home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > projects & restorations

Reply
 
Thread Tools Display Modes
Old 05-19-2018, 09:33 PM   #451
PeaceEngineered
Sarcastic Optimist
 
Join Date: Sep 2015
Location: Evanston, IL
Default

Awesome. Congrats! Do you do this type of work for a living? At least some artistic expression?
__________________
2006 V70R a turbo finally!
1989 245 'Angry Moose' 5.0 GT-40 with T5 transmission.
2009 S80 Interim Road Trip Car
PeaceEngineered is offline   Reply With Quote
Old 05-19-2018, 09:48 PM   #452
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Quote:
Originally Posted by PeaceEngineered View Post
Awesome. Congrats! Do you do this type of work for a living? At least some artistic expression?
I’m an integration engineer with a satellite antenna company in Seattle. I’m basically responsible for putting our antenna into/onto things that move.

Last edited by Atom D&D; 05-21-2018 at 07:26 AM..
Atom D&D is offline   Reply With Quote
Old 05-20-2018, 06:14 PM   #453
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Here’s some of the stuff I did previous to iPd

\\\———————————————///

Splitter:

Atom D&D is offline   Reply With Quote
Old 05-20-2018, 06:14 PM   #454
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Spoiler:

I’ve always wanted to build a hatch spoiler for this car. The first thing I did was make a template of the contour of the top of the hatch out of 1/4” MDF. Then, when I had it shaped the way I wanted, I made several copies with the table router to create a mold to do the top part of the spoiler.



Easiest way to make a part off this is to glue down some foil and spray it with PVA mold release.



Then I vacuum bagged a layup of two layers carbon and two CSM fiberglass layers.



Then I figured out about how much I wanted it to stick out and trimmed it to match the contour of the hatch opening. Adding holes to access the hatch mounts.



Next I masked off the top of the hatch. The tip here is to plan ahead. Lay down some double backed tape and mask over that. That will create space for adhesive later.



Next I laid down three layers of CSM fiberglass and while it was still wet I added the top layer.



Once dry, trim and check fit.



Next, tape off all the outside surfaces and add two part expanding foam. Then shape with razor knife and sandpaper (shapes easy)



Then I brushed on a layer or two of fiberglass resin to create a skin then bondo smooth



Next, mask off (again) all the outer surfaces and add multiple layers of masking tape around the edges. Then I gently (so it doesn’t crush the foam) vacuum bag two layers of carbon to the bottom.



The reason for multiple layers around the edge is so that you can grind the new carbon back around the perimeter until you get to the tape and the other surfaces will be safe.



Next comes a couple layers of clear gel coat. Interesting note: fiberglass resin is air inhibited. Meaning that it stays tacky when exposed to air so that you can add layers and have them stick to each other. In my experience, if you want a surface cure on your gel coat, you can spray PVA over the gel coat and it’ll seal the surface. Then when you sand the PVA will peel off.



Once it’s sanded flat, I clear coat with automotive clear to add UV protection.



Then it’s time to install. I use a combo of 3M tape (now stick) and urethane adhesive (long term stick).



Rinse, dry, repeat. The whole process took about a week of mornings and evenings in between trying to troubleshoot my cooling issues. It’s not perfect, but it sure is good enough.
Atom D&D is offline   Reply With Quote
Old 05-20-2018, 06:15 PM   #455
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

DIY BBK:

Stock rotor/caliper



This pic is important because with this offset wheel on this particular car, I can’t run a spacer any thicker than 5mm



So, I measured the distance between the ball joint and the back of the rotor and started searching for something in the diameter I wanted (330mm) with a center bore larger than the E30’s (so I can use centering rings instead of machining our the rotors) and had a deep enough “hat” to push the rotor back towards the tie rod end.



Turns out 2014 Jeep Cherokee Sport rotors fit the bill. Available from AutoZone for +/-$75 each.



