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Old 04-24-2006, 02:58 AM   #1
the poi
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Default The b6304/t6 hybrid thread!

So I guess I'll start a thread for this whole project. So I have my new T6 motor, or rather, a heinous lump of aluminum and steel:



Sweet mother of god





Thats not an optical illusion. that turbo inlet is seriously only slightly bigger than my oil drain nut

Anyway, I digress,



Bunny! Oh **** I did it again


So after a couple days at the wrenchs, you'll have three equal size piles. The engine, the transmission, and all the crap previously bolted to the engine. There's seriously a lot of crap.



(its 8t88! anyone get the reference?)







Oh, and this can really ruin your day:



THAT was annoying. Always feels like the headbolts are about to snap when taking the head off but I guess that one actually did. Ended up wrapping tape around drill bit to center the bit, drilled it, filled the bolt hole with liquid wrench, and then backed it out with an EZout (first time I actually got one of those things to work, weird...). Everything looks good, scared the hell out of me though at first...

So here's where I'm at: blocks stripped down



Rear drain is tapped for 3/4"NPT



Front drain is plugged with a penny and some JBweld



And I cleaned up the pistons! The sleeves are in fantastic shape: the crosshatch is very clear and there aren't any scrapes. And no cracks in them either.




Tune in next time, where I guess I'll get more stuff done. I'll probably prep the head--I'm using my b6304 head so i can use the PC cams. I'll beadblast it, and swap the t6 exh valves in (assuming they fit and stuff) as they are sodium filled. I'll smooth the ports and polish the chambers too.

One question:

A few of the the 8mm bolt holes on my b6304 head are stripped. I'm planning on drilling and helicoiling them...any reason why I shouldn't? I'd assume the existing hole ought the keep the drill and tap centered and straight right?
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Old 04-24-2006, 03:11 AM   #2
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Chris, http://www.volvotechinfo.com/index.c...m.serviceparts order the blue books for the 960 and S80 engine overhaul manuals.

They are cheap and worth their weight in gold. Even tell you for each bolt if they are stripped what helicoils to use ect ect. VeryVERY good info.

otherwise looks great!
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Old 04-24-2006, 03:11 AM   #3
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mmmmm tasty! looking good man!
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Old 04-24-2006, 03:42 AM   #4
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Quote:
Originally Posted by the poi


Thats not an optical illusion. that turbo inlet is seriously only slightly bigger than my oil drain nut
So small I can imagine a quad turbo setup ...

(So who's gonna be the first benchracer doing this? )

Quote:


Front drain is plugged with a penny and some JBweld
Cheapest plug you can get, really! It's sorta like how the vintage crowd plugs the FI ports on the B20 engines with nickels. 20 cents doesn't even buy one freeze plug, let alone a penny!

-- Kane ... oh, and JB weld for teh win!
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Old 04-24-2006, 04:08 AM   #5
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Hi,
Will you run this on MegaSquirt?
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Old 04-24-2006, 04:21 AM   #6
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Quote:
Originally Posted by the poi
A few of the the 8mm bolt holes on my b6304 head are stripped. I'm planning on drilling and helicoiling them...any reason why I shouldn't? I'd assume the existing hole ought the keep the drill and tap centered and straight right?
I think the only do not repair threads are in the block and/or intermediate section. Doug's right, the manuals have all the thread specs and **** that you'd want to know.

http://blarf.homeip.net/greenbook/album/TP2103201/p043
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Last edited by blarf; 10-13-2013 at 04:08 PM..
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Old 04-24-2006, 04:24 AM   #7
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Quote:
Originally Posted by DaButcher
Hi,
Will you run this on MegaSquirt?
Most likely.
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Old 04-24-2006, 04:26 AM   #8
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nice thick walls on that one.
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Old 04-24-2006, 07:54 AM   #9
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your skills > my skills

i'd be so scared to tackle a job like that, mad props
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Old 04-24-2006, 08:51 AM   #10
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seriously, props on the courage to swap everything out, but dude, I learned, by my own error, than when you swap, keep your parts well organized and labelled. I think you might be cursing when trying to find which bolt goes where and which parts went where. Im not too worried tho, you'll figure it out, just might curse a little more than necessary.

Good luck, cant wait to see it
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Old 04-24-2006, 09:38 AM   #11
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Holy crap Chris, that post was hilarious.



