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Old 12-26-2011, 10:02 PM   #1
poulrais
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Default Poulrais's 745 16V from up North

Ok so I'm going to start this build thread. I just hope I find the time to feed it!!

A friend of mine bought this car on November 2009 and he had this idea of building a very fast wagon to surprise the crowd at the local dragstrip... He stored the car for winter and began buying bits and pieces from EBay and other TB members. He bought the Getrag swap kit from qwkswede and a nice Garrett T04E on EBay. He also ordered a plug and play MS kit from Linuxman. 3 months later he told me he was going to sell the car. I couldn't let this pass so I broke the piggy bank and bought the car for $4000 including the uninstalled Getrag kit, turbo and MS (not installed).

The car came with the following mods and upgrades:

Motor: B230FT 1995 (940)
Black leather seats
Getrag 5 sp. Swap
Brand new Mitsubishi TD04h 15G 2009
new ported headers
Ford brown top injectors
Complete 3'' exhaust with downpipe,high flow CAT and Magnaflow muffler
K&N cone filter and heat shield
MBC
Coil Blaster 2
MS v3 Plug and Play with many options
Brand new Jumbo calipers front and rear
F/R stainless steel brake hoses
F/R cross drilled rotors
ATE Superblue brake fluid
Upper and lower frame braces (Cherry Turbo)
In tank Walbro 255 fuel pump
850 fuel filter conversion
Brand new flame trap
Electric fan conv.
Rack & pinion + pump brand new
New alternator
Brand new HD rear coils
Bilstein TC front, Sachs back
IPD back sway bar
17' Eikers (Polaris replicas) mint condition, New BFGoodrich G Force KDW
New balljoints
tie-rods inners and outers new
New end links with poly bushings
New heater core
New blower motor
2007 exterior paint
V90 door and rear panel handles
V90 rear spoiler
Real Euro headlight assembly (not the Scantech replicas) with 65w high-beam, low 55w, yellow fogs and auxiliaries 100w
Euro flashers
Euro side markers
SE side skirts and rear bumper
V90 rear lights
redone black headliner
780 center pod with 3 gauges (voltmeter, oil pressure and boost)
Blaupunkt Long BeachDVD35 CD DVD MP3 with speakers
sub MTX 2 x 10'' with MTX Thunder amp…


Since I'm a total noob in anything electrical, I had the MS installed by Roger-Dee in May 2010 but I left the LH system in place for awhile since I had no time to sort out the bugs from MS and no time to tune. I finalized the MS install and tuning at the end of the 2010 summer, still running on the crank position sensor flaky signal, 15G and browntops.

We took out the AW71 in June 2010 and installed the Getrag. And it felt very good right away!!

I stored the car for the 2010-2011 winter. Took the car out in April 2011 and blew the HG not long after that but it was a slow leaking gasket so no harm to the head and it only needed a regular resurfacing. I drove the car alot last spring, summer and fall and managed a best 9,23 on the 1/8 local dragstrip which is not bad for an almost stock heavy wagon on street tires. But since I sold my 331 stroked Mustang on December 2010, I was badly in need of a HP boost on this wagon!

Bought a house with a 3 car garage this summer so this winter is major engine work time!!! Here's what I have already in hand to install:

-Garrett T04E A/R .63
-Nathaninwa's custom 16V intake mani with fuel rail and 960 TB
-16V head with Yoshifab's valve springs upgrade
-Tubular exhaust mani bought from Linuxman, used to be in the car he rolled over with...
-Yoshifab's 16V timing belt conversion kit
-1995 B230ft block with squiters, bored to 96,5mm
-Forged 16V CP pistons from JVAB
-160mm H-Beam rods also from JVAB
-DSM CAS
-LS1 coils
-New crank and rod bearings

Here's what I have to gather up in the following month:

-Injectors, at least 1000cc
-A rightly sized intercooler
-Crank scraper
-Intake hoses kit
-Yoshifab's CAS adaptor
-T5 with appropriate PP, clutch and Flywheel
-Wilwood brake upgrade, front and rear
-adjustable FPR
-more money...