I used four piston Wilwood calipers bought from JEGS for $125 a piece (pads were an additional $50 and they have WAYYYYY too many compound options). Then I made some aluminum adapters on my CNC router and bolted them on. I bought Empi adapters to convert the 1/8” NPT opening on the calipers to M10 bubble flare ($28 a pair) and used some Volvo stainless brake lines I had around from a C30 (you might be able to use the stock E30 lines since they are M10 bubble flare, but the length is iffy)



Notes/disclaimers:
-Yes, I’m aware that it will upset the brake bias of the car. I’m ok with that. I don’t track it, but I LOVE big brakes (and I cannot lie)
-The pad surface is about 25% bigger than an E30’s, but it still only uses the outer 2/3 of the rotor. I’m ok with that too. I’m on a budget and clearances were tight. Plus, if you’re only gonna catch 2/3, it’s best to be the outer 2/3
-I need to put a bigger bore master cylinder in. There’s more travel in the pedal than I’d like. I’ve read there’s a 25mm upgrade that came OE on another BMW. I’m gonna look into that

Gains:
-More pad area
-Increased moment
-More piston clamping area
-More rotor mass for heat dissipation

-I don’t think brake fluid is supposed to look like this



That came out while bleeding the rears.
Atom D&D is offline   Reply With Quote
Old 05-20-2018, 06:16 PM   #456
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Next is something annoying, but simple. Defrost ducts:

You don’t think about stuff like that until only the center of your windshield defogs from air just passing up through holes in the dash. I still have to make the part that connects the heater box to this diverter, but it’s a start.

My hand built “hot work” station. This was the oven out of my house when we remodeled. I use an Eastwood powdercoat gun and a made a vacuu-forming jig



I basically have a wood frame to clamp the plastic in that fits in the shelf spots in the oven. Then I wired up a receptacle to a push button that turns on the shop vac when you push down on the frame.



https://youtu.be/tzWrbcK0wUc



That’s it for now.
Atom D&D is offline   Reply With Quote
Old 05-20-2018, 06:36 PM   #457
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default



Last time I took this picture, Headquarters was on a trailer. Feels much better this time.
Atom D&D is offline   Reply With Quote
Old 05-20-2018, 07:03 PM   #458
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Expansion tank:

The discolored plastic tank drove me crazy and they’re over $100 for a replacement, so I made my own.

Atom D&D is offline   Reply With Quote
Old 05-20-2018, 09:20 PM   #459
NONHOG
equal opportunity car guy
 
NONHOG's Avatar
 
Join Date: Oct 2008
Location: Tacoma ish
Default

That tank is like a modern Ford Thunderbird tank, love it!
__________________
_____________________________________________
80 Bertone (part-time driver) learn how to 5.0-Volvo here.... http://forums.turbobricks.com/showthread.php?t=250257
B20 sound! https://www.youtube.com/watch?v=6FpMWALskko
NONHOG is offline   Reply With Quote
Old 05-21-2018, 05:15 AM   #460
Finnish240
Board Member
 
Finnish240's Avatar
 
Join Date: May 2011
Location: Finland
Default

That splitter and spoiler do look awesome! I need splitter like yours under my 240!
__________________
Volvo 240 GL - not so low, but yes.... it is slow
Finnish240 is offline   Reply With Quote
Old 05-23-2018, 12:56 PM   #461
Vol242vo
Board Member
 
Vol242vo's Avatar
 
Join Date: Feb 2005
Location: Spokane, WA
Default

You are extremely talented, I only wish I had a portion of your knowledge and skill. Superb build.
__________________
Derek - 1980 242
Vol242vo is offline   Reply With Quote
Old 05-23-2018, 01:11 PM   #462
Stiggy Pop
Board Member
 
Stiggy Pop's Avatar
 
Join Date: Feb 2011
Location: Granville, MA
Default

The spoiler is definitely impressive, very cool.

That expansion tank was just begging to be polished though!
__________________
'79 242
943 pickup
Stiggy Pop is offline   Reply With Quote
Old 05-24-2018, 05:45 PM   #463
volvobrage
Board Member
 
Join Date: Jan 2011
Default

So much awesome work here!:D
volvobrage is offline   Reply With Quote
Old 05-24-2018, 06:47 PM   #464
PeaceEngineered
Sarcastic Optimist
 
Join Date: Sep 2015
Location: Evanston, IL
Default

Quote:
Originally Posted by Atom D&D View Post
I’m an integration engineer with a satellite antenna company in Seattle. I’m basically responsible for putting our antenna into/onto things that move.
They are lucky to have you. And I am envious of the forming tools at your disposal. I have been eyeing vacuum kits. Good stuff.
Quote:
Originally Posted by Stiggy Pop View Post
The spoiler is definitely impressive, very cool.

