Not quite normal 245.

[suterman]

Thought I'd start a thread to document this thing,

I'm taking the goodies off the GLT I have and swapping them onto this 245.

I have a cunning plan to change the engine from a b200f to a stage 0 b230ft.

Heres the progress so far.

Its a 1990 245, a bit rusty round the boot and rear arches.

A bit of elbow grease and it will come up nice.





Looking at the rusty tailgate panel.





Leaf blockers


More rust




Anyone know where to get repair panels?

I am thinking of leaving off the rear bumper and making a smoothed panel to fit.


The car whos suspension is being used.


Went over to Kinver tonight and got the old beast started up an moved out from under the trees, after a jump and a few cranks it started up and ran fine.

We parked it over the pit where the work will commence, didn't get any pictures, not much to see yet but will be going over Tuesday and more will happen then.

In the mean time I picked this up from Griz.


Its a stock 530. 270,000 miles on it.




The shim clearance was between 0.040mm and 0.050mm so just under half way to needing re-shimming.



The usual flattened valve hushers.




Made a spring compressor using a large F clamp, a short piece of pipe and an old valve bucket. It works better that the old one I had (G-clamp0 and is easy for me to use by myself.







Gave it a bit of a wash in the parts washer and then hosed it off and dried it infront of the heater.







Using a sharpening stone to clean the face.



Thats better


Combustion chamber cleaned up


leaned up the exhaust bowel and runners some more to get the carbon off.



Then lapped in the valves, they wern't too bad but I'm sure lapping will be worthwhile.
Exhaust valve before lapping (I have cleaned the carbon off the valve in the picture already)



The same valve after..



Same with the valve seats in the head.
Before..


After..



The Valve train showing three completed valves.


I complete the lapping today but didn't have time to reassemble the head as I had to go off with griz on a treasure hunt. I will try and get it done tomorrow night so I can wrap it up to keep it clean until I need it.








Whats in here?



Whatever it is, its dirty.



Heeaaavee, hump, ngggnnng, urrgh, oooof!

Phew!


Its a 1995 b230fk, it belongs to the head, came off griz's Komfort waggon.

It needs new pistons, a crank grind and rebore to 2nd oversize.

More to come soon.

[Cameron]

Best. Shoelaces. Ever.
Looks like a fun project -- can't wait to see progress pics!

[RedFridge]

Awesome thread....Keep it up to date.

Smile on...don't break a fingernail or anything.

[norcal505]

i see a diamond in a ruff.
keep us posted, see you have quite the project ahead of you.
nice double clear tails!

[suterman]

My plan is to have it complete by the end of november

[TheJoyOfSix]

Originally Posted by Cameron

Best. Shoelaces. Ever.
Looks like a fun project -- can't wait to see progress pics!

Furry string FTW!

[suterman]

Originally Posted by TheJoyOfSix

Furry string FTW!

sisal string is what it is.

[volvorsport]

are you sure you need second oversize ?

ive got a 1st oversize penta block here - all yours .

[suterman]

Originally Posted by volvorsport

are you sure you need second oversize ?

ive got a 1st oversize penta block here - all yours .

From what I can tell, the block and piston are not a good fit, (dont forget its done 270,000 miles)

I admit I dont have the best measuring equipment and am no engineer.

I Want a new (fully overhauled) engine to play with that wont leak, smoke or burn oil.

I am going to order an oversize piston set and give them and the crank to a machine shop and have the block machined to match.

I slipped a (0.05mm) feeler down the side of the piston in the bore and its was well over the wear limit (0.03mm)


If I'm doing it wrong tell me because I dont want to buy new parts if I dont have to.

[CHESH740R]

I'm pretty sure that it has it, but make sure the block has been machined for a block mount dizzy, it will be if you can knock the blanking cap out.

[RobSmith]

Originally Posted by suterman

From what I can tell, the block and piston are not a good fit, (dont forget its done 270,000 miles)

I admit I dont have the best measuring equipment and am no engineer.

I Want a new (fully overhauled) engine to play with that wont leak, smoke or burn oil.

I am going to order an oversize piston set and give them and the crank to a machine shop and have the block machined to match.

I slipped a (0.05mm) feeler down the side of the piston in the bore and its was well over the wear limit (0.03mm)


If I'm doing it wrong tell me because I dont want to buy new parts if I dont have to.