Right now the block is at the machine shop, bored and ready to be painted, red. I'm taking the crank to another machine shop next week to have it balanced. We should start assembling the engine back in a couple of weeks.

Btw, I'm hoping for around 400 whp on crushed fossil juice of the 94 octane kind...

Pictures? ->>

Time to take the sh**t out!


And UP she goes!!




B230ft and Getrag separation...


This will need to be cleaned up!


Crank removal


Done!


Let her squirt!!!


The old slappers


Is this normal wear?!






Prepped 16V head




Tougher rods and pistons!


Nathaninwa's artwork


Linuxman's old tubular mani


Garrett T04E




Washed block


Block turbo oil return tapped for a Dodge 2.2 heater core fitting




Engine block in the cross hatching machine... Notice the nice torque plate we had Roger-Dee make!!






So this is about all for now!!
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Old 12-26-2011, 10:06 PM   #2
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http://forums.turbobricks.com/showthread.php?t=316428 91'744T .57 t3/t4, big ic, greddy type s, 55lb/hr injectors, bosch 044, tloa ecu/ezk, 3"amm, rsi stg 3 cam, ttr cam gear, top mount header, 3" exhaust, kevlar tbelt, e-fan, 22 psi, intrax springs, cherry turbo brace, ipd rear sway, dual front sway bars, bilstein struts, camber mod, accum mod
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Old 12-26-2011, 10:37 PM   #3
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Thanks I needed this a lot
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Old 12-27-2011, 12:42 AM   #4
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nice project! excited for more updates!
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Old 12-27-2011, 01:00 AM   #5
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Thanks! I'm excited too! We don't see many high perf RWD Volvos around here! Most are either in the hands of grandpas or in a state of disrepair!!
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Old 12-27-2011, 06:27 AM   #6
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thisis the shizz...


subscribed !
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Old 12-27-2011, 08:15 AM   #7
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nice project.

i like that honing machine. i'm always stuck with a squirt can of oil and some cheap hone in a drill.

when were those pistons made?
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Old 12-27-2011, 08:39 AM   #8
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Originally Posted by 500dollar744ti View Post
nice project.

i like that honing machine. i'm always stuck with a squirt can of oil and some cheap hone in a drill.

when were those pistons made?
They were made last November I think... Why?

And yes the honing machine is pretty cool. My machinist friend says they getting quite rare around here too...
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Old 12-27-2011, 02:23 PM   #9
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Nice to see a build thread started!
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Old 12-30-2011, 10:55 PM   #10
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Great thread! And a 16v+t will appear here soon!
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Old 12-31-2011, 09:11 PM   #11
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I like it. I'm glad to see more performance Volvo's east of BC :D
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Old 01-01-2012, 01:43 PM   #12
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Picked up the crank, rods and pistons to have all this balanced at National in Montreal next week!

