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Old 06-02-2015, 04:16 AM   #1
Alex Buchka
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Default The Buchka 242 Daily Driver



I bought this '83 DL about a while back ago from Chris (duder) here on the forums. I had recently moved to LA for work and needed something to drive around. It was all stock when I got it and had about 290k on the clock. Chris rescued it from the crusher, got it basically road worthy and past california smog testing. I took care of some other basic maintenance items and installed a short throw shifter along with a MOMO R-Sport steering wheel just for the hell of it.

After commuting with it for a while I really started to dislike how crappy the car was to drive. All the bushings were blown out, the struts and shocks were used up, the tie rods and rack boots were annihilated, and the brakes squealed like a garbage truck.

Suspension was first up. Basic mod list:

Front:
Koni 8610-1437RACE short strut inserts
500lb/in springs
Kaplhenke roll center correction spacers
25mm iPD bar
Coilover bits from Coleman Racing
Delrin control arm bushings
Chromoly strut tubes
Upper spring perches with 740 thrust bearings
Group-A style camber plates

Rear:
Bilstein F4-B46-0930-H5 dampers
250lb/in 5" ID springs (~375lb/in wheel rate)
Adjustable perches from Coleman Racing
Panhard bar and torque rods with spherical bearings
3/4" shortened lower trailing arms
Stock 19mm bar

Also replaced all the tie rods and the rack boots while I was in there, plus installed some cheapo parts store pads and insulating goop to fix the squealing brakes.















After this it was time for wheels and tires. I covered this in detail in my "Best damn garage in town" thread. Click Here. Basically made a set of 17x8 two piece Gemini wheels using BMW Style 5 barrels and a 10lb box of TIG filler rod. Never again. Karl and Homer helped out a bunch so props to them.

Tires are 235/40-17 Falken Azenis RT615K










Sometime between then and now I put a flathood on it with 7" round Hella H4's

In the beginning of January 2015 I went to Sweden for couple of months to study a few classes in college. Without my knowledge or consent my sneaky brother decided to completely replace the dull beige interior and restore the paint as a surprise.

Interior bits:
Black carpet and rear seat
Manual C30 seats in black T-Tec
Sound deadening mat inside the entire car
Repaired and flocked 1992 black dashboard
All the interior plastic was either replaced with black parts or painted to match
Suede headliner and hat shelf
Replaced the heater box with a 1992 model
New late model windshield
Keyless entry using all 850 hardware
Blaupunkt tape deck with bluetooth line in
MB Quart speakers




















Paint:

The paint on the car is all original single stage 139 white. It was seriously neglected by most of the previous owners and myself. I washed it a few times but it never really got clean, there were always specs of crud stuck in the paint that no amount of washing would get off. I've never been one to have nice cars or take care of paint so I didn't really care.

Karl and Chris went to town fixing and painting a few rust spots which turned out awesome. They then got a bunch of friends together for a paint restoration party. I heard it involved absurd amounts of clay bar, DA cutting, buffing, and waxing. The results were staggering, the paint actually shines now.

Karl did a kick-ass job and the car is now an absolute pleasure to drive around in.
































Alden took this picture at the Davis meet:



That more or less brings this to the present. I have a few more pictures of stuff to show for the next evolution of the car, I'll add that in the next post.
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Old 06-02-2015, 04:43 AM   #2
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ha.. and again the buchkas got some **** done nice looking car !
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Old 06-02-2015, 05:10 AM   #3
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I like this. A lot.
You have strange friends. Mine would have filled the interior with balloons and silly string.

Is it my imagination or is that Panhard rod straight? How does it clear the differential housing?
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Old 06-02-2015, 06:37 AM   #4
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Thats a damn nice ride
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Old 06-02-2015, 07:53 AM   #5
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Wow, that looks excellent. Spot on interior, too.
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Old 06-02-2015, 10:26 AM   #6
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Hmm. I dunno.
That should work.
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Old 06-02-2015, 10:56 AM   #7
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That must be a joy to drive. You've got me wondering how/where to source those widened spherical bearings. They look ideal.
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Old 06-02-2015, 12:39 PM   #8
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Neat. Any plans to make this smog excempt?
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Old 06-02-2015, 12:40 PM   #9
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Those 2 piece Gems are so dang baller. I want some.
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Old 06-02-2015, 12:44 PM   #10
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Quote:
Originally Posted by Alex Buchka View Post
I've never been one to have nice cars or take care of paint so I didn't really care.
Same here. My '92 is looking really neglected now, and I have to do something. Going to be spending some quality time with the clay bar soon, it really does wonders to that embedded crud.

Davis 2015
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Old 06-02-2015, 12:45 PM   #11
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Oh yeah, make some center caps please.
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Old 06-02-2015, 01:33 PM   #12
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rock on! great work as usual!
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Old 06-02-2015, 02:29 PM   #13
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Curious to see how the Delrin bushings do.
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Old 06-02-2015, 02:33 PM   #14
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That is great!! And i didn't believe what a clay bar and a few hours can do to the car untill we did my 244... Keep up the good work! ;)

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Old 06-02-2015, 02:36 PM   #15
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Looks fantastic! Love the wheels
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Old 06-02-2015, 06:37 PM   #16
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Just posting here because I feel it's appropriate to assert myself on the front page of what will become an epic thread. Millions of years from now, our children's children will regale their children with tales of Ernesto, the slammed 242 on 3-pc Geminis.

