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Old 01-23-2022, 03:28 PM   #1
kcpaz
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Default 242 Turbo LS blah, blah, blah

Started out as a completely stock car with 150Kmi. Bought it with the intention of using it as a daily driver, and then "some day" do an LS swap. Well... it ran well for the first few weeks, and then it started running like garbage. Spent a bunch of time and resources trying to fix the issues, and determined that I had no interested in working and maintaining on a K-Jet car... so out with old, and in with the new.

The goal was to build a nice driver, with good power and reliability. Saving money where I could, but spending money where it matters.

Didn't take any pictures of the car with the OEM Virgos on it. It needed new tires anyway, and since I had a set of Style 42's from a previous BMW project (free), and some new take-off tires from a FR-S race car build (free), these were mounted so the car could be driven/rolled around.


Also swapped out the original seats for some seats that came out of the previously mentioned FR-S (free). Made the car so much better to drive


Stock engine bay. Looking back on it now, I sort of feel bad about "hacking up" such a nice example of a relatively rare car. I didn't realize how what I had at the time. I just bought the car because it reminded me of the many Volvo 240's that my family had growing up. I wasn't really a "Volvo guy"




Last edited by kcpaz; 01-23-2022 at 04:05 PM..
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Old 01-23-2022, 04:00 PM   #2
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I never really liked the look of the coffin hood cars, so I sourced a flat-hood conversion and some quad-rounds
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Old 01-23-2022, 04:24 PM   #3
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The engine is an aluminum 5.3 (LM4) out of a Buick Rainier with 148k mi that I able to source for $500. Since that's what I was able to sell the Volvo engine for, I consider this engine a freebie. Unfortunately the Holley manifold didn't fit under the hood, so I sold that and bought a Speedmaster unit. I decided to use the GM Performance CTS-V accessory drive kit. Expensive, but I didn't want to waste time piecing together a bunch of used stuff



STS engine mounts to get it bolted in, and then I modified the stock trans mount to work with the TR6060 trans that I was able to score for $800. It had a very small puncture in the tail housing that I was able to weld up without removing anything.


I had a left over (free) Bimmerworld shifter from another BMW build that I was able to retrofit with an adapter plate, and a hybrid shift rod.




I had a left over radiator core from a production run for another vehicle, so I made up a custom double pass radiator that uses the OEM mounts.


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Old 01-23-2022, 04:42 PM   #4
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Started fabricating the hot side of the turbo kit. All of the material is 304 stainless and fully back-purged. Apparently I didn't take very many pictures of this process. The turbo is a Garrett GT4092 with twin scroll housing. Wastegates are TurboSmart Comp-Gate 40's, recirculated back through the exhaust to keep things quiet. THe post-turbo exhaust is 3.5", and it was a very tight fit between the firewall and trans bellhousing. Some hammering may have been involved...






[img]htt[img]https://i.imgur.com/HFs44bpl.jpg






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Old 01-23-2022, 05:00 PM   #5
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Intercooler system started with a Garrett bar/plate core (18"x11.2"x4.5"), and a bunch of 3" aluminum mandrel bends, silicone couplers, and a Turbospart Raceport BOV. I'm beginning to think I have ore pictures on an old phone (I started this build in 2016) because I don't have any pictures of the intercooler itself on the fab bench.






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Old 01-23-2022, 05:22 PM   #6
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Rear suspension. I wanted to stick with OEM style rear suspension rather than do the whole coil-over thing, but I wanted to have adjustable suspension. So, I modified the lower arms, made custom upper arms, and modified the OEM panhard bar to make it adjustable. Then everything got poly bushings and rod ends were applicable. The axle is of course a narrowed 8.8, tubes welded to the housing and everything straightened after welding, and I reused the Volvo brackets and reinforced/boxed them. Because the car was meant to be a daily driver, and will never really be lowered all that much, I decided to beat the hell out of the transmission tunnel to make room for a one-piece aluminum driveshaft. At full bump, its a VERY tight fit.










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Old 01-24-2022, 01:27 AM   #7
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I love everything about this build but especially this.

