and bores.


Alex tore the engine down and did an awesome job shortening the intake runners and porting it for a 960 throttle body.






Cleaned the pistons with simple green in the ultrasonic cleaner at work.


Yoshifab rods installed in the stock pistons.


The head itself is stock and has just been cleaned up. I nuked the valves in an ultrasonic cleaner and lapped them before installing them with Yoshifab springs.






Fabricated new engine mounts out of a hacked up torque rod. The vehicle side uses the front subframe pickup points.


Added a 60-2 to a flat flywheel in the CNC.


Upskirt of the HX35. Since I'm running a 90+ I have no use for the divided housing. I roughed it out in the mill and did the cleanup with a die grinder. Also opened up the wastegate port.


Mounted the IC and the 7" rounds from my old car.


Welded up some 3" tubing for charge pipes.


Added a compression fitting to the pan for an oil temperature sensor.


Plugged balance shaft ports. Turns out a 240 wheel stud with the threads cut off makes for a nice press fit plug.


Stripped and painted the block.


Got an uncracked valve cover from Poik that I added two baffled -10 vent fittings to.


BMRS ProGold -10 oil return, courtesy of Homer. There's also a Swagelok fitting on the header that I'll use to log exhaust backpressure.


Stripped, power washed, and masked off the engine bay.


Went with a Yoshifab-inspired battleship gray, with black behind the slam panel and headlight surrounds.


4" downpipe.


Mounted the VEMS, resistors, and fuse panel on a brushed sheet of aluminum. It bolts to the passenger side kickpanel.


Re-assembled and dressed.


Re-installed.




That brings us up to date. There are tons of little jobs that aren't pictured, but for anyone wanting a more detailed look, here's a link to the gallery where I've been keeping all the photos.
https://picasaweb.google.com/1091212...keStreetCar242

The photos I've posted here represent the last ten weeks or so. I have worked on the car literally every single day for that period. It's been a grind. Getting the engine in is a huge milestone. I'm looking forward to getting it on the road.
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Old 09-16-2013, 02:30 AM   #2
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Gonna be sweet!!!! You know I've been enjoying watching
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Old 09-16-2013, 02:48 AM   #3
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Nice work. Those engine mounts are interesting, I'm guessing they'd work for any redblock 240?
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Old 09-16-2013, 02:55 AM   #4
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Quote:
Originally Posted by Dauntless View Post
Nice work. Those engine mounts are interesting, I'm guessing they'd work for any redblock 240?
any b234 240.

i have to ask, why the b234? less work than b230 besides mounts? by the way very nice! cant wait to see more!
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Old 09-16-2013, 03:40 AM   #5
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Looks awesome, as always!
The welds on the pressurepipes are so beatiful

Any plans for suspension also?

Stå på!
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Old 09-16-2013, 03:41 AM   #6
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jeeeez... you do on one weekend where i need years for.. grml.. nice project..




One question.. did you drop in in the springs right on or did you measure seatpressure and do some shiming?
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Old 09-16-2013, 07:10 AM   #7
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Neat. I will be eagerly watching.
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Old 09-16-2013, 08:06 AM   #8
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Nice job guys, your idea of "simple" is more overdone than most here on TB, lo
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Old 09-16-2013, 09:42 AM   #9
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I like the BFH job on the strut tower.
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Old 09-16-2013, 10:08 AM   #10
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I won't be watching. This is ridiculous. DIRY?
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Old 09-16-2013, 10:16 AM   #11
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I had better ship that muffler, huh?
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Old 09-16-2013, 12:17 PM   #12
Karl Buchka
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Thanks guys!

Quote:
Originally Posted by 2fast242gt View Post
any b234 240.

i have to ask, why the b234? less work than b230 besides mounts? by the way very nice! cant wait to see more!
Yeah, that's pretty much it. The B234f was there, and it's got some nice features that you don't get on a B230. I wanted to do new mounts anyway. I hate stock 240 mounts.

Quote:
Originally Posted by volvobrage View Post
Looks awesome, as always!
The welds on the pressurepipes are so beatiful

Any plans for suspension also?

Stå på!
Thanks! Suspension is up in the air right now. I'll probably get some DIY coilovers together with some manner of camber plates. Kildea has a G80 that I can probably use and I've already got a set of adjustable torque rods from Homer.

Quote:
Originally Posted by MadDog_945 View Post
jeeeez... you do on one weekend where i need years for.. grml.. nice project..




One question.. did you drop in in the springs right on or did you measure seatpressure and do some shiming?
I didn't do any shimming. I made some cursory measurements of the installed height and it looked fine, so I'm not terribly concerned.

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I had better ship that muffler, huh?
Probably. :D
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Old 09-16-2013, 12:22 PM   #13
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no originality, no worksmanship. it's like you're not even trying.
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Old 09-16-2013, 12:34 PM   #14
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Looking great Karl.
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Old 09-16-2013, 02:04 PM   #15
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Bitchin'.
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Old 09-16-2013, 02:24 PM   #16
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Great idea on the engine mounts.
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Old 09-16-2013, 02:42 PM   #17
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Cool project! Put in an oil scraper/windage tray from a B204 for added cool factor
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Old 09-16-2013, 02:53 PM   #18
Karl Buchka
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Quote:
Originally Posted by Turbosteen View Post
Cool project! Put in an oil scraper/windage tray from a B204 for added cool factor
Sander tipped me off to those earlier. I tried to order one, but the part number is invalid in the US parts system. I'll have to get one when I go back to Sweden.
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Old 09-16-2013, 02:56 PM   #19
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very nice as usual, keep up the good work!
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Old 09-16-2013, 03:01 PM   #20
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so it's running today then, yes?
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Old 09-16-2013, 03:07 PM   #21
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Incredible work! Looking forward to updates.
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Old 09-16-2013, 04:20 PM   #22
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How do you manage to always make things look so easy,great thread
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Old 09-16-2013, 04:21 PM   #23
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This is nice.

Also nice DNF mod in the strut tower.
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Old 09-16-2013, 05:50 PM   #24
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Quote:
Originally Posted by Karl Buchka View Post
Sander tipped me off to those earlier. I tried to order one, but the part number is invalid in the US parts system. I'll have to get one when I go back to Sweden.
Would one of these fit?

http://www.crank-scrapers.com/Volvo.html
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Old 09-16-2013, 07:53 PM   #25
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Awesome!
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