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Old 01-14-2007, 11:54 PM   #1
DavoS40
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Default 242 Build

The project originally started out as a 245 then in 2003 I decided to switch to a 242. I've been working on it off and on when I'm home from school the past couple years. I'm just going to start off with the work that's taken place since springbreak 2005.

Engine:
B21FT
-align honed mains, decked for .030 squish
-2nd oversize stock pistons, balanced
-stock rods resized, cyrotreated, new hardware, balanced
-reground crank, balanced
-bmw oil piston squirters
-meling oil pump

Cylinder Head:
-398 SCP
-port & polished, unshrouded exhaust valves
-40mm exhaust valves, stock intake valves
-K cam

Turbo Setup:
-Holset HY35
-Powerstroke intercooler
-SS header from Jonathan(Stereophile33)
-XS RFL blow off valve
-3 inch exhaust (half of it from Doug's old car!)

Suspension/Brakes:
-front coilovers 315 lb springs
-rear coilovers 250lb springs
-revalved/shortened Bilsteins (towery's specs)
-Kaphlenke camber plates
-IPD adjustable torque rods
-adjustable panhard rod (homemade)
-poly bushings from Dale (245gti)
-new rotors, calipers, pads, ss lines, master cylinder, junction block

Driveline:
-93 Cobra