Quote:
Originally Posted by kcpaz View Post
I never really liked the look of the coffin hood cars, so I sourced a flat-hood conversion and some quad-rounds
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Old 01-24-2022, 01:32 AM   #8
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I love everything about this build but especially this.
Honestly, that's one of my favorite things too.
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Old 01-24-2022, 01:44 AM   #9
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Honestly, that's one of my favorite things too.
I'm running the same set up. Beautiful ugliness.
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Old 01-24-2022, 01:46 AM   #10
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I'm running the same set up. Beautiful ugliness.
exactly
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Old 02-07-2022, 10:07 PM   #11
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Quote:
Originally Posted by kcpaz View Post
I never really liked the look of the coffin hood cars, so I sourced a flat-hood conversion and some quad-rounds
The car will look great when you're done, with all the nice touches you're adding - the headlights, I think it's funny how everyone wants the flat hood/round light setup - those look like more of an afterthought of how to deal with the US regs than the quad Wagner bulbs ever will - all that black void around the bulbs...
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Old 02-07-2022, 11:59 PM   #12
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Originally Posted by lookforjoe View Post
The car will look great when you're done, with all the nice touches you're adding - the headlights, I think it's funny how everyone wants the flat hood/round light setup - those look like more of an afterthought of how to deal with the US regs than the quad Wagner bulbs ever will - all that black void around the bulbs...
For me, it has to do with the fact that I’ve always loved the front end styling of the E30 BMW’s, and the flat hood/quad-round set up is like Volvo’s version to me.
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Old 02-08-2022, 01:27 AM   #13
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Originally Posted by lookforjoe View Post
The car will look great when you're done, with all the nice touches you're adding - the headlights, I think it's funny how everyone wants the flat hood/round light setup - those look like more of an afterthought of how to deal with the US regs than the quad Wagner bulbs ever will - all that black void around the bulbs...
Not a fan of single round. I love both double square and round. The round e-code lamps are better for sure especially if you add a relay. Its like having modern headlights.
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Old 02-20-2022, 07:18 PM   #14
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Had a randomly warm day today, so I started stripping the paint. Chemical strippers did absolutely nothing to the OEM paint, so I'm abrasive stripping everything. Found a few hidden dents under some body filler but nothing terrible. As I suspected based on the paint checking, the car was resprayed at some point from the belt molding up. Not wanting to risk any adverse reactions between the original paint and new top coat, I decided bare metal was the way to go.





Still a long way to go, but this was a good start. Need to remove the rest of the glass, door handles/locks, wipers, bumpers....
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Old 01-23-2022, 04:18 PM   #15
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Fix that k-jet and get it running good while building your motor and gathering parts in the meantime, not a whole lot to these systems and once they're going they don't stop going. Damn minty car though!

Edit:spoke too soon
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Old 01-23-2022, 05:55 PM   #16
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Good stuff!

I left my old 3" exhaust on the car (with 2 mufflers). It's somewhat stealthy off boost, it's not all that loud. Of course, it sounds like a V8. But the wastegates are hooked up to screamer pipes that dump out in front of the front crossmember, so it's not as corked by the 3" exhaust. But it gets loud and nasty sounding with the wastegates open.
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Old 01-23-2022, 06:10 PM   #17
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Good stuff!

I left my old 3" exhaust on the car (with 2 mufflers). It's somewhat stealthy off boost, it's not all that loud. Of course, it sounds like a V8. But the wastegates are hooked up to screamer pipes that dump out in front of the front crossmember, so it's not as corked by the 3" exhaust. But it gets loud and nasty sounding with the wastegates open.
I've tempted to delete the big suitcase muffler. Sometimes I wish it was louder, but I always talk myself out of it. Maybe I'll find a way to add an electric cut-out some day.
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Old 01-23-2022, 06:27 PM   #18
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I ran V70R calipers up front with the STS brackets, but I wanted to be able to run the V70R rear calipers too. Whipped up a quick bracket for the 8.8 axle, and drilled the axle shafts for the BMW bolt pattern. Make a hubcentric adapter to go from the Ford diameter to the BMW diameter, and used BMW E46 rotors and bolted everything up. For engine management, I went with an AEM Infinity ECU and wiring harness. Then modified the stock cluster housing to be able to mount an AiM MXS display behind the original lens for a stealth look. Then it was a simple CAN connection between the two and a GPS antenna for speedo. All of the analog dash gauges are functional as well.









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Old 01-23-2022, 06:09 PM   #19
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That is some beautiful work my friend. I look forward to seeing your progress
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Old 01-23-2022, 06:17 PM   #20
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When you upgrade turbos can I have that beautiful manifold? I got a couple V8s that could use some Chinese bois
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Old 01-23-2022, 06:29 PM   #21
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When you upgrade turbos can I have that beautiful manifold? I got a couple V8s that could use some Chinese bois
HAHA, I'll let you know.
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Old 01-23-2022, 06:46 PM   #22
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Pulled everything out. Resealed the engine. Had the heads surfaced. Lapped the valves, replaced valve stem seals, installed PAC 1218 springs and Sloppy Stage II cam. Added ARP head studs, OEM LS9 twin disc clutch with aluminum flywheel to work with the 6 bolt crank. This clutch holds all the power, but allows for super smooth engagement, and a super light pedal push just like a modern, stock car. I also took the time to repaint the engine bay, and wind a boat load of header wrap around the hot bits of the exhaust.











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Old 01-23-2022, 06:58 PM   #23
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Some final assembly...







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Old 01-23-2022, 08:07 PM   #24
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Lots of boring details later, it was running, and moving under it's own power again. In August of 2019, it was finally ready for dyno tuning. Also decided to quickly recover the rear seat with some material I had laying around. Eventually I'm gonna have the all of the seats recovered so they all match. The dyno results...
Some Youtube videos beols


On 91 pump gas, it made 587whp, and 534lb/ft
On E85, it made 706whp, and 638lb/ft





https://youtu.be/GoCqOsua9Ew

https://youtu.be/SQjYUjxmzYo

https://youtu.be/w3A3Vjcdl5s

https://youtu.be/ha4yNweX_Dc

https://youtu.be/gTCFT5kOHqw

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Old 01-23-2022, 06:47 PM   #25
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Cool project and nice fab work.
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