If you a slipping a feeler guage down the side of the piston from the top the pistons are a little smaller above the top ring than further down the piston I believe.
Rob

Edit: Try volvo for panels. I am not being funny they provided some for my 245 and they were very good quality (as you would expect) and they were also as cheap as the pattern parts.
Rob

[suterman]

Originally Posted by RobSmith

If you a slipping a feeler guage down the side of the piston from the top the pistons are a little smaller above the top ring than further down the piston I believe.
Rob





Edit: Try volvo for panels. I am not being funny they provided some for my 245 and they were very good quality (as you would expect) and they were also as cheap as the pattern parts.
Rob

Hmmm, but the piston doesn't ever sit centrally in the bore so how can I measure the mean gap?

I'll see what happens with what I have got first and see how it looks.

[volvorsport]

your only ever measuring side clearance when you do that (nothing wrong with that of course)

best way is take said block to machinist and get him to measure it , and use that against the volvo specs .dont buy anything until you have it measured , not that only boring first oversize would be a lot cheaper - just makes sense unless you want the extra capacity to stay at 1st oversize.

i was up at the workshop today , ive got a std/std crank and bearings , a decent penta block , and a load of shell bearings i forgot to look at for rob !!!

[suterman]

Pete, can you bring the lines for the turbo just incase mine dont fit. have you got a spare IAV and bracket also? Cheers.


I have ordered the brakes and pistons, they should be arriving this week, then I can get the machining done

I also did some work in the shed

Dirty



Clean



couldn't help myself.


Head reassembled apart from the cam.




More progress soon.

[suterman]

I got a 1"- 3/4" reducer and a barbed 45* barbed pipe fitting.

Milled the reducer down to a perfect fit in the return boss and cut out a groove for an O-ring, with some hydraulic sealant it should be oil tight (fingers crossed)

hmmm

its a bit big.



I can connect this to the original pipe now though.


more to come.

[suterman]

New stuff arrived today!

New Cross drilled Zimmerman discs all round, nice pads and some nice new flexy lines.




Retaining pins and springs


B230ft pistons


Now I have to get the block off to the Machine shop and give the shed a good clean in preperation for the rebuild. Until the engine comes back I have to concentrate on the car itself. Giving it a thorough clean, getting the suspension off and cleaning up the rusty bits. I will hopefully be able to get a good day in this weekend.

[lclark96]

Will keep an eye on this one!

[760T man]

That ball cap is fail.

You need to get a Boston Red Sox cap ASAP. The New York Yankees are FAIL.

[suterman]

Originally Posted by 240T man

That ball cap is fail.

You need to get a Boston Red Sox cap ASAP. The New York Yankees are FAIL.

heheh, its just to keep my hair out of my face.

[RobSmith]

Looks good,
I am wanting to do a similar thing and was wondering how much were the pistons?

Rob

[suterman]

£317 delivered, I got them from Brookhouse Volvo, but he got them from Sweden, he said they were hard to find as there is not much call for them.

[BB-Q]

Mike, remember to give Ruth a hug of biblical proportions for this (as married stuff is always a joint decision). Good job you married her as she's definitely a keeper!!!!

[suterman]

Originally Posted by BB-Q

Mike, remember to give Ruth a hug of biblical proportions for this (as married stuff is always a joint decision). Good job you married her as she's definitely a keeper!!!!

Yep, do everyday. She has her drumming and I have my Volvo, it works out great.


Went over to Griz towers today as I have been itching to get started on the car itself.

It looked in a pretty sorry state with algae and snail trails all over it. The bonnet vents were full of leaves and rotting organic matter with woodlice crawling around in it.

I used my petrol leaf blower to suck most of the leaves out then flushed the rest down into the sills (will get them later)

Gave it a quick but comprehensive wash and got all the green gunk out of the corners and form round the trim and window seals with a soft dustpan type brush.

Dirty








Cleaning



Clean



There is a rust problem with the tailgate slam panel, I want to fit the bumper more flush with the rear of the car (or remove it) so removed the rear trim and cut all out all the rusty bits in preperation for welding in new metal, I also went over the rear arches with the grinder to investigate their condition, mediocre, with signs of previous tidying (filler and antirust) under the blistering paint.




After grinding.





Thinking



More cleaning





I will do more soon, the clock is really ticking now.

[Chris_R]

Looking really good!

Very interested in how you fix the rear panel... Love to see a rolled pan.

[745wagon]

what was that you used to clean your engine bay on the 245? looks like it did a great job!