That expansion tank was just begging to be polished though!
Meh. Then one must keep polishing it! The copper would be cool polished too, but patina works as well. Keep it simple (as simple as this car can be- haha)
PeaceEngineered is offline   Reply With Quote
Old 05-25-2018, 03:57 PM   #465
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

https://jalopnik.com/true-hero-swapp...bmw-1826320988
Atom D&D is offline   Reply With Quote
Old 05-25-2018, 04:04 PM   #466
doucheNozzle
Newbie
 
doucheNozzle's Avatar
 
Join Date: Feb 2009
Location: The Pitt, 15147
Default

Just read that
__________________

'99 V70 NAA - So Slow
'04 V70 T5A - Feels Fast
doucheNozzle is offline   Reply With Quote
Old 05-26-2018, 11:31 PM   #467
fortbrick
Board Member
 
fortbrick's Avatar
 
Join Date: Jan 2012
Location: Indiana
Default

Not sure if this has been covered yet, but when undertaking a project like this - do you have to apply for some sort of custom title and have a new vin number, or is one of the two original vins retained?

Always enjoy seeing anything new involving this car!

Andy
fortbrick is offline   Reply With Quote
Old 05-27-2018, 01:07 AM   #468
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Quote:
Originally Posted by fortbrick View Post
Not sure if this has been covered yet, but when undertaking a project like this - do you have to apply for some sort of custom title and have a new vin number, or is one of the two original vins retained?

Always enjoy seeing anything new involving this car!

Andy
It’s licensed as the Volvo. This was via the guidance of the DOL here in Washington. They said it “could” be a different story if either car had not been more than 25 years old and therefore emissions exempt. The way I understood it the state wants the records to match the body of the vehicle for reporting reasons (either the plate being run or an APB/BOLO for the plate number).
Atom D&D is offline   Reply With Quote
Old 05-27-2018, 09:52 AM   #469
fortbrick
Board Member
 
fortbrick's Avatar
 
Join Date: Jan 2012
Location: Indiana
Default

That makes sense! Good to know. I hadn’t thought of how emissions might interfere.
fortbrick is offline   Reply With Quote
Old 05-27-2018, 10:59 AM   #470
matt b
Board Member
 
Join Date: Apr 2007
Location: Tucson
Default

A friend sent me the article and asked if I knew of the car. He's a rocket engineer with Ratheon and he was very impressed with your work.

As others have said: your fab skills speak for themselves and most of us wish we had even a fraction of your creativity and fabrication skills. Mad props Adam, I love reading this thread and seeing what you're doing with the car.
matt b is offline   Reply With Quote
Old 05-27-2018, 08:52 PM   #471
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Quote:
Originally Posted by matt b View Post
A friend sent me the article and asked if I knew of the car. He's a rocket engineer with Ratheon and he was very impressed with your work.

As others have said: your fab skills speak for themselves and most of us wish we had even a fraction of your creativity and fabrication skills. Mad props Adam, I love reading this thread and seeing what you're doing with the car.
I mostly just post so other guys can maybe see something and say “maybe I’ll give that a try”.
Atom D&D is offline   Reply With Quote
Old 05-27-2018, 08:52 PM   #472
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

Doing a little side work in exchange for car parts today.
Atom D&D is offline   Reply With Quote
Old 05-28-2018, 08:01 PM   #473
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default



3.73 limited slip. Gonna replace the clutches and seals before I throw it in.
Atom D&D is offline   Reply With Quote
Old 05-29-2018, 02:20 PM   #474
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

35lb/ft breakaway torque...... definitely needs clutches.
Atom D&D is offline   Reply With Quote
Old 06-01-2018, 09:26 AM   #475
Atom D&D
Board Member
 
Atom D&D's Avatar
 
Join Date: Jan 2010
Default

While I’m messing with other stuff and trying to round up cash for my diff rebuild I started thinking (like I always seem to do) “what can I do to upgrade this?” I looked at finned diff covers, but those prices are crazy! So I made a set of bolt on cooling fins. Will the heat transfer be the same....no, not at all. Will it actually do anything....no idea. I do know that thermal mass and conduction “could” play a part in this cooling the diff, but mostly it just kinda looks cool.

“I mustache you a question about diff fins”



Also, my thought was by thinning it out some at the mounting ears if I clip something the fins can be sacrificial and break off. Then I can just bolt another set on.
Atom D&D is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


All times are GMT -4. The time now is 06:58 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2018, vBulletin Solutions Inc.