home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > projects & restorations

Reply
 
Thread Tools Display Modes
Old 11-05-2007, 01:56 AM   #1
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default Roger's 94 940 Turbo

Hi everyone!

This thread is about my 94 944 turbo and everything related to it. All comments are much than welcome! First of all I want to say that english is not my first language, feel free to quote or comment my error it's the only way I can get better. So let's start!

I'm a member here since 2006 and I had my first volvo at 17 years old. It was a blue 744ti 85 with only a few miles left in reserve, mostly due to my lack of money at that time. Anyway, it was my first car, manual, rwd, turbo, big sunroof, power windows and leather seat... so it set my standard a bit high. Well, maybe! I've ran a year and a half after the death of the 740 with a 1991 automatic camry. In the meanwhile I've got my certificate as a machinist so I found a job and started to look for a new car. I was an e-bay maniac at the time, not that I've changed so much but I'm just wiser on the buy-it-now button. While surfing on e-bay, I fall on a white 94 940 Turbo with only 95 508 miles and 2 owners, 3 with the seller. It was well equiped with a/c, grey interior with grey leather seat, and it was a california car, "migrate" to NY in 1993 so it may have seen 2 winter, maybe not. The price was set at 4900us. I didn't knew what to do. I always loved white cars, plus the fact that it was more than clean... After a long 2 days of thinking, I finally it the buy it now button. The 2th of may 2005.
Here's the picture that was on e-bay.









Importing a car here in canada is a long process that cannot be bypassed. The painfull thing is I discover it after the button was hit. I paid my car on the beginning of june, 4900$ us or 6300$ can at that time. The seller didn't want to drop the price at all, and I wanted that car so much, so I said f*ck it I'll pay the price. I waited one week before the seller receive the money. After that I called a local trucking company and 2 weeks later they picked up the car at Tillson, NY. 4 days later I went to the nearest U.S. Custom wich is Rock Island, where I waited a few hours 'til I saw my car on a flat bed, the first of 4 cars, but the only one that wasn't salvage ! I took a quick sprint, jumped into the trailer, popped the door, take a little look everywhere to see if something was missing (car has been sitting on the flat bed for the whole weekend at the derby line... ) but I was so happy and stressed at the same time, so I just run back to the building. It was my car for one month already but it was the first time I was given to see it! Filling the custom papers and paying for the importation took a big hour, so I was back on the higway heading home at 2 p.m. And oh, cost me 650$ of duty and excise tax, 200$ of gouvernemental process paper that was mailed to me, and 450$ of shipping. The trucker was unloading the 3 other car before because that was the only way mine could get out. After that they called a towing and bed-to-bed they transferred the car on the towing. At 4p.m. a big jacob sound on my street alerted me that my car was now at home. I jumped out of the house, looked at my car being unloaded. It was a pure moment of happinness, so sad it didn't last long... My dad was with the driver of the tow truck, so when I saw him I yelled; Gimme the KeY!!! And he look'd at me and said: WIch keY??

Yes. There was a car, but no key. All the thing I was able to try was the 4 flasher, the power seat and the high beam when holding the switch, oh and wow, the parking light too. I wasn't happy! A bunch of friend kept showing up, I had to repeat each time that I don't have the key... I e-mailed the seller, he said he didn't have it. I ended up thinking that the tow company that loaded the car at NY put the key in his pocket as a reflex. It's Bill's Auto Service Inc. in Rosendale, if someone knows him maybe I could get my original back I'm kiding, what are the chance of it happening! So I removed the lock from the passenger door, and paid 50$ for a locksmith? to open it and fab me a key. I only had my car for 2 days that I was already forced to remove a door panel... It's a good thing I'm not afraid to get dirty or to explore unknown territories. Two days later, I finally have a chance to start it. It started like a charm, everything was good so I will not take too much time explaining how happy I was! Now we are the 30th of june, already one month after the purchase on e-bay!

After that I had to wait for my 200$ papers to came in. When they shows up, the first thing on the list was to get the car at the local volvo dealer for a recall, and to get the airbag checked. Called them and got a rendez-vous for the next week. I drove the car with the toyota plate on it to the dealer, they changed the crank sensor and they was amaze at how clean it was under the hood. Always a good thing for the ego when all the mechanics stop working to look your old boxy 94 940... I drove the car home, and now it was time to get it inspected. Took another rendez-vous, waited again to get it, then got the car inspected on 05 of july. The car was so clean It passes the inspection haut-la-main. But a problem showed up, the airbag system wasn't checked, when I asked the volvo dealer about it they didn't know what to check. The guy at the inspection told me he couldn't give me the paper if I didn't have it checked. I drove the car home & jumped into the camry right to the dealer. Believe it or not, it's only 15 days later that volvo find the answer to the airbag thing. The customer department representative FINAlly find a publication on the volvo website about them extending the life for their airbag sytem. They printed, stamped and signed it. I was beginning to run out of time, I have 60 days to get the car inpsected and registered, passed that delay I must ship back the car to the US, don't ask me why! That time, the inspection guy signed the 200$ form and faxed it. He said now you have to wait for the answer! I was beginning to suffer from a lack of patience, so I said WTF am I gonna have it on the road this winter or what... He said calm down little boy, it will only take a few minutes... I'M CALM, I'm calm... We finally got a fax back from the "registrar of imported vehicule" with an approbation number, he writed it on a new (free!) form and I finally got the car registered later that day. But as everything goes so well since the beginning, it took an hour for the girl at the registration to understand how U.S. Titles works, and there was only 3, it would have take the day if there was more!

