Cameron's IPD/RSI 16v Turbo 240 Wagon Project

Cameron · 01-29-2009, 01:21 AM

So first the boring history of my wagon.

Built in 1980
Someone drove it around a bunch
A bunch of other stuff happened
It got a paint job to the current crappy black paint job in 1997 (according to the receipt w/ the records)
My brother-in-law bought it back in 2002(?) - did some basic upgrades on it
In November of 2005 I got it in a sale/trade of my '96 855 to said brother-in-law

So at that point it looked mostly like this:

Not a bad start! Originally I just had minor aspirations for the wagon. Maybe lower it, put some nice wheels on it, etc. Just a fun cruiser. Shortly thereafter, I started working at iPd. Needless to say being surrounded by Volvo stuff 40+ hours/week changed my plans very quickly. So over the next 3 years my wagon has undergone some major changes, with the newest part of the insanity just beginning. More on that later.

Details are boring and you don't care about boring so here's a quick and dirty of the mods done.

iPd Sway Bars
iPd Adjustable Torque Rods and Panhard Rod
Volvo/BBS Propus wheels
Converted dash from early style to later 81+ dash
New interior (seats/door panels)
Kaplhenke Coilover Kit with shortened front tubes - more on that here
S60R front brakes - click on the coilover link right above this for that too
Flathood/single round conversion - more on that here

At some point I also figured I'd see how "easily" I could turbo the car without changing out any of the stock fuel injection stuff. Worked out pretty OK and ended up looking like this:

Ugly but functional

So that's all the boring stuff about the chassis, etc. Now onto the real project which will be dominating this thread (especially over the next few weeks).

The old craptacular B21 I turboed was OK, but I wanted more. So what to do? I decided to build up a real turbo motor. So I put together some plans for a 2.3 liter 16v turbo motor for my humble little wagon

So with this in mind I worked with Jonathan @ RSI to work up some specs and a parts list that looked like this:

RSI H-Beam Rods
RSI Rollerwave 16v Pistons
RSI 16v Stainless Header
Cometic HG
RSI Getrag Adapter Kit

Got the pistons/rods from Jonathan and they look like this:

Then the block/crank/rods/pistons went to the machine shop (Eastco Machine here in Portland). Crank was ground .010" and rotating assembly was balanced. When I got the block back from the machine shop I spent some time cleaning up/evening out the exterior in preparation for painting the block -- clear.

Before:

After:

At this point all the pieces went over to Jonathan/RSI for blueprinting and basic bottom end assembly. RSI installed crank/rods/pistons and BMW squirters. At which point I picked up the block to finish assembly.

While the pieces were at RSI I started prepping the wagon for the new engine. See sequence of events below:

Using my devil eyes to stare the B21 into submission

Ewwwww.

Painted the new empty engine bay:

New engine on the stand (where it currently sits) awaiting some more cool parts and waiting for the head to come back from the machine shop.

My dogs are super interested in the whole process:

*Disclaimer: my dogs could care less about my new motor, in reality they're looking at a squirrel out the front window

So that's my long winded first post on this project

More to come as I progress on this over the next few weeks. Still waiting on my RSI header, my 16v head back from the machine shop and some additional super rad parts for the engine from a friend in Norway. Once that happens I'll finally decide what turbo I want to run, what clutch I want to run with the Getrag 265 I picked up and actually put it in the car.
More pictures and stuff here: http://www.ipdusa.com/tm-7

Tenacious Todd · 01-29-2009, 01:25 AM

You guys still sell parts for the older 2XX cars?

Karl Buchka · 01-29-2009, 01:26 AM

Nice project. You should have kept the quad rounds.

What are your power goals? Details on the head/cam/valvetrain?

Harlard · 01-29-2009, 01:35 AM

wow dude this is seriously impressive! i wanna be there when the engine drops in, can i come look ?

Cameron · 01-29-2009, 01:49 AM

Quote:

Originally Posted by Tenacious Todd

You guys still sell parts for the older 2XX cars?

