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Old 09-22-2020, 07:32 PM   #251
lookforjoe
Making Volvo Parts Fit
 
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Made the spacer sleeves ('top hats") to properly center the end links in the swaybar







finished the two brackets



4.00:1 FD gear set came, so that will go in when I pull the drivetrain to do the head gasket



....and dropped the X off at the bodyshop to have them paint & blend the nose - I can't do that myself

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Old 10-12-2020, 04:38 PM   #252
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Finally got the car back from the bodyshop - pouring rain, but it's gonna be like this for days & I just want it home

Happy with the nose, the lines where I had to merge the planes came out OK





They did have to redo some of my work on top





spolier (modified S40 rear bumper cap)...





hopefully get it all back together over the next week or so



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Old 10-15-2020, 10:20 PM   #253
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More front end work needed - probably due to the accident, the r/f wheel bearing has play - makes for a very nasty crunchy feel to the steering & twitchy handling

press out hub



remove some bits, press out bearing



uses two v-ring seals similar to 240 -



new bearing going in



using a (Volvo) carrier bearing (32008x) race to finish pressing



reinstall the various seal plates & retainers, Torque spindle to 160ft/lb, done



Also found the left upper strut mount has deformed - which will mess with the camber, so I modded the Coil overs I made to take Ford Focus top mounts - still using the Kaplhenke 2.5" (Luxe Steer) spring seat from my V70 coilover setup & Volvo 700 pivot bearing (3530341)



this



replaces all this



just had to shave the ridges off the bearing to allow it to sit flush on the back of the strut mount



much cleaner



just have to redrill the top plate for the new mount

Last edited by lookforjoe; 10-19-2020 at 12:23 PM..
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Old 10-18-2020, 09:08 PM   #254
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Started putting the nose back together, now that the suspension /steering work is resolved.







Got the 760 sway bar back in with the C30 end links, and SuperPro bushings (SPF1025-23K)











Drilled the strut towers for the Ford mounts






Last edited by lookforjoe; 10-18-2020 at 09:38 PM..
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Old 10-24-2020, 09:57 PM   #255
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Got a K20Z3 (RBC-1) head - better flow than the RBB I have now. It is all nicely cleaned, decked & valve seats recut. Keeping the TSX cams & RBC gear limited to 40º. I'll swap it out when I drop the drivetrain to deal with the currently leaking HG, and install the 4:00 R&P.







Car went back to the bodyshop this week to fix a few small things that just weren't right. All good now.





Worked on the tape stripes and decals whilst the temps are still in the 60's - I cut the decals from 3M 1080 film - easier to deal with than old school vinyl for sure















Used a 3mm gold strip to even out the (hand) cut edge



S40 rear bumper cover worked out great for the spoiler :D


Last edited by lookforjoe; 10-28-2020 at 11:03 AM..
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Old Yesterday, 10:49 PM   #256
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Quote:
Originally Posted by lookforjoe View Post
Forgot - I also did this to my C30 over the summer







This past summer I added a VW - based Haldex controller - had to use a VW Gen2 DEM for it to interface.

had to make a harness that would interface with the module/factory wiring





installed in pass rear seat well



VW DEM replacing the Volvo unit





Uses a BT app on my phone



After much back & forth through mechanical and software issues, I now have full control over the AWD torque split - I can go from 50/50 down to 90/10



They are developing a version that will work with the Volvo DEM, now that I have worked with him on extracting all the Volvo CAN inputs needed for brake, steering angle, reverse, speed, etc.



using CAN Analyzer to figure out the inputs



With the CAN inputs working, I can set the parameters for disengagement when parking, turning corners at low speed, etc., that will normally cause axle bind with a locked diff.

Very happy it is figured out before the winter weather begins in ernest!

Put a Quaife QDF 11J in a spare rear diff I bought, so that can go in now I know the AWD is fully functional





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