But when ridin' in my volvo that night, those bad part were all part of the past. I was happy, and nothing could have removed that smile on my face. I was literraly flying, the head in the clouds... well maybe it was all the herb I smoked but I felt sooo good. Writing this makes me want to go take a ride!

There is one important thing I didn't told you about this whole story. When I decided to buy the 940, wich can be considered somewhat pricey, I didn't knew of turbobricks. It would have changed a lot of thing, I think I would have buy a car from a member, with a few mod on it. It would also have saved the lost money I invested in my car not really knowing what I was really doing. It's sure that while searching on the net for volvo part or information I was linked to turbobricks thread, but the search engine are linking to a non-grapgic version of the archive & board and at the time my english was not like today so without picture I didn't understand most of what I was reading. Also I was not a fan of forum. But I learned so much thing here, I'm so thankfull to the members of this forum.


To be continued...
__________________
94 944T - 16v turbo - 12,14@122
Lm7 5.3, S475, Ms3Pro, 4l80e - 10,36 @ 134 / 6,70 @ 107
www.deeworks.ca
Need T5 Adapter? T5 Speedometer Plug? Gm Torque Converter Adapter? Freeze plug retainer? HE351 solenoid plug? Pm me!

Last edited by Roger-Dee; 11-07-2007 at 11:42 PM..
Roger-Dee is offline   Reply With Quote
Old 11-08-2007, 12:47 AM   #2
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Well I see it take more than a stock car to get comments :P

Since my car hit the road at the end of july and is stored from mid-october, I didn't had much time to mod the car the first year I got it. It was slow, big, and too much stock. Before the car get stored I did have the time to make one piece, it's an aluminum trim that replace the stock center air vent. First year was with boost & afr cheapo obx gauge, but the second year I installed a wideband and an Ultra-Lite II Autometer boost gauge in the trim. I filled the remaining hole with the old obx gauge, I know that two afr gauge looks like crap, and one is like the 1/10 of the price of the other! But I left it unwired, I barely notice it anymore... Still, waiting to get an egt to finally remove the obx sh1tz.




As my car was stored, I removed the two front door panels and the cluster. This gave me the winter to put some custom stuff on them. First, in my spare time at the job, I've made those few little parts:




And now for the door and the cluster...
The cluster is the first thing I did, as it was somewhat a cool part to fab. It tooks us like 10 hours and 2 try, and we can add to this the time it took to remove the plastic window ... It was a bit hard to get good measurements, so it's not a 100% fit, but it's 100% home-made so who cares!

Out of the car, resealed:



Now in the car (That mean winter is gone!):

(Not my 850...)


As for the door panel, well carpets always look better on a floor IMO so I removed the front carpet in the door and replaced them with those trim, and on this one I got some help from my co-worker and the cnc mill. The first version was without a ball-mill groove, it was nice but as I did some groove on the first part I've made, I decided to remove the door insert and add a groove on them. Let me know wich one is your favorite!




About in the middle of the summer I made up this another trim, still with the help of my personal cnc operator I removed the Sliding type potentiometer and replaced it with a standard one, and made a new button for the parking/main light. The black rocker switch is my line lock. I try hard not to use it when I'm not at the dragway



But don't think I forgot I said it was too slow! The cost of the trim was a big 0$, so why not ?! But while those part were being fab, a beautiful package from sweden got delivered! Yay for 46-38 valves from kg! Coupled with double spring... All that stuff is now a property of benflynn, wich have a much better use of them than I did. That's the first part of the wasted money, or we could call that I don't know what I do, or even Why I havn't found yet turbobricks.com... Now for some picture before the explanation.





