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Old 06-24-2009, 11:26 AM   #1
mullen1120
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Default 745 rebuild to stock....and a t5 (gigitty)

ahh i can remember when i first joined turbobricks, and i would read threads like this about 300 hp builds and t5 swaps. i dreamed and thought this day would never come. but it has!

i guess the car originally came from cali since it has egr. but i bought the car from my good friend erik rhodenburg (spelling) for only 2 grand. all it had was cut stock springs and a 2.5 crush bent cat back lol.

before erik the wagon was used by lehman volvo in york, pa as a errands car for many years. i can actually remember when i used to go to the dealership with my 850t5 and see it parked out back lol.
but when i wrecked my 850 i couldnt pass up another volvo for cheap esp when it was a dealership car that i knew was taken very good care of

the reason for this build is my tbelt snapped bending valves and stamping pistons
but im rebuilding the engine to stock internals (for now) along with some other goodies.

Parts i have (some were on the car before this rebuild):
ipd springs, ipd sway bars, ipd panhard bar, ipd turbo cam kit, cherry turbo upper and lower strut braces, 15g turbo, oil squirters, 3" SAM turbo back exhaust, fred's chips, k&n cone, all poly urethane bushings in the front, ebay ic, g80 locker, ss braided brake lines, e-fan, relocated optima battery, removed ac, v70r front seats, suede headliner, 940 euro headlamps, afr boost and oil pressure gauges, aero side skirts, and of course the icing on the cake my world class t5 tranny!

here are some pictures (taken with a cell phone) of the beginning stages of the rebuild. as soon as i get the engine back from the machine shop and start putting stuff together i will post more pics. -Ryan








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old 745 project

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Old 06-24-2009, 02:52 PM   #2
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Nice. I was at Lawrences shop when you were talking to him on the phone, he is a good guy.
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Old 06-24-2009, 04:16 PM   #3
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We are excited to be helping out on this project!
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Old 06-24-2009, 04:40 PM   #4
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Sweet! Looking forward to this build. What are you doing about the T5 shifter placement in the 740?
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Old 06-24-2009, 05:03 PM   #5
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Sweet! Looking forward to this build. What are you doing about the T5 shifter placement in the 740?
im going to use one of bne's adapters he already has made.
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Old 06-24-2009, 05:08 PM   #6
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if i want to break into the 250hp range, what kind of injectors should i get?

will i have to mess with the spark at all?
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Old 06-24-2009, 05:21 PM   #7
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im going to use one of bne's adapters he already has made.
whose adapter? Link if possible thanx
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Old 06-24-2009, 05:23 PM   #8
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whose adapter? Link if possible thanx
kaplhenke's, no link but he makes them.
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Old 06-24-2009, 05:40 PM   #9
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We are excited to be helping out on this project!
hell yeah, i wouldnt even be attempting this rebuild if it wasnt for this forum.
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Old 06-24-2009, 08:54 PM   #10
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That body looks to be in great shape. Should be a fun re-build/build up.
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Old 06-25-2009, 12:54 PM   #11
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im pretty lucky that the closest machine shop to my house is also the one that does all the work for the volvo dealership lol


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Old 06-25-2009, 01:49 PM   #12
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for fuel and spark i'd recommend a set of chips from thelostartof. for 250whp you'd need something probably a touch bigger than browntops, something probably in the 42-46lb range.
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Old 06-25-2009, 03:42 PM   #13
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for fuel and spark i'd recommend a set of chips from thelostartof. for 250whp you'd need something probably a touch bigger than browntops, something probably in the 42-46lb range.
i do have fred's chips. id like to run a set of injectors that i wont have to change anything else like the fpr or coil pack.
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Old 06-25-2009, 06:07 PM   #14
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browntops will do fine.
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Old 06-25-2009, 06:11 PM   #15
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ive heard browntops leak though. i doubt 850 injectors would be big enough?

whats the biggest injector someone on here is running (reliably) with only upgrading to the 3" amm?
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Old 06-25-2009, 09:02 PM   #16
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daaaaamn




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Old 06-26-2009, 01:42 PM   #17
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can u guys give me some tips putting this back together? i wanna make sure everything is done right and seals. no leaks.
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Old 06-26-2009, 01:56 PM   #18
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New gaskets;) hehe

Here u go, should bee a little help.
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Old 06-26-2009, 03:44 PM   #19
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can u guys give me some tips putting this back together? i wanna make sure everything is done right and seals. no leaks.
...no leaks. Haha. Don't you know that's a Volvo standard feature?
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Old 06-27-2009, 03:03 PM   #20
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...no leaks. Haha. Don't you know that's a Volvo standard feature?
haha oh i know, ive just heard on here that guys have had problems with crank and cam shaft seals leaking. i really wanna avoid that.
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Old 06-29-2009, 06:19 PM   #21
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Did you buy your headliner material by the yard? How much did you buy? Looks great, and good luck!
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Old 06-29-2009, 08:12 PM   #22
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yep, at jo ann fabrics. use upholstery spray glue, i got mine at advanced auto.
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Old 06-29-2009, 08:19 PM   #23
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okay so i got the pistons, rod, and crank in. im doing the crank seal covers now and i think i got the seals in there really good but we shall see on start up lol.
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Old 06-30-2009, 12:52 AM   #24
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Old 06-30-2009, 11:50 PM   #25
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get the head tom, gonna try and put it all together in a day.


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