For anyone who wants more back story on the car, see the Daily Turismo Project Car posts here: http://www.dailyturismo.com/search/label/DTPC

Fun facts: it was a San Diego car from new, I was the 3rd owner, the 2nd owner was a graphic designer guy in the film industry and the car was featured in some tiny-budget Indie flick that probably never got released called "51 West." It was entered in the ipd $25k build-off and was the 1st or 2nd runner up.

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Old 06-02-2015, 07:16 PM   #17
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I've been craving more of this car since the custom gemini build thread. Needless to say, the work done to the car so far looks great and I'm sure only more is to come.
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Old 06-02-2015, 07:20 PM   #18
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White always cleans up so well. Looks great, and nice pictures.
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Old 06-02-2015, 07:43 PM   #19
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Nice job! Love the wheels.

Jelly about those rustfree original paint cars.

I want to ask also, how are those delring bushings do in the front control arms? Doesn't it make the ride much much harsher?
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Old 06-02-2015, 10:18 PM   #20
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I'm not a wheel guy, but those are pretty ****ing incredible. Like the rest of your car. Good work.
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Old 06-02-2015, 10:39 PM   #21
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Looking good! Widen my Propus C's like that and give me some lip!
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Old 06-02-2015, 11:28 PM   #22
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Adjustable torque rods and trailing rods (arms?). If so would you make your favorite Sacramento friend a set too?
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Old 06-03-2015, 02:09 AM   #23
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2 piece Gemini wheels? so much awesomeness! also very nice car.
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Old 06-03-2015, 02:35 AM   #24
Alex Buchka
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Thanks for the kind words dudes, really means a lot!

Quote:
Originally Posted by crogthomas View Post
I like this. A lot.
You have strange friends. Mine would have filled the interior with balloons and silly string.

Is it my imagination or is that Panhard rod straight? How does it clear the differential housing?
The panhard rod is completely straight. I massaged the diff cover with a hammer to get some clearance. It was very close but just worked. Once I shortened the lower trailing arms it got a lot better.

Quote:
Originally Posted by Pete.M View Post
That must be a joy to drive. You've got me wondering how/where to source those widened spherical bearings. They look ideal.
I turned spacers/adapters to fit 5/8" rod ends into the stock mounting locations. The spacer ID was reamed to 12mm for a tight fit with the standard M12 fasteners.

Quote:
Originally Posted by harribert View Post
Neat. Any plans to make this smog excempt?
It is already registered out of state where smog is not a concern.

Quote:
Originally Posted by towerymt View Post
Oh yeah, make some center caps please.
I have center caps, just been too lazy to refinish them. I would also need new lug nuts, the shiny chrome ones I got from Homer don't work with the center caps

Quote:
Originally Posted by Tuff240 View Post
Curious to see how the Delrin bushings do.
I have put over 10k miles on the car so far and the bushings are holding up great. I greased them on assembly and they haven't started squeaking. The bushings have grease zerks on them in case I ever need to lube them up.

Quote:
Originally Posted by Hank Scorpio View Post
Adjustable torque rods and trailing rods (arms?). If so would you make your favorite Sacramento friend a set too?
I don't have any stuff to make more. All the bits are available on www.midwestcontrol.com for very short money. They even make threaded aluminum hex rod in different lengths, you could put together a set that doesn't require any welding at all.


The next evolution for the car is a six cylinder whiteblock swap. I got the engine out of Chris Wiita's 960 wagon. It was rebuilt no more than 5k miles ago and is an ideal specimen. Chris also never hooked up the EGR or smog pump so the engine is really clean inside.

The transmission is a five speed Toyota W58 out of an MK3 turbo supra, clutch is a twin-disc Quartermaster Rally-V mounted to a steel flywheel I got from AndyEG several years ago. Coincidentally the automatic transmission in a 960 has the same bolt pattern as the trans used in 1UZ-FE powered lexus cars. This meant I could take a commonly available lexus v8 to W58 adapter plate and bolt the manual transmission to the volvo bellhousing. Some minor clearancing on the bellhousing was required.

For clutch release I'm using a 260 master cylinder and a concentric release bearing for some roundy-round application. The pilot bearing was made with a mish mash of a ball bearing and an oilite flanged bushing from McMaster.

I got most of the driveline parts came from my good friend Justin, the hookup on parts was a massive help so huge props to him for that.



Getting the stack-height correct for the hydraulic release bearing was interesting. Karl and I had to mill down the input shaft bearing retainer and make a backplate to take the thrust load. The bearing floats on the input shaft sleeve and the moment is reacted by a shoulder bolt I modified for proper thread engagement. The hydraulic feed and bleed lines are plumbed to some AN4 bulkhead fittings bolted to the bellhousing.







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Old 06-03-2015, 02:59 AM   #25
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Wow
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Was a sandals-and-socks elbow-patch-cardigan-wearing bearded college-professor 10mph-under-the-limit-in-the-fast-lane typical Volvo buyer from 1993 really caring about some sort of limited edition numbering?
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