The valve and the spring, coupled with an ipd turbo cam and a newbie ported 530, bigger seats everywhere, was my "Theorical perfect setup for the time". Yeah we all start somewhere... I started real low! Still with the 13c, not even ported the 90+... Added an mbc to ~12psi, just before the fuel-cut cause yes I still was on lh, not even chipped. But stock everything else. The result of this mix was ~1200$, dead 530, a now-in-the-trash ipd cam that grinded himself on the valve shim. Had it regrinded (140$) and putted it back in the head, started to grind again so I gave up... The T cam was the "between" cam and didn't grind at all. And the car wasn't that much powerfull. At the end of the summer the engine started to make strange noise and to loose power, so I removed the engine before storing it. I put the ported 530 to the trash after I cut it in two to see how much wall was left with our crazy porting job.

Just a week after my car get stored, I received my chip from Fred. Another week later, I received this getrag from GtJordan I remember that day like it was yesterday, a few days before the tranny got to my house a thread was started on T5 vs Getrag and the getrag received so (many) bad comments, I was feeling bad




But I kept the focus on what was important... rebuild the engine. When the engine will run, install the getrag. But some parts have been thrown in. Some of you may recognize my car, I posted a few of those picture in the showroom section.

But it will be the on the next post(s)!

Roger-D.

Last edited by Roger-Dee; 11-08-2007 at 01:02 AM..
Roger-Dee is offline   Reply With Quote
Old 11-08-2007, 01:19 AM   #3
Geoff240Ti
Board Member
 
Geoff240Ti's Avatar
 
Join Date: Nov 2002
Location: Estevan, Sask Canada
Default

I really enjoyed reading your project thread!

I know the feeling of bringing a car across the line.. (paying for it.. not seeing it for awhile). The feeling when you actually get the car licensed in Canada is great!

Great job on the interior pieces too, definitely sets yours apart!
__________________
Geoff
Geoff240Ti is offline   Reply With Quote
Old 11-09-2007, 10:57 PM   #4
brickborg
Board Member
 
brickborg's Avatar
 
Join Date: Mar 2007
Location: Nomi, MN
Default

Badass! Can't wait to see it running again.
__________________
1985 760 Jurbo- 80k miles, finally running. Build thread HERE
2000 Honda CRV- Ã…snan
2012 Honda Civic LX- Reliable.
brickborg is offline   Reply With Quote
Old 11-09-2007, 11:08 PM   #5
Tick
ASSFACEHOLE
 
Tick's Avatar
 
Join Date: Oct 2005
Location: Atascadero, CA
Default

I really like the interior work.
__________________
67' 220
84' Honda sabre v65
85' Ford Econoline E350 Box Van
90' 740 16v
90' 740 turbo (parts)
00' xc70

Quote:
Originally Posted by Disco Inferno View Post
**** you, filthy ****ing non-smoker. I hate your type, and when I see you coming I intentionally exhale strongly in your direction.
Tick is offline   Reply With Quote
Old 11-11-2007, 01:19 AM   #6
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Quote:
Originally Posted by Geoff240Ti View Post
I really enjoyed reading your project thread!

I know the feeling of bringing a car across the line.. (paying for it.. not seeing it for awhile). The feeling when you actually get the car licensed in Canada is great!

Great job on the interior pieces too, definitely sets yours apart!
Thanks ! I really like your 242... Before I fall on turbobricks I found that 240 body were ugly, and I didn't knew there was 242 model. But since I saw so much of them totally worked out that I've started to think of buying one. Did we got any 242 in canada ? I would like to do a 16v turbo, but I don't think it's worth doing it into the 940. A 242 is a much unique car who definitively have a spirit on the road. And guess what, I just bought a 93 245 for this winter. I'm slowly reaching the goal of getting a 242!

It's a really strange feeling to buy a car you didn't even test drive. I was expecting some little ding here and there, a missing trim or something, but no the car was nicer than I tought it would be. I had never drove a 940 before, nor an automatic from volvo, so I was in a new world!

Quote:
Originally Posted by BrickBorg612 View Post
Badass! Can't wait to see it running again.
The project thread is actually 1 year late, still have a lot to write & show! But don't worry the 940 is back on the road since a few months now. I'm just slow when i'm writting in english!

Quote:
Originally Posted by Tick View Post
I really like the interior work.
Yeah I put a lot of time in that interior stuff. It wasn't that expensive, well for what I've shown until now, and it kept me busy for a while! But you should come back in the following days/weeks, I will post my latest project.
Roger-Dee is offline   Reply With Quote
Old 11-11-2007, 03:12 AM   #7
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

I think I will add a little more tonight. Maybe I will be unstopable!

So I am now at the end of the winter, driving a 50$ firefly and crying the death of my engine. The firefly was really cheap and the gas was a joke. This gave me the oportunity to save money for the rebuild.

The first thing I've done is to trade my set of 46-38 valves & double spring to benflynn, in exchange of a td04hl-13t and an A cam, + a pump and a nozzle for wather injection. After that I took my block and my old stock head to my machine shop, not the one I work at coz we don't do engine. Since I don't pay for labor, my friend did my engine in his spare time. So it was dealt before that it could take the winter to have it done. So I moved on into fab'ing up other stuff for my car, i.just.cant.stop... Oh no I couldn't stop, and not even wait because this time it was the kind of part a machinist would like to have to do 40hr/week.

