Double Dutch

[Chilm]

Hello TB enthousiasts,

I'd like to make my own thread about my Dutch Volvo 945, to get comments and advice and for people who want to be inspired modding a steel brick
It will be wth bits and pieces because i did a lot an can not post everything in one evening duhuh.

Dunno if this is the right place or it has to be in "Showroom" mod's, do what you have to do

I am very precise in sorting my "stuff", it saved me many many times.



I bought this air tools and carbid burs for the ruff stuff, i can tell with this tools it's going a bit too fast, Aluminium is soft as you know. I will do the fine work and finishing with my good old Dremel, the best tool I ever bought. A friend of me milled a nice long shaft for it to get deep and smooth







And then i bought the so much sought after 531 head, very common here in Holland har har
I marked the holes with a Widia pen and used the gaskets as a guide:



The bowls from the 531, much is said about it, i'm gonna unshroud the outlet side and take some other material from the bowl and spark plug surroundings, mark the angle of the spark plug thread.



Some more marking, take it to the limit





And now for the first time the ruff grinding, don't hesitate just do it:











The outlet side:





Bowls:





The inlet side, also a huge mismatch with the gaskets:

















Now it can be shaved, i also like to go tight squish but haven't the numbers yet (deck and amount of shaving).





Also going to drill the extra holes 3,4 and 5 mm. for more equal cooling of the head and to avoid hot spots. Next picture is from Stoni's website just to show you where to drill.

Nr.1 has a 3mm hole, Nr.2 has a 4mm hole, Nr.3 has a 5mm hole, Nr.4 has two 5mm holes at the rear end.







Again above 3 pictures thanks to Stoni's World website: click

Well... that's it for now. i will make updates asp

The brandnew 3inch stainless steel exhaust with racecat handmade by Jelmar from www.crossroadmotorsport.nl a real peace of art if you'll ask me, a craftsman "pur sang".





I am reeeeeally going to sleep now

[Roy 940]

Nice head! Well done!

[Chilm]

Originally Posted by Roy 940

Nice head! Well done!

Thank you Roy.

[Roy 940]

Very nice exhaust!!! And what about the price and the sound?

[MDVLN]

Great wagon colour

Great head work as well!!! I just hope njal doesn't see this, I love the guy but he might have a few words for you... haha

[Chilm]

Originally Posted by Roy 940

Very nice exhaust!!! And what about the price and the sound?

You have got a PM. Sound is great, dark haul...

@Madvillan: Who is "njal"

[aaron740gl]

Our resident aeronautical physicist...

[Chilm]

Originally Posted by aaron740gl

Our resident aeronautical physicist...

Omg, keep him away, kill it with fire lol.

[940wagon]

Nice work. What's the story on "Limited Edition" badges?

[Chilm]

Originally Posted by 940wagon

Nice work. What's the story on "Limited Edition" badges?

Well the story is i saw an ad on "Marktplaats" (the dutch E-Bay) and thought YES, he had two of them, brand new and original Volvo. I have never seen them before and now also got one spare. I could have sold them several times but i won't as you will understand

P.S. the car is an original LE with the full options of an LE, meaning everything possible exept the sunroof which is a sad thing lol.

[MDVLN]

Originally Posted by Chilm

Omg, keep him away, kill it with fire lol.

I didn't mean to offend any parties, that had just crossed my mind - should have been one of those thoughts that I kept to myself.

If your statement means you have a lack of a sunroof, I'd consider that a good thing. I'm not a big fan of sunroofs or convertibles and the like though so there's that, haha.

Looking forward to seeing anything else you may do - Your undercar shot gave me a few ideas on what to do for my exhaust; If I do it "proper" and don't do a short exit. Ha.

[Chilm]

After I followed the wasted spark initiatives from Karl Buchka and Blabla (Martijn) I could not wait to install this because imho it would be a huge improvement in fuel consumption and "burn" efficiency.

I bought the Buchka board but used the Blabla board that i bought too, and only because it was easyer communicating for me living in Holland (so does Blabla as you probably know).

The only thing I hated from the start was the mounting of the bracket most people did, it looked so DIY and "not original". So i decided to fab my own bracket from scratch and put it elsewhere (see pictures below).

This is the Blabla board that must be soldered in to the EZK



And I bought some soldering equipment because I had nothing, soldering was not part of my system lol.



And some other well known goodies.



Making the cable from yunkyard stuff i collected.







And the finished tiny board ready to be married to the EZK



And allmost done now.



Sexy looks





After this was done I was going to make a brace from a piece of scrap Aluminium from an Alumnium illuminated sign, in the Netherlands we say "he, who is not strong. must be smart" ahum. This was done from a paper mold that i made first to have the correct measurements.























And finally test fitting, looks good i think.



