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Old 09-04-2011, 09:20 PM   #1
B-dub
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Default The 242 Hotness of Doom

Updated: 4/19/13

This build starts with these two cars:
523whp 245
242 Group A replica


Pat (Group A) made this beauty with me when it was intended to be a GP race car and a initially a daily driver. The guy builds works of art. And now I'm going to enhance it.

Upgrades on the way marked in BLUE

The basics:
1983 242 DL

Engine:
'93 B230f Squirter motor
RSI long rods
RSI spec Weisco pistons
RSI stage V 531 head, 1 of 1 298 CFM@28" .600"lift
Header - Designed, built by, and welded at RSI World headquarters
GT3076R turbo - UPGRADE! GTX3076R should be good for another 100 whp
Twin Tial MVS 38mm v-band wastegates
Tial "Q" BOV
Full 3" mandrel exhaust
Nickle coated brass PTC fittings for all vacuum lines
Nathan in Wa Intake Manifold! (bolt on 60+whp, dyno verified)

Transmission/rearend/Wheels:
Getrag 265 - TKO when the Getrag dies
Volvo OE Hydraulic clutch Master cylinder - Wilwood master w/adapter by NIW (Shhhhh, he doesn't know yet)
Volvo OE Slave cylinder - OE GM clutch slave
RSI 13lb flywheel w/60-2 VR pickup - Yoshi CAS adapter
Custom 4puck clutch w/high pressure plate
1031 rear, welded w/3.31 gearing - Ford 8.8 limited slip 3:73 final
RPF1 17x9.5 all the way around
Nitto NT01 255/40-17 tires

Extended studs

Chassis/Suspension/brakes:
Stitch welded chassis
RSI Short Strut Coilovers
Bilstein custom valved short strut inserts
RSI Engine mounts - I love them BTW
IPD Adjustable panhard rod
IPD Adjustable torque rods
IPD 25mm sways
Complete poly suspension mounts - Kaplhenke Spherical bearings
IPD Stainless brake lines

Fuel:
Walbro 255hp intank
Bosch 044 inline - Dual 044's w/surge tank
--Both run with independent 30a relays
Stainless braided-10 supply lines -8 return
Aeromotive -10 FPR
Injector Dynamics 1000cc injectors

Electronics:
MSPro
DIYAutotune race coil packs
Custom made plug wires

Generic fuse block
Hand wired chassis

Gauges:
Speedhut gauge set
Autometer 5" tach
Autometer boost gauge
Autometer Wideband
Other gauges to be determined


The idea is a full interior, fully streetable, and track monster. She has much work yet to be done, but I have a good start.

Pre transplant:









That's better! Maybe not the color combo...

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242: Stage X It's a process.

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Last edited by B-dub; 04-19-2013 at 05:27 PM..
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Old 09-04-2011, 09:20 PM   #2
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Here is the whole process to date. I apologize the 4th update is not attached.

Swapping, stitch welding, gutting, wiring, moar faster....



Strip and deep clean the interior.

Fate knew that I would be facing Nathan at some point and left me some wood screws to keep the doors from being blown off.


Won’t need any of this.



Completely strip the interior.


I’ll be hand laying the whole harness from scratch.


Remove all the sound deadening tar paper.


Strip engine bay down to sexy smoothness. No need for unsightly wires here.



Last edited by B-dub; 03-15-2013 at 02:12 PM..
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Old 09-04-2011, 09:22 PM   #3
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This stuff is everywhere! All must go.


Needs moar power!


Tar paper removed.


Prep all seams for stitch welding.





More seam preparation.



Stitch welding for days.



















Last edited by B-dub; 03-12-2013 at 02:16 AM..
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Old 09-04-2011, 09:22 PM   #4
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This whole process of stripping the interior, taking out the engine, taking out the tar paper, prepping the seams, welding, cleaning the residue off, painting and primer took a solid two weeks.
I could not be happier with the result but it was one of the more time consuming PITA parts of any build I’ve done.


Aaaaaand the stitch welding continues…





Now that all the tar paper is gone, only the residue remains. Why do a job half assed? Off with the residue!






Once everything was made shiny clean primer and paint were layed down.





Some “green” paint to seal it all up, and have more than just primer peeking past the carpet and interior.



Here sits my wagon… ready for disassembly. It’s a sad day, but it’s going to be awesome when it’s done.








Subframe out of the 242. I will swap over the one from the wagon as a whole unit.



Suspension out of the 242. Some stitch welding showing through.


Effed up battery tray going bye bye.




Engine bay all painted for protection from the elements.
I will be using my chassis media blasting system on this and it will be repainted after the drivetrain and the rest of the chassis is dialed.


Interior will stay the same though. Deal with it.

Last edited by B-dub; 04-05-2013 at 04:26 PM..
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Old 09-04-2011, 09:23 PM   #5
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The old Saginaw steering pump bracket was broken. No real surprise there. This will be changed out to a late model pump.



Ripping her heart out.



And now she’s leaving me. :tear:

I Loooove this hotside. So sexy.


A B230 that isn’t caked in oil… It doesn’t seem right, but I’ll allow it.