I don't have a picture of everything I did, only the important stuff. The A cam I got wasn't slotted, so I took it to my job and using the T as a ref I slotted the A. It wasn't an easy job, we don't have an horizontal mill so it complicated the job a little! I thought that was all, but hey the dizzy have a shaft that extend 2"-3" and have a seal on it, so I got to put it on the lathe and drill the hole. And after I found that it need a big c'bore. So what I thought would take 1/2hr took like 2½-3hrs. Now on the interesting stuff!

There was this small puck of aluminum that was catching my attention everytime I walked by. In fact it was hard to miss, 8" O.D. x 4" lgt. One day I just couldn't resist the temptation... so I took it and put it into my tool box. 2 or 3 days later I was alone at my job, so I chucked the little puck. Everything was going well, the puck went from 8" to 5.5" in just a few minutes, and my home-made round insert holder with a 1/2" round insert on it was doing a mirror finish. The desired result was this:




But sometimes thing seem to go well and BAM something happen. The first side is the one that got hard treated. Emptying the center of the pulley, going from 8" o.d. to 5.5" o.d & doing the groove for the strap put a lots of efforts on the parts so it was firmly held. But for the second side I was holding my pulley with the O.D., so if I chuck it too tight it will damage it. So I was slowly facing the other side with .050" of cut with my round tool. At the very last cut, the pulley jumped out of the chuck as the tool bitten in the radius. But just look at it you will understand.

The side where the tool bite

What I was trying to avoid by not thighten to much the chuck:




The first picture is the one that will be installed in the car. As soon as we got another recut out of round aluminum with an O.D. of 5.5 and more, I took the evening to redid the pulley. And guess what, at the same and exact operation, the damn pulley jumped out of the chuck again
This time the damage was small and a little cut on every damaged faces brought back a smile on my face. It's now sitting for like 9 months on my desk, didn't got the chance to install it, ya know removing the rad & IC to unbolt the crank bolt...

Just as I was making those part, the car was waiting for a bit of love from me. Everytime I went to my friend house where my car was parked I sat in the car for a few minutes. Always took the time to pop the hood, it was dirty and full of snow:



When I joined turbobricks, the group buy for TTR cam gear was closed just a few days earlier. I was really disapointed because I really wanted to have an adjustable gear that you don't have to remove, and I must admit that the TTR gear was automotive porn, I mean that was a beautiful piece! So in the same mentality I always have, I started to seek for another recut of aluminum. This time it wasn't 5.5" in diameter so we got plenty of recut. So I started by drawing the gear on solidworks because this time there was a lot of operation. I started with the stock cast gear, I removed the center by boring a hole of ~1.5". That was all the work needed on the late for the stock gear. I then chucked the aluminum, and ya know what's next!

Except for the interior trim, I always try to do my work myself. The crank and cam pulley are both fab'ed on conventional mill and lathe. I'm telling this because I'm a little proud of how great the milling process goes on the cam gear. All the mill work is done using an indexing chuck. I want to change the s.h.c.s. by some button head, I think it's the best looking screw and it also has the biggest head sitting area. Here is the picture of the final result, scotchbrited to hell!:


The Gear with the home-made catch can


The thread in the catch can hole seems to be incomplete but it's the flash!

That's all for tonight. I must sleep now!

Thanks everyone for the comments, and for reading me out. Nothing on my english yet, is it that great
Haha

Roger-Dee.
Roger-Dee is offline   Reply With Quote
Old 11-11-2007, 11:51 AM   #8
nederzweed
Board Member
 
nederzweed's Avatar
 
Join Date: Jan 2007
Default

you have some serious skills !!

i drooled when seeing your adj. cam gear. are you willing to make more of those ?? man it looks so sexy !!!

keep up the work!!
__________________
Quote:
Originally Posted by linuxman51 View Post
an m46 will break, cry, and run home to moma behind a 200hp b230.
nederzweed is offline   Reply With Quote
Old 11-19-2007, 11:30 PM   #9
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Quote:
Originally Posted by nederzweed View Post
you have some serious skills !!

i drooled when seeing your adj. cam gear. are you willing to make more of those ?? man it looks so sexy !!!

keep up the work!!

Thanks !

It's funny to see how thing happen, Lucky has just started another group buy for the real one, wich look even better than mine. Now you don't have to wait to get one!
Roger-Dee is offline   Reply With Quote
Old 11-20-2007, 12:12 AM   #10
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

And now for the rebuilt.