Quote:

Originally Posted by Karl Buchka

Nice project. You should have kept the quad rounds.

What are your power goals? Details on the head/cam/valvetrain?

Thanks!
Ideally I'd like to produce 100hp/cylinder but that'll take some time and likely some revisions once it's running/tuned -- we'll see. For now the head/cams/valvetrain will be stock B234. Valve job/new lifters/etc. but stock cams and stuff. Down the road I want to put together another head for it (solid lifters/stiffer springs/cams/etc). At that time I'd really like to work up a variable length runner intake manifold too but it just seemed silly to me to go crazy on the head before I even get the thing running. For now I want to get it running and broken in.

Quote:

Originally Posted by 1harribert

wow dude this is seriously impressive! i wanna be there when the engine drops in, can i come look ?

That could probably be arranged.

norcal505 · 01-29-2009, 02:29 AM

nice. 245.

volvo-slyder · 01-29-2009, 02:35 AM

is that sum kinda windage tray? where you get that ****?

DurableSwedish · 01-29-2009, 02:43 AM

its a crank scraper...the portland guys are crazy about them, I lost the link to them though. like $50-70 for one I think.

550 · 01-29-2009, 02:47 AM

I may be drunk right now but I Know what hot sex in a car looks like.

740tankDriver · 01-29-2009, 03:00 AM

Quote:

Originally Posted by 550

I may be drunk right now but I Know what hot sex in a car looks like.

well said.

and the scrapers...http://www.crank-scrapers.com/Volvo.html

Harlard · 01-29-2009, 04:32 AM

Quote:

Originally Posted by 550

I may be drunk right now but I Know what hot sex in a car looks like.

+1, and its not the beer goggles at all either

Cameron · 01-29-2009, 12:35 PM

Quote:

Originally Posted by norcal505

nice. 245.

Thanks!

Quote:

Originally Posted by volvo-slyder

is that sum kinda windage tray? where you get that ****?

Quote:

Originally Posted by DurableSwedish

its a crank scraper...the portland guys are crazy about them, I lost the link to them though. like $50-70 for one I think.

Quote:

Originally Posted by 740tankDriver

and the scrapers...http://www.crank-scrapers.com/Volvo.html

Yup - I forgot I left that detail out - Ishihara Johnson crank scraper.

Quote:

Originally Posted by 550

I may be drunk right now but I Know what hot sex in a car looks like.

WeezilUSA · 01-29-2009, 12:44 PM

I like it! Go big or go home

DavoS40 · 01-29-2009, 12:54 PM

Awesome project, should be a killer wagon once it's back together!

brickborg · 01-29-2009, 01:02 PM

Cameron your wagon is the ****! I can't wait to see it come back together!

DecalServiceBrett · 01-29-2009, 09:19 PM

Quote:

Originally Posted by DavoS40

Awesome project, should be a killer wagon once it's back together!

your car is rediculously awesome.

as is cameron's wagagagagon.

2fast242gt · 01-29-2009, 09:28 PM

your car makes me....

Jerd · 01-29-2009, 09:56 PM

xD

This build is beyond sexy!

firenice13035 · 01-29-2009, 10:43 PM

i like it. i look forward to seeing the 16v project. i just hope it doesnt give me ideas.... NOOOOOO

towerymt · 01-29-2009, 11:12 PM

Quote:

Originally Posted by Cameron

After:

How does the oil return to the sump?

Cameron · 01-30-2009, 12:42 AM

Quote:

Originally Posted by towerymt

How does the oil return to the sump?

With magic.

GabAlmighty · 01-30-2009, 01:17 AM

Is said RSI header and bondo header?

RvolvoR · 01-30-2009, 03:10 AM

Quote:

Originally Posted by GabAlmighty

Is said RSI header and bondo header?

one in the same

DecalServiceBrett · 01-31-2009, 01:22 AM

You could grille a slab of chicken with that hefty mofo.