Yep! Just as ugly.
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Old 04-24-2006, 10:31 AM   #12
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That transmission realy is massivly tiny!!!
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Old 04-24-2006, 12:51 PM   #13
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Quote:
Originally Posted by blarf
I think the only do not repair threads are in the block and/or intermediate section. Doug's right, the manuals have all the thread specs and **** that you'd want to know.

http://blarf.homeip.net/greenbook/al...43?size=medium
sweet jeebus, nice! And all the cam aligning info too... gonna need it, the cam and crank marks are in different places on the t6 and 6304 stuff. hopefully the crank mark is the same...
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Old 04-24-2006, 12:59 PM   #14
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get some pictures of the doofy mechanical lifter head if you can...
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Old 04-24-2006, 01:01 PM   #15
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Quote:
Originally Posted by the poi
sweet jeebus, nice! And all the cam aligning info too... gonna need it, the cam and crank marks are in different places on the t6 and 6304 stuff. hopefully the crank mark is the same...
i have a volvo tech manaul about the 960 engine. torque specs, alignments, everuthing IIRC. A big pdf file... wanna have it?
edit: I'm uploading it on my server right now...
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Old 04-24-2006, 01:07 PM   #16
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Quote:
Originally Posted by the poi
sweet jeebus, nice! And all the cam aligning info too... gonna need it, the cam and crank marks are in different places on the t6 and 6304 stuff. hopefully the crank mark is the same...
should be. Straight up theres a lump on the oil pump to match
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Old 04-24-2006, 01:08 PM   #17
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Chris DO use Time-Serts for your thread repairs. They can be had in any length you like for holes of different depths......Much stronger and more reliable then Heli-Coil.

Thems a pair of teeny-tiny turbos. Small wonder the 'Twin-charged' six is such a slug.
Make it exciting Chris!!
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Old 04-24-2006, 01:17 PM   #18
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(hosting expired)
23 mb pdf file, 68 pages, loots of things.

Last edited by JW240; 06-26-2011 at 06:44 AM.. Reason: link non active
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Old 04-24-2006, 03:59 PM   #19
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Quote:
Originally Posted by JohnLane
Chris DO use Time-Serts for your thread repairs. They can be had in any length you like for holes of different depths......Much stronger and more reliable then Heli-Coil.

Thems a pair of teeny-tiny turbos. Small wonder the 'Twin-charged' six is such a slug.
Make it exciting Chris!!

this man speaks the truth, i would recommend them as well i use them for big brake kits i design and they hold up great. although they do not come in any length which sucks, i have a time-sert chart and manual i work off of and theres just a few different sizes for each thread pitch. so yea use of time-serts is highly recommended from experience.
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Old 04-24-2006, 05:51 PM   #20
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Timeserts = expensive
Chris = has money + smart
Chris + money +smart = get timeserts, do it right

They sell a special TimeSert kit for "when the helicoil pulls out". That should tell you something .
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Old 04-24-2006, 06:56 PM   #21
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I can't find a timesert distributor online that lists a price for the set I need...anyone know where I can get one? And like, 20 inserts?
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Old 04-24-2006, 07:11 PM   #22
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Quote:
Originally Posted by JW240
here is is
23 mb pdf file, 68 pages, loots of things.
You're welcome.

The "original" copy is also available from my site (along with some other manuals and such).
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Old 04-24-2006, 07:27 PM   #23
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Quote:
Originally Posted by the poi
Front drain is plugged with a penny and some JBweld
Hey Chris, that was nice But volvo makes a nice little metal plug to go in there, as the later n/a blocks came with return line holes, just plugged I know it's too late, but thought you should know.
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Old 04-24-2006, 08:25 PM   #24
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Quote:
Originally Posted by Volvorules
Hey Chris, that was nice But volvo makes a nice little metal plug to go in there, as the later n/a blocks came with return line holes, just plugged I know it's too late, but thought you should know.
Ya, but if I'm ever buying a soda and I'm a cent short, I know where to get one. Can't say that 'bout your fancy blockoff plates now can ya?!

blarf: downloaded the full manual from you earlier. gonna be helpful.
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Old 04-24-2006, 08:30 PM   #25
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Ya, but if I'm ever buying a soda and I'm a cent short, I know where to get one. Can't say that 'bout your fancy blockoff plates now can ya?!


<-has $.40 in his intake :P
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