I didn't take a lot of picture of the rebuild, in fact I almost took none... I'm not really proud of me. I was alone to reinstall everything and my hand was too dirty to use the camera. It wasn't a big rebuild anyway, mostly with stock volvo parts.

Parts list / What was installed

Block:
Stock 94 b230ft block
Stock 8.7cr piston & rod
New ring
A small hone (A few .0001")
OS1 on Rod & Main bearing
Polished Crank
Decked block (.010")
Stock oil pump retighted

Head:
Stock 530
A cam
4 groove per cylinder (got pic somewhere... )

Random Part:
Adjustable Cam Gear
2 Stage MBC
3" Downpipe
td04hl-13t
Ported 90+
The Aspirator/Dales ignition wire
Cap/rotor/spark plug & every other stage zero bits, for sure!

The block was bolted on the car without the head on it. The engine bay was cleaned with Spray Nine & Super Clean (Purple power?) and it came out so great I had to show it to all of my friend! At that point, I have a picture!







After installing the head we moved on to make the 3" downpipe. It's more than a downpipe since the pipe extend until the resonator. It was our first time in making a downpipe, and we were surprise it came out so good. The adapter on the turbo is about 1"½ thick and the interior is a big taper from 2" 3/8 to 3". I've used S.H.C.S. to bolt it to the turbo, I like the way it look. The downpipe is welded right on. A standard exhaust clamp combiend with a getto mount secure the whole thing.

Don't look at the brown hose on the pre-turbo hose... I had in the past some excessive crankcase pressure...

Ehhhhh yesss it is the stock sensor as a plug for the egr... The sensor itself is removed






That's all for tonight...

But the next time a lot of picture, I promise.

Roger-Dee.
Roger-Dee is offline   Reply With Quote
Old 11-20-2007, 12:45 AM   #11
Biesey
Board Member
 
Biesey's Avatar
 
Join Date: Jan 2007
Location: Abbotsford BC
Default

nice work bro! The catch can and the timing gear looks really sweet.
__________________
- Dan

2002 A4 | 1986 280GE | 1971 1800e
Biesey is offline   Reply With Quote
Old 11-20-2007, 02:17 PM   #12
Canuckvolvo
Drunk as ****
 
Canuckvolvo's Avatar
 
Join Date: Nov 2002
Location: Beautiful BC
Default

J'aime beaucoup les pieces interieur! I prefer the door piece without the border, if I had to choose. If I didn't have wood trim on my 940 I'd ask about ordering some from you!
__________________
Currently Volvo-less
Canuckvolvo is offline   Reply With Quote
Old 05-25-2008, 10:43 PM   #13
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Hey I forgot to update this thread since a long time... lots'o things to show! Let's start with my custom center console, or wathever you call it :P In french, it's "Mon panneau qui tourne" so give it the name you want

I'm been thinking about this project for a few years. I wanted to do it in my 740 but it never happened. It all started when I was 16 years old, I bought myself a jvc sound system with a front panel that was turning to let you use the control. I then wanted to remove the whole center console in the 740 and do a "sliding" door to hide the radio and a few extra switches.



The final design changed a bit, but it still based on the jvc unit. Finally over the years a lot of product became cheaper and cheaper, here I'm referring to the dvd player and lcd screen for car. So I started my research for the perfect component before doing any drawing.

I found a nice little lcd screen for 110$, just like I wanted with no control in the front panel:

That was cheap.

The dvd player I ended up with is not of the best quality, but I chose this one for his small size and is front face in stainless that goes really well with my aluminum interior.

It was more expensive, 270$ shipped to my door.




I also bought for at least 60$ of switch, near 100$ in wire, molex connector, terminals, fuse box, shrink tube and even cupboard knob! I wanted to do a real esthetical job that was as fast to remove as the stock console. I had to relocate the heater control in the glove box, picture to follow. I also needed to relocate the stock fuse box/realy board; it's now sitting in vertical where the stock air dam was. I removed all the air dam for the face position, my car is a summer car so feet & defrost is the only position I need. I then added my own fuse box in place of the old, and starded my wiring from it.

This project was spread out the whole 2006/2007 winter, and I started something bigger than I expected. That's what I realized after a 10hr wiring&soldering day in the car. But that was worth every effort! Let's see some picture now.







I must buy a good camera and learn to take good picture... oh sorry

I don't have a final picture of it in the car because the shifter still miss a shift boot. But I do have this vid from last summer just after the installation. The panel open as you put the key in the contact and close as you remove it.


