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Old 09-27-2018, 05:29 AM   #1
Swedbrick
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Default The red 1986 745 build

Hi All, Since I'm new to turbobrick I thought I would create a thread to keep track of my progress on my track/daily red wagon, for myself and those interested. Here's what has been done thusfar:p

Engine Thread: https://forums.tbforums.com/showthread.php?t=345333

The start of it all, a clean 1986 Volvo 745GL with a b230k, pierburg (junk) carb and ezk118, m47 5-speed and a 945 interior swap.


The first step, some new wheels with new rubber, the switch to some hankook tires with decent rain performance was made, because well, the Netherlands to be short. I also liked the sirius wheel look, so the upgrade to alloy was also made.


At the yearly volvo convention, I found some hubcaps that fitted perfectly and where better looking than the stock option so I threw those on.


From there on it was time to get started with the performance upgrades, first up, a cluster capable of rpm indication.


Next up, a set of IPD progressive lowering springs


And I managed to find a set of cheap koni yellow rear shocks, just look at the difference with the stock gas struts

Last edited by Swedbrick; 10-11-2018 at 06:25 PM..
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Old 09-27-2018, 05:34 AM   #2
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Nice car! I hope you keep the ride height
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Old 09-27-2018, 05:43 AM   #3
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Default Second update

In order to keep my thread somewhat readable, I have split up the progress in two parts.

The next step was to upgrade the engine, I ordered a k-profile camshaft from KGtrimmning, in the form of the kg004 cam (lift: 11,95 LSA: 111° Duration in/out: 273°), aka streetable (although the pierburg agreed to a lesser extend although mixture and idle air screws can get you far)


Installation and valve shim adjustment.


Next up, IPD sways at a 2nd hand discount, lower brace was also included, yay!


Since I had access to a welder, and had my subframe out for reinforcement (a 2.0 version of this with pictures will be coming up) I made my panhard bar ajustable to some extend to get the wheels back in line.


Since I was getting sick of the pierburgs bad behaviour, and the volvo had already proven quite the towing rig, I got myself all the bits to start a turbo conversion which is currently a build in progress, hopefully I'll find the images once more to give it it's own post. Below some pictures of the bits, and the mighty brick towing my moped project.



Last edited by Swedbrick; 09-27-2018 at 12:00 PM..
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Old 09-27-2018, 09:58 AM   #4
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Default Update 3

Found the latest pictures hidden away on my pc after some more procastination, so with this update we should have all the progress thusfar.

During winter I helped out some friends from the surfing association with the parting out of their old tired 945, from which I bought an M90L2, the radiatior, the turbo, the engine harness and several other bits. Somewhere in the following weeks I welded the 3rd gear syncro, repainted it, and forgot about it until I got around to ordering the new clutch.


Very snowy, for dutch standards that is


As the second project for the winter, I chose to paint a set of wheels in a bronze color, after much deliberation, starting off with a silver base coat, following a gold-bronze coat, and finishing with a strong clear laquer. Since the tires would have to come off for this process to do it well, I bought a second set, and sold the old set to my brother who also owns an old wagon.




And yes the turbo's received a coat as well


For the final result I also upgraded to a set of Vredenstein Sportrac 5 tires, 205/60 r15, which have proven very good, especially in the rain. I was doubtful about the gold at first, but it has really grown on me.





During my second trackday at Zandvoort circuit, they proved very effective in the rain, improving my best dry time thusfar in the wet by 7 seconds, from 2.50 to 2.43, crazy Below an impression of what they had to cope with.

Passing a GTR with cold toyo proxxes


Nice shot on track


Next up were some more chassis upgrades, first of which, roll-steer correctors from RetroTurbo that also perform a quick rack functionality. Due to the longer length of the steering arms, the tires were rubbing against the front swaybar, which I was able to prevent with two ABS stops for the steering rack, simple enough.

Roll steer correctors, with adjustable ackermann


Secondly, a change of diff ratio's was required (from 3.31 -> 3.94) since during a previous trackday at Zandvoort circuit, the shift between 2nd and 3rd gear was less than ideal, since it would drop the k-cam right out of the powerband. At this point the reinforced subframe (v1.0) was installed as well.

The new rear axle, all nice and prepped


The old subframe and rear axle


The car without it's rear axle, still looking good


With all of the suspension/chassis upgrades finished for now, it is time to get into the serious stuff. First up, convert to the M90 transmission and hydraulic clutch, with a diesel clutch, and a sachs sintered pressureplate from KGtrimmning, good for approx 440Nm. To make sure the M90 could hold all this, I also installed the M90 thrust bearing adapter once more from retroturbo, to assure it would hold my 300whp goal. The flywheel was sandblasted beforehand, to create a good surface for bedding in.

Sandblasted flywheel and retroturbo m90 pilot bearing adapter


Pressure plate in place


With the new flywheel in place, the preparation for fuel injection conversion could begin.

Nicely painted mainfold with new seals and all


Walboro 450 install, including upgrade to later model fuel pump hangar (less chance of rusted fuel lines), pump shimmed with aluminium foil (tightly rolled, no chance of flakes) and tightened in place with hose clamps


Loom sorting mayhem


Upgrade to bigger radiator and e-fan with unavoidable issues with brittle plastic.