The final fitting.. I did make an other cable, this one was a bit too long and had a strange angle towards the bobine or DIS. The DIS was from a Alfa Romeo and the powerstage from a Volvo 960. I will make a picture tomorrow with an overview of the engine bay and how it sits.



The latest "overview" picture.



The WS is working very well and without any malfunction or other oddities. As stated before a much stronger spark, better throttle response and last but not least better fuel economy. So a win/win situation in my case,
I can really recommend it to you.

[+Kardboard+]

Super cool. Love the custom bracket for the power stage!

[Chilm]

After I had (for the third time) bought the PCV breather thingy because it was broken again I decided to make the whole thing myself from Aluminium tubing. Easy to bend with my tube bender (for plumbing tubing) and easy to polish



Above the original but ugly PCV pipe with broken "thingy".



Above the broken "thingy" that started this little project



Aluminium tubing from the DIY: 20, 16 en 6 mm. tubing is 2 mm. thick so i have enough material to tap threads for the little vacuum hose.



Bending measuring, bending measuring, it wend well after all, patience is a good habit lol. Bend it with a piece of fabric in the bender just to prevent scouring and scratching.



Tubing cut (6 mm. section) tapped thread (m6) for the vacuum hose to the inlet. I will position this higher up just for convenience.



Drilled a hole for the little tubing and tapped it.



Mounted it with Loctite just to be sure.



"cuff" 20 mm. for mounting on the inlet. Sandpaper 600 did the first polish job.



Just cold fitted (tapped with hammer) with Loctite, it's a snug fit. the inner and outer sizes match allmost exactly, outer 16 mm. to inner 16 mm. and: chrome polish ha ha.



The TUBE lol.



Mounted and much more attractive imho.



Detail to inlet.



Detail to pre turbo and pre heater.

After reading THE PCV thread i decided to go for the real thing and buy the Mann ProVent as CC so I'll have something to do when that comes in. Don't know yet if I am going the tube- or the hose way..

[Roy 940]

Looks very nice! Well done!

[Chilm]

Thanks Roy.

[Dirty Rooster]

The big ugly foam-covered PCV hose always bothers me ... yours is excellent but do I want to spend such time on it?
Maybe a brass/copper one ... Hmmmm

[Chilm]

Originally Posted by Dirty Rooster

The big ugly foam-covered PCV hose always bothers me ... yours is excellent but do I want to spend such time on it?
Maybe a brass/copper one ... Hmmmm

Only for the bling bling no "oemphhh", I agree it's a bit gay-ish, lol.
Brass/copper will be the same amount of work imo and does not match the overall looks.

[Chilm]

Some 13c porting just to have a look what the gains are... Well after some heavy test driving I'm now in doubt if I will swap it for my also ported 15G because it spools so fast (got a full length 3 inch exhaust too) that I'm beating a whole lot of cars in the first hundreds of meters gna gna. The faces of Audi, VW Golf etc. yes even Porsche drivers are hilarious to look at when they finally are passing me ha ha.

I've never heard a loud whistle in a 13C but mine does. Not stating this to show off but to express what fun it can be with a little port work on that tiny 13C, it will spool like hell.

I'm on 1 bar (14,5 psi), tuning on LPG (liquid gas), no gasoline, cool (but slightly slower) burn and high Octane (105) so less knock. Chipped (Blabla) ECU and EZK and an Erland Cox regrind (lash caps) as a camshaft.



Wastegate ported and polished to let it react quick when foot off the paddle. Rounded everything up for the flow...



Other site of the "dome".



Nice smooth me like.



Opened the inlet and got rid of some material, this one was cracked too, I had it welded just to be sure.



Close up with little cracks, don't worry they will close if everything is heated up (and it will).



Go with the flow, after 2 years it's still working, no setbacks whatsoever.

[blkaplan]

Originally Posted by Chilm

The WS is working very well and without any malfunction or other oddities. As stated before a much stronger spark, better throttle response and last but not least better fuel economy. So a win/win situation in my case,
I can really recommend it to you.

What kind of change in economy did you see?

[Chilm]

Originally Posted by blkaplan

What kind of change in economy did you see?

An overall fuel economy of at least 10% in fuel consumption (LPG).
No hick-ups anymore and a much better throttle response, and last but not least more torque (I like torque over horsepower).

[Dirty Rooster]

Originally Posted by Chilm

Brass/copper will be the same amount of work imo and does not match the overall looks.

...until everything is brass/copper ...

[Chilm]

I don't like the normal gauge pod's as used at the left side of the windscreen so I made my own. Bought a second ash tray set to modify and to use the plastic from it to fab some segments. And remember, Epoxy raisin is your friend.



























































Cheers

[rcdude]

POD is from a 240?

[Chilm]

Originally Posted by rcdude

POD is from a 240?

It's a steel aftermarket 52 mm. template you can buy on allmost every tuning site for a couple of dollars. Just grinded off the clamps and modelled the sides.