This video was watched a lot of times on youtube and I always wanted to know if someone from tbricks saw it. Somebody?! Haha! I also received some comments from the swedes, if someone could translate them to me :P

See ya!
Roger-Dee

Last edited by Roger-Dee; 05-26-2008 at 05:56 PM..
Roger-Dee is offline   Reply With Quote
Old 05-25-2008, 11:05 PM   #14
foggyjames
Ryan's spanner monkey
 
foggyjames's Avatar
 
Join Date: Jan 2004
Location: Lincoln, UK
Default

Haha, that flip-over panel is awesome

cheers

James
__________________
'13 V70 D4
'89 740 Turbo Intercooler
'88 360 Turbo Intercooler
'84 360 GLT
'81 343 GLS R-Sport
'80 343 DL
'70 164 - Under Restoration

PM me if you're looking for Euro parts!
foggyjames is offline   Reply With Quote
Old 05-25-2008, 11:06 PM   #15
mikes02ls1
Stolz, deutsch zu sein!
 
mikes02ls1's Avatar
 
Join Date: Dec 2006
Location: Casa Grande,AZ
Default

Quote:
Originally Posted by Roger-Dee View Post
Hey I forgot to update this thread since a long time... lots'o things to show! Let's start with my custom center console, or wathever you call it :P In french, it's "Mon panneau qui tourne" so give it the name you want

I'm been thinking about this project for a few years. I wanted to do it in my 740 but it never happened. It all started when I was 16 years old, I bought myself a jvc sound system with a front panel that was turning to let you use the control. I then wanted to remove the whole center console in the 740 and do a "sliding" door to hide the radio and a few extra switches.



The final design changed a bit, but it still based on the jvc unit. Finally over the years a lot of product became cheaper and cheaper, here I'm referring to the dvd player and lcd screen for car. So I started my research for the perfect component before doing any drawing.

I found a nice little lcd screen for 110$, just like I wanted with no control in the front panel:

That was cheap.

The dvd player I ended up with is not of the best quality, but I chose this one for his small size and is front face in stainless that goes really well with my aluminum interior.

It was more expensive, 270$ shipped to my door.




I also bought for at least 60$ of switch, near 100$ in wire, molex connector, terminals, fuse box, shrink tube and even cupboard knob! I wanted to do a real esthetical job that was as fast to remove as the stock console. I had to relocate the heater control in the glove box, picture to follow. I also needed to relocate the stock fuse box/realy board; it's now sitting in vertical where the stock air dam was. I removed all the air dam for the face position, my car is a summer car so feet & defrost is the only position I need. I then added my own fuse box in place of the old, and starded my wiring from it.

This project was spread out the whole 2006/2007 winter, and I started something bigger than I expected. That's what I realized after a 10hr wiring&soldering day in the car. But that was worth every effort! Let's see some picture now.







I must buy a good camera and learn to take good picture... oh sorry

I don't have a final picture of it in the car because the shifter still miss a shift boot. But I do have this vid from last summer just after the installation. The panel open as you put the key in the contact and close as you remove it.
http://www.youtube.com/watch?v=GHEHdKk02dM

This video was watched a lot of times on youtube and I always wanted to know if someone from tbricks saw it. Somebody?! Haha! I also received some comments from the swedes, if someone could translate them to me :P

See ya!
Roger-Dee
Stereo stuff looks hawt!!! Interior is looking real good, keep up the good work!!
__________________
Desert Detail & More LLC
89 Toyota Cressida
Uncle Ben's Powered..
Old car 2002 Z28

http://lsx.streetfire.net/video/610d...73014ac34d.htm
mikes02ls1 is offline   Reply With Quote
Old 05-25-2008, 11:10 PM   #16
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

The connection at the bottom-right is now my 12vdc outlet. I'm using a banana plug for it, I keep a male connector in the glove box and I'm all set. And at the right it's two rca plug, for an ipod or any other audio device. Trying to get the most use out of everyting :P
Roger-Dee is offline   Reply With Quote
Old 05-26-2008, 01:22 AM   #17
DurableSwedish
Hunting for a turbo
 
DurableSwedish's Avatar
 
Join Date: Dec 2003
Location: Hillsboro, OR
Default

you really need a bigger turbo...that 12b is sad
__________________
One Volvo left.
1982 244ti (313chp), 2011 Audi S4 (333chp) , 2016 Kawasaki 650R (76chp)
DurableSwedish is offline   Reply With Quote
Old 05-26-2008, 04:43 PM   #18
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Quote:
Originally Posted by DurableSwedish View Post
you really need a bigger turbo...that 12b is sad
Not only sad, he's way out of it's effiency range... It's a 13t, but who care anyway it's such a small thing! I should upgrade it this year for something real.
Roger-Dee is offline   Reply With Quote
Old 05-27-2008, 10:35 AM   #19
550
Board Member
 
Join Date: Sep 2004
Location: Illinois
Default

dude. wow!
__________________
Joe Bieda
V.C.O.A. Midwest Chapter President.