Fuel filter install


Manifold install and cooling system revamp (plugging coolant holes in head for carb manifold), with all new air intake


Those where the updates for now, more will follow soon! As far as the engine build is concerned, a little teaser below (and yes I will explain more about the TT, and why)


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Old 09-27-2018, 11:01 AM   #5
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yes!!! someone finally got this!! subbed!
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Old 09-27-2018, 05:00 PM   #6
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Great build!



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Old 09-30-2018, 03:01 PM   #7
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Hooray! A TT red block build, awesome!

2 13c's?
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My build thread: http://forums.turbobricks.com/showthread.php?t=340910
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Old 10-02-2018, 01:49 PM   #8
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Hooray! A TT red block build, awesome!

2 13c's?
Hey, yes two slightly ported and polished 13C's, should be an interesting mess of cooling and oil lines when it's all sorted out
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Old 10-02-2018, 10:13 PM   #9
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Nice build. What kind of bike is it towing?
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Old 10-03-2018, 09:50 AM   #10
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Nice build. What kind of bike is it towing?
Thanks!, the bike it's towing is an Peripoli Guilietta Super Sport, built in 1962 in Italy to get exported to Germany. It has a 50cc, 3-speed, air cooled moto morini engine, and used to do 70-80km/h which I had to dial back a bit due to regulations, it also has twin exhausts from factory for those extra .5 hp's
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Old 10-03-2018, 11:41 AM   #11
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oh erm.. plz report back when you drove it a bit.. curios if the m90 bearing will silence the m90 noises..
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Old 10-03-2018, 04:38 PM   #12
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I like the simplicity of your header.
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Old 10-04-2018, 02:19 PM   #13
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I am impressed with the amount of work you have done. I used to have a 1986 745 turbo and i still regret selling it.

If you really want to unleash the full potential of your suspension, you should do the camber mod, do the caster mod and install the volvo 960 lower braces.

http://forums.turbobricks.com/showthread.php?t=230362
http://forums.turbobricks.com/showthread.php?t=319020

The caster mod is done by putting spacer rings behind the lower control arm bushing. Longer trailing arms are available from volvo, but spacers are cheap, and you can buy them at you local gamma/praxis/etc.
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1986 745 B230FT, 302mm V70 brakes, camber mod. (sold)
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1987 244 GLT - Polaris, Strutbar, viking motorsport lower chassis brace, k-cam, gaz strut/shocks, pu-bushings
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Old 10-05-2018, 11:56 AM   #14
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oh erm.. plz report back when you drove it a bit.. curios if the m90 bearing will silence the m90 noises..
Hi MadDog, I've already made a couple of trips with the M90, the difference is quite noticable, my brother also has an M90 behind his 6304 without the bearing and mine almost never crunches compared to his. However it must be said, both have the welded 3rd gear retainer ring, but with my brother's trans it had already sprung loose before it got welded and it has an even shorter shift, so it is not a fair comparison.

I also used a good quality gear oil from 'De Kroon' a dutch quality brand, in the right spec for the M90 since the volvo oil is annoying to get, which from what I have read makes quite some difference.
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Old 10-05-2018, 12:06 PM   #15
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Originally Posted by mark244turbo View Post
I am impressed with the amount of work you have done. I used to have a 1986 745 turbo and i still regret selling it.

If you really want to unleash the full potential of your suspension, you should do the camber mod, do the caster mod and install the volvo 960 lower braces.

http://forums.turbobricks.com/showthread.php?t=230362
http://forums.turbobricks.com/showthread.php?t=319020

The caster mod is done by putting spacer rings behind the lower control arm bushing. Longer trailing arms are available from volvo, but spacers are cheap, and you can buy them at you local gamma/praxis/etc.
Hi, Thanks for the tips, I'll put those on the list for after the injection conversion, something to work on during winter, the 960 brace is more triangulated I presume?

P.S. Was the 1986 turbo dark silver, and sold somewhere around Brabant?
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Old 10-05-2018, 12:10 PM   #16
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I like the simplicity of your header.
Thanks, I will post a more detailed explanation on how I got there soon, pie cuts, cardboard and all.
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Old 10-08-2018, 02:48 PM   #17
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The 960 braces reduce flexing of the subframe. The camber and caster mod improve grip and eliminate understeer, the 960 braces improve steering precision. It nice if the car follows your steering instructions exactly and not having to constantly make little corrections.

My 745 was blue metallic and sold from brabant to belgium.

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Old 10-10-2018, 06:30 AM   #18
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The 960 braces reduce flexing of the subframe. The camber and caster mod improve grip and eliminate understeer, the 960 braces improve steering precision. It nice if the car follows your steering instructions exactly and not having to constantly make little corrections.
Alright, I was already trying to figure out the cause of this flex, but I never looked at the subframe as the cause before. Since I am planning on getting into some fabricating for the rear subframe and strutbrace, I'll probably order a little extra for some adjustable tubular control arms and improved underbody to subframe bracing then.

Maybe I might be able create some solidworks files, and be able to construct some extra's afterwards for those interested.

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My 745 was blue metallic and sold from brabant to belgium.
Ah okay, maybe one day I will come along. The one my brother bought was imported recently and had an not so legal turbo swap, which made a perfect excuse to put a b6304 in (still trying to get him to do a writeup)
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Old 10-11-2018, 07:25 PM   #19
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Default Engine thread now live, in potato HD

For those interested, I got around to starting the engine build thread, which can be found here: https://forums.tbforums.com/showthre...t=345333:cool:
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Old 10-13-2018, 08:40 AM   #20
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Can't wait to see some more details regarding the Twin Turbo setup!
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