Needs moar 9000rpm rev limit, and gt40R

Cameron · 01-31-2009, 02:00 AM

Thanks for all the kind words on my hooptie project

Should be some good progress on the car/engine this weekend and I'll get some pictures up of that Sunday/Monday. Until then I figure I'd post some "filler" pics of the car and various stages of it's modified life over the last couple years -- although honestly, most these pics are from the last year or so.

Enough filler for now.

01-29-2009, 01:21 AM	#1
Cameron ドクターマリオ Join Date: Dec 2006 Location: Crawling around under the car	Cameron's IPD/RSI 16v Turbo 240 Wagon Project So first the boring history of my wagon. Built in 1980 Someone drove it around a bunch A bunch of other stuff happened It got a paint job to the current crappy black paint job in 1997 (according to the receipt w/ the records) My brother-in-law bought it back in 2002(?) - did some basic upgrades on it In November of 2005 I got it in a sale/trade of my '96 855 to said brother-in-law So at that point it looked mostly like this: Not a bad start! Originally I just had minor aspirations for the wagon. Maybe lower it, put some nice wheels on it, etc. Just a fun cruiser. Shortly thereafter, I started working at iPd. Needless to say being surrounded by Volvo stuff 40+ hours/week changed my plans very quickly. So over the next 3 years my wagon has undergone some major changes, with the newest part of the insanity just beginning. More on that later. Details are boring and you don't care about boring so here's a quick and dirty of the mods done. iPd Sway Bars iPd Adjustable Torque Rods and Panhard Rod Volvo/BBS Propus wheels Converted dash from early style to later 81+ dash New interior (seats/door panels) Kaplhenke Coilover Kit with shortened front tubes - more on that here S60R front brakes - click on the coilover link right above this for that too Flathood/single round conversion - more on that here At some point I also figured I'd see how "easily" I could turbo the car without changing out any of the stock fuel injection stuff. Worked out pretty OK and ended up looking like this: Ugly but functional So that's all the boring stuff about the chassis, etc. Now onto the real project which will be dominating this thread (especially over the next few weeks). The old craptacular B21 I turboed was OK, but I wanted more. So what to do? I decided to build up a real turbo motor. So I put together some plans for a 2.3 liter 16v turbo motor for my humble little wagon So with this in mind I worked with Jonathan @ RSI to work up some specs and a parts list that looked like this: RSI H-Beam Rods RSI Rollerwave 16v Pistons RSI 16v Stainless Header Cometic HG RSI Getrag Adapter Kit Got the pistons/rods from Jonathan and they look like this: Then the block/crank/rods/pistons went to the machine shop (Eastco Machine here in Portland). Crank was ground .010" and rotating assembly was balanced. When I got the block back from the machine shop I spent some time cleaning up/evening out the exterior in preparation for painting the block -- clear. Before: After: At this point all the pieces went over to Jonathan/RSI for blueprinting and basic bottom end assembly. RSI installed crank/rods/pistons and BMW squirters. At which point I picked up the block to finish assembly. While the pieces were at RSI I started prepping the wagon for the new engine. See sequence of events below: Using my devil eyes to stare the B21 into submission Ewwwww. Painted the new empty engine bay: New engine on the stand (where it currently sits) awaiting some more cool parts and waiting for the head to come back from the machine shop. My dogs are super interested in the whole process: *Disclaimer: my dogs could care less about my new motor, in reality they're looking at a squirrel out the front window So that's my long winded first post on this project More to come as I progress on this over the next few weeks. Still waiting on my RSI header, my 16v head back from the machine shop and some additional super rad parts for the engine from a friend in Norway. Once that happens I'll finally decide what turbo I want to run, what clutch I want to run with the Getrag 265 I picked up and actually put it in the car. More pictures and stuff here: http://www.ipdusa.com/tm-7

01-29-2009, 01:25 AM	#2
Tenacious Todd Board Member Join Date: Nov 2002 Location: Sykesville MD 21784	You guys still sell parts for the older 2XX cars? __________________ 2013 C30 Polestar 1998 C70 Coupe