1984 242 M46 GLT.
-Couple of things done to it

1998 S70 Auto.
-LONG history.

1983 242 M46

Check out http://JJFAB.net For your K24 CBV blanking plates and oil feed/return flanges!!
550 is offline   Reply With Quote
Old 05-27-2008, 12:03 PM   #20
blkaplan
50 shades of beige
 
blkaplan's Avatar
 
Join Date: Jul 2002
Location: Rockville, MD
Default

that flip panel is sooo hawt. personally i would of preferred a brushed finish on the back side without the volvo engraving but either way its pretty cool.

what do those buttons control?
__________________
www.BEIGEPOWER.com
Kaplhenke Racing Facebook
Quote:
Originally Posted by DarkKratoz View Post
The only safe bet is Ben.©
blkaplan is offline   Reply With Quote
Old 05-27-2008, 09:16 PM   #21
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Quote:
Originally Posted by blkaplan View Post
that flip panel is sooo hawt. personally i would of preferred a brushed finish on the back side without the volvo engraving but either way its pretty cool.

what do those buttons control?
I wasn't sure what to do with the back side of the panel... At first I wanted to put a blinking led in the center but I didn't like the look, a led out of nowhere wth... :P
I would like to have a personal logo that I could put on every parts I make, but since I don't take the time to create one I write Volvo my custom parts

Only 4 button out of six have a use for now. The first one is foot led ligtning, that I never used in fact... 2nd is the 2 stage boost controller, 3rd is the launch control, 4th will be the ex. cutout, five was suppose to be for the water injection but I no longer see me diving into this project so let's say it's a blank for now. And finally the last is for the lcd screen. The two pushbutton under the fip panel are for the power window (no key needed to roll the window when pressing the first one (very handy feature of my car)) and the other will gradually open the ex. cutout.
Roger-Dee is offline   Reply With Quote
Old 08-10-2008, 11:18 PM   #22
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default Getrag time

I keep forgetting to update this thread. One day I will have so much to write that it will take me a whole day Well I will do the getrag part tonight.

From an old thread:
This weekend it was Getrag time. This is the kit that I purchased from GTJordan in 2006, less the clutch, flywheel and PP. Since I got my car I wanted to install a manual tranny in it. I was not that unhappy with the aw71 but I like to have the control of the shift.

My weekend doesn't end really good, I got a sliping clutch problem but at least I know why. Today was a funny day but the run on the way home was painfully. But anyway I stay positive, I will take care of it all tomorrow. I'm not that happy to have to remove all that again but really, i don't have the choice... Enough with the problem, let's see some picture.


Let's start with the old aw71 (95K, not that old!) less a few thingy

The parts waiting to be installed


Getrag close-up

This is the perfect breather box kit for a newb like me that thought the engine would be fine without it and just a catch can...

this is what running breather box-less will make your engine look... and yes it's all new seal on a previously sandblaster head... nasty

The stock clutch, flywheel and PP for the first year or so

I liked that view, didn't have a chance to look there everyday

Engine ready to get the tranny

And the misfortune started here. As we installed the tranny, we didn't saw that the cutout for the crank sensor on the bellhousing wasn't big enough for my type of sensore... As we were tightening the tranny bolt they was some strange noise, followed by aluminum chunk falling on the ground... here's the damage:


That's when JB-welb proove himself to be very handy :P

The moment I've been waiting since I bought the car... the tranny bolted, and the exhaust full of dirty hand.

The crossmember is bolting in different hole than the automatic one

A quick fix for the shifter


We got some surprise when it was tome to put the central support. The oem support was not gonna fit, impossible to add hole where we needed to. So we had to improvise and the first thing that falled on our hand was that iron-angle (sorry babelfish transaltion...) and I must say it's rock solid in comparison of the stock one... but ugly I agree.


I also got some problem with the rear driveshaft. In fact I never got to make it fit to the one I got with the getrag. I got to use an old one from a 85 740 that I had lying around.

My first impression now! As soon as I started the car, I felt that there was much more vibration transmitted to the chassis. That was quite a surprise. The tranny bushing are far from soft and I guess a lot of vibration come from the fact there is two bushing instead of a central one just like any volvo tranny. The engine has now a very limited amount of movement under the hood and in the end I was really happy with that added vibration. I was a bit less happier when I pressed the clutch and wasn't able to get in any gear. I had to stop the car, engage a gear then start it. The clutch slip sooo bad, it won't bite no matter how much gas I gave it, no way my car could do 60mph. I will fix it tomorrow and hopefully I could give some "running" feedback. But I tell ya, that night when I poped the door and saw 3 pedals and a shifter out of nowhere, I felt good inside.

The next day at work I machined some small washer that I grinded to .080". That night we removed the tranny and we installed these shims on the pressure plate. The bmw disc is thicker than the volvo one by .080", and since I didn't knew it when i had my flywheel resufaced, the step was put to stock. We also changed the driveshaft centering bushing because it was causing alot of vibration on the take-off. We then put everything back in place and hoped for the best.