Firewall pieces and crossmember installed.



In she goes!



I used some of the polycarbonate from the wagon windows to make templates and other bits for the interior of the 242. Here is a plug for the heater intake. I will be using a Mohave unit from Summit instead of a stock system.



Getting started on the MS relay board.

Mocked up the center console for wiring and function… Not going to stay this way.

Last edited by B-dub; 04-05-2013 at 04:33 PM..
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Old 09-04-2011, 09:31 PM   #6
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Looks like your going to be way baller than me!, wait.....I'm starting work on my car again!
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SHEETMETAL INTAKEhttp://forums.turbobricks.com/showth...etmetal+intake

THIS IS FORSALE V
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Old 09-04-2011, 09:40 PM   #7
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I've heard it's pimp. One question: did the color scheme change?
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Old 09-04-2011, 10:15 PM   #8
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its night here on the east coast so post pictures!!!!!
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b230+16v+holset hx35 16cm hot side +75shot CRUSHED

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Old 09-04-2011, 10:29 PM   #9
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Quote:
Originally Posted by Group A View Post
He put all the drive-train from the wagon in it. Won't be a GP car anymore.

I have a hunch...
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B5.5 passat wagon, low af sexier than most wagons here.
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I've got a real issue with you Wilford
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Old 09-05-2011, 12:58 AM   #10
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Quote:
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I have a hunch...
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Old 09-05-2011, 05:10 AM   #11
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takes a genius to figure that one out...
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Old 09-05-2011, 02:47 PM   #12
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WHat a teazeee!

I mean rly...not even an old pic of that green 2-door....or a nice carnage shot of the donor????

tell me you pulled off that lumpy SOHC top end, and sold it to a kid in Botswana....telling him it'd make his bamboo bike rly fast...or did we "simply" salvage what was left of the 11-second hearse and strap that biatch in to da green monstahhh??????????

Come on, i'm on the edge of my seat herrre...juss give us a tasteee

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Old 09-05-2011, 03:06 PM   #13
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I've been known to lock project threads that lack pictures and/or information. Better get to work!
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Old 09-05-2011, 03:34 PM   #14
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Uh oh.....

don't anger Mr. T

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Old 09-06-2011, 06:22 PM   #15
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Oh Towery, powerful and almost as fast as Pat, Spare my thread!

I've added pictures. Specifications, and build plans to follow.
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Old 09-06-2011, 06:30 PM   #16
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Planning on using a tru-trac or G80 instead of a welded diff?
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Old 09-06-2011, 07:09 PM   #17
Cameron
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Quote:
Originally Posted by B-dub View Post
I've added pictures. Specifications, and build plans to follow.
Looks OK I guess

Man, did Jordan rub off on you for that color scheme?

For serious though, really nice progress man. I'm sure it will be just as cool or cooler than the wagon
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Old 09-06-2011, 07:16 PM   #18
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Originally Posted by RCArmy434 View Post
Planning on using a tru-trac or G80 instead of a welded diff?
Better hope so...don't want another one backwards into a wall.





Oh, B-Dub, two green's won't make it right.
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Old 09-06-2011, 07:21 PM   #19
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Is the engine bay only going to be half way painted?

I loved the wagon. Can't wait to see how this turns out.
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Old 09-06-2011, 07:23 PM   #20
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^

It makes the engine look better, by comparison...

You know, like when a cute girl brings along, well, her, umm...not so cute friends.

An evil trick.
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Old 09-06-2011, 07:23 PM   #21
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Originally Posted by RCArmy434 View Post
Planning on using a tru-trac or G80 instead of a welded diff?
Some sort of limited slip option in a Ford 8.8. For now the welded will stay as I make other adjustments on the car.
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Old 09-06-2011, 07:24 PM   #22
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look forward to riding in it this year.

time to ditch that old, heavy power steering pump
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Old 09-06-2011, 07:26 PM   #23
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Looks like you're doing it right. Excellent work so far!

So no heater box at all or are you installing an electric heater? Also, lexan center stack? :'(
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Old 09-06-2011, 07:31 PM   #24
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Quote:
Originally Posted by Mylesofsmyles View Post
Oh, B-Dub, two green's won't make it right.
Quote:
Originally Posted by euroshark View Post
Is the engine bay only going to be half way painted?

I loved the wagon. Can't wait to see how this turns out.
Quote:
Originally Posted by Mylesofsmyles View Post
^

It makes the engine look better, by comparison...

You know, like when a cute girl brings along, well, her, umm...not so cute friends.

An evil trick.
The color is temporary. Once everything is dialed in the motor is coming out, and it's getting repainted.
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Old 09-06-2011, 07:38 PM   #25
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Originally Posted by Karl Buchka View Post
Looks like you're doing it right. Excellent work so far!

So no heater box at all or are you installing an electric heater? Also, lexan center stack? :'(
Thanks!
I'm going with a Mojave heater for a little cabin temp and defrost.
Don't worry about the center panel, It's all I had laying around for mock-up. That'll be aluminum or steel when it hits the street.
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