Gotta to order the crank scrapper and still waiting on some news from JohnV about my ARP head studs...
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Old 01-01-2012, 02:27 PM   #13
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what crankscraper? who offers this as a bolt on?
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Old 01-01-2012, 02:45 PM   #14
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Originally Posted by MadDog_945 View Post
what crankscraper? who offers this as a bolt on?
http://www.crank-scrapers.com/Volvo.html
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Old 01-05-2012, 11:09 PM   #15
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Gawd, If you have anymore friends who sell cars like you got PLEASE tell me. RWD Bricks is decent shape not to mention extras are damn near impossible to find here. Nice garage. I put in a real 2 post hoist in mine, 2K delivered installed myself in 2 easy days. Let me know if you want to know who in Canada sells them. Pretty basic model but nice to stand underneath.
ian
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Old 01-06-2012, 09:00 AM   #16
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Originally Posted by ibs740 View Post
Gawd, If you have anymore friends who sell cars like you got PLEASE tell me. RWD Bricks is decent shape not to mention extras are damn near impossible to find here. Nice garage. I put in a real 2 post hoist in mine, 2K delivered installed myself in 2 easy days. Let me know if you want to know who in Canada sells them. Pretty basic model but nice to stand underneath.
ian
How much ceiling height do you need to installe this? And on what type of current does it run? 220V? Problem is I would have to level the floor cause it presently has a slope going to the drain in the center of the garage... Right now I can get 3 cars in there and still able to open the doors. With the hoist I don't think this will be possible anymore. That's why I was more inclined to buy a bodyshop type of hoist.
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Old 01-06-2012, 12:59 PM   #17
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220VAC. There are 2 versions, low ceiling and high ceiling. I have 12.5' ceiling so I used the high hoist. With the low version the equalizing cables run along the floor between the posts. Lump to drive over and salt and sh!t falls on it in the winter. I bought mine in 2010. Depends how sloped the is but you just use steel shims. I've seen lots of commercial garages with shimed hoists. Ask the supplier.
This is the USA site but ask for the Canadian rep. in Mississauga area. http://www.directlift.com/Two-Post-Lifts-C8.aspx
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Old 02-24-2012, 09:39 PM   #18
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Time for an update!!!! Got the block back a while ago but needed the ARP head studs to put the motor back together. Then I noticed that I missed the 3 spacers to install the ARP's and I had to have these fabed (Thanks Roger-Dee!!). So my friend Dave (Dave242GT) who is also my machinist came to my garage and we started assembling back this engine. Some pictures:


Crank in place


Used plastigauge to check the clearances...


Oil pan back on to protect the interns from dust and particles...






Interested skunk!! My cat Benjamin!!!


Pistons and rods waiting to be installed!


Benjamin loves the Getrag!!


Rod end caps, clearance also verified with plastigauge. All is fine at 75lbs of torque


Shiny ashtrays in!


Prepped head...




ARP head studs in


Drilled the coolant holes, 2 X 6mm at the back and 1 X 4mm hole on the left front. Hope this will help keep the HG in good shape.


First part of the 16V head in. Notice the 3 aluminum spacers on the right. 1" OD X 1,5" long drilled .5"... Yoshifab's upgraded valve springs stiffness!!!






Head bolted. 95 lbs of torque using ARP lube...


Lifters in.... Still hydraulic Next upgrade maybe?


Brand new Melling oil pump




TADA!!!!!


Nathan's art work


Butifull!!!! Linuxman's old tubular exhaust mani repainted!!

So this is it for now... Gotta order injectors, new clutch disk and this and that...
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Old 02-25-2012, 12:18 AM   #19
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startin to look like something, eh?
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Old 02-25-2012, 12:23 AM   #20
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Originally Posted by poulrais View Post
They were made last November I think... Why?
are they the "updated" design? i just had a bad experience with those.
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Old 02-25-2012, 05:25 AM   #21
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Originally Posted by ibs740 View Post
Gawd, If you have anymore friends who sell cars like you got PLEASE tell me. RWD Bricks is decent shape not to mention extras are damn near impossible to find here. Nice garage. I put in a real 2 post hoist in mine, 2K delivered installed myself in 2 easy days. Let me know if you want to know who in Canada sells them. Pretty basic model but nice to stand underneath.
ian
whoa hey, an ottawan? There's a few of us in the offtopic canada chat thread, stop in some time...
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Old 02-25-2012, 08:09 AM   #22
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Wow! Very nice engine!
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Old 02-25-2012, 08:27 AM   #23
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are they the "updated" design? i just had a bad experience with those.
What type of "bad experience"? When were yours made?
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Old 02-25-2012, 08:29 AM   #24
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startin to look like something, eh?
Yeah! First time I do an engine build and it's fun to see a bunch of scattered parts come together!
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Old 02-25-2012, 08:35 AM   #25
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Wow! Very nice engine!
Thanks! Not sure what I want to do with the valve cover yet... Red or just leave it like this with a clear coat?
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