I couldn't wait to drop the car from the lift and to go take a ride. When the tire made a loud sqweeeeeek in the garage I had little feeling that we did suceed in our mission! We then took the car for a drive and oh, pure happiness. No more vibration from the driveshaft, it now shift well with the clutch completely disengaging and it will hold stock boost @ 3 poeple easily. I was amazed when I realized I can now feel the car going from closed to open loop.

So that day I had my first idea of what a getrag look like. The tranny shift well and soft. The ratio are a bit close and the first is almost useless with a 3.77 but I got used to it real fast. Fuel economy suffer abit from the 2900~3000rpm at 60~65mph. I have a big noise when decelerating and a ratling sound a idle, but I guess it's what you get when you buy used stuff already runned hard. Maybe it would be wise to open it and make a little investigation but I know next to nothing to it. I'll beat on it 'til it explode and then I'll put a T5 in place.

Last edited by Roger-Dee; 08-11-2008 at 05:08 PM..
Roger-Dee is offline   Reply With Quote
Old 08-10-2008, 11:23 PM   #23
linuxman51
BRANDSCHUTZVORSCHRIFTEN!
 
linuxman51's Avatar
 
Join Date: Dec 2002
Location: mont, AL
Default

so hows that ms treatin ya?
__________________
"They bum rushed them in their own crib, they drank all their beer, they partied with their ladies and they left with the trophy"

Now with in-house Dyno tuning!

Megasquirt Tuning!
Plug and play LH 2.4 Megasquirt, now with stealth mode!
linuxman51 is offline   Reply With Quote
Old 08-10-2008, 11:47 PM   #24
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

From an old thread too, translated from french. Sorry if the verb tense don't fit :P
It's from the 8th of april 2008


Welcome everyone!

The problem;
I decided to start documenting my most recent project. Last summer I was a bit surprised and happy at the same time to see that my stock PP & clutch wouldn't hold. As the winter came, I looked in the not so many options to upgrade the pressure plate and the clutch. I was disapointed to see that everything is sold as a "kit" plus the fact we don't really know what we buy when choosing between "stage"...

The solution;
John V bring the idea to me that a company named KEP does a lot of PP for the vw and porsche crowd. They are listed by stage but every stage is clamp rated. John was in the process of adapting one to a 9" stepped flywheel and had a part of the job done, but I wasn't gonna wait for his result to get me started.
So here is the pictures as seen from the Kep website. Actual product is sligtly different.


The "because" of the "why" (haha);
This kind of pressure plate is really similar to the one fitted to our volvo, well the one with the stepped flywheel. The biggest difference beeing the bolt cirlce, it's a little smaller than the Volvo one so some custom work was in order. That's when it really got me on it, because I really love to adapt and modify stuff.

That big lump of steel to start with...
Here is a picture of my stock flywheel prior to any modification.

My friend who work with solidworks in a daily basis did some drawing for me of a lightened flywheel since I was computerless, and he made some test of pression to see how much it's "suppose" to handle. I would think the flywheel will explode before looking like that!



The serious thing now...
The big fun start here. The PP is ordered, 290us well invested. The step one is now done and since it's the costfull step, that's a great thing! But there is some part of the puzzle left. I need to:
- Measure te bolt circle of the KEP PP;
- Drill & tap the new B.C.;
- Remove the old dowel and put new one in;
- Do a little diet to my flywheel, somewhere between 18~22lbs.;
- Have it resufaced and had the step modified;
- Bolt it all together and send it for balancing;
- Install & enjoy.

Some picture:
Down to 25lbs


Back view


....


What it should look like (pics is from JohnV);



That's all for now! I will write the second part in a few minutes but I don't think I will have the courage to do it all tonight (the test & drive part). I remember when I first wrote this thread in our french forum, I was so nervous about this project just about to get started. The same day I received the pressure plate it was adapted and ready for the balancing. Project like that really turn me on! Thanks to JohnV for letting me know about this wonderfull company!

Last edited by Roger-Dee; 08-10-2008 at 11:56 PM..
Roger-Dee is offline   Reply With Quote
Old 08-10-2008, 11:52 PM   #25
Roger-Dee
is DeeWorks.ca
 
Roger-Dee's Avatar
 
Join Date: Aug 2006
Location: Sherbrooke, Qc
Default

Quote:
Originally Posted by linuxman51 View Post
so hows that ms treatin ya?
Well, better than I thought

Idle is still giving me nightmare, as well as cold start and warmup enrich. The car is running pretty decent when hot and have a better response than it had with lh-sh1t. It never let me down on the road since I put it in. Anyway I'm having a lot of fun with it, I should have made the switch a long time ago.
Roger-Dee 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 06:01 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2021, vBulletin Solutions Inc.