01-29-2009, 02:29 AM	#6
norcal505 Board Member Join Date: Sep 2006 Location: Los Angeles, CA (SGV); Chicago, IL; San Diego, CA; SF Bay Area, CA	nice. 245. __________________ 1991 BMW 318i (Old Shell RIP, Now Re-shelled & Reborn) 1983 Peugeot 505 STI 1992 Volvo 245 Euro Delivery

01-29-2009, 02:43 AM	#8
DurableSwedish Hunting for a turbo Join Date: Dec 2003 Location: Hillsboro, OR	its a crank scraper...the portland guys are crazy about them, I lost the link to them though. like $50-70 for one I think. __________________ One Volvo left. 1982 244ti (313chp), 2020 Nissan Leaf daily driver, 86 Yugo GV junk pile/gambler car

01-29-2009, 02:47 AM	#9
550 Board Member Join Date: Sep 2004 Location: Illinois	I may be drunk right now but I Know what hot sex in a car looks like. __________________ 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!!

01-29-2009, 01:26 AM	#3
Karl Buchka Board Member Join Date: Mar 2007 Location: Los Angeles	Nice project. You should have kept the quad rounds. What are your power goals? Details on the head/cam/valvetrain?

01-29-2009, 02:35 AM	#7
volvo-slyder Board Member Join Date: Aug 2004 Location: EastBay california	is that sum kinda windage tray? where you get that ****?

01-29-2009, 12:44 PM	#13
WeezilUSA Board Member Join Date: Nov 2002 Location: Vancouver WA	I like it! Go big or go home __________________ 1983 242 ICSCC GP Race Car

01-29-2009, 12:54 PM	#14
DavoS40 Board Member Join Date: Nov 2002 Location: Fort Collins, CO	Awesome project, should be a killer wagon once it's back together! __________________ 1983 245DL, 2011 WRX, 1978 SR500

01-29-2009, 01:02 PM	#15
brickborg Board Member Join Date: Mar 2007 Location: Nomi, MN	Cameron your wagon is the **! I can't wait to see it come back together! __________________ 1985 760 Jurbo- 80k miles, finally running. Build thread HERE 2000 Honda CRV- Ã…snan 2012 Honda Civic LX- Reliable.**

01-29-2009, 09:28 PM	#17
2fast242gt Do you have a cobalt? Join Date: Nov 2005 Location: appleton WI	your car makes me.... __________________ 1983 242dl 6.0 lq4 swaped Build thread http://forums.turbobricks.com/showthread.php?t=282323

01-29-2009, 09:56 PM	#18
Jerd Board Member Join Date: Mar 2008 Location: Vancouver WA	xD This build is beyond sexy!

01-29-2009, 10:43 PM	#19
firenice13035 Board Member Join Date: Aug 2003 Location: York, PA	i like it. i look forward to seeing the 16v project. i just hope it doesnt give me ideas.... NOOOOOO __________________ 1984 Project 242 http://forums.turbobricks.com/showthread.php?t=81142 1995 854 T5R

01-30-2009, 01:17 AM	#22
GabAlmighty Board Member Join Date: Sep 2008 Location: Port Moody, B.C.	Is said RSI header and bondo header? __________________ '12 Raptor

01-31-2009, 01:22 AM	#24
DecalServiceBrett Board Member Join Date: Apr 2007	You could grille a slab of chicken with that hefty mofo. Needs moar 9000rpm rev limit, and gt40R

01-31-2009, 02:00 AM	#25
Cameron ドクターマリオ Join Date: Dec 2006 Location: Crawling around under the car	Some Filler Thanks for all the kind words on my hooptie project Should be some good progress on the car/engine this weekend and I'll get some pictures up of that Sunday/Monday. Until then I figure I'd post some "filler" pics of the car and various stages of it's modified life over the last couple years -- although honestly, most these pics are from the last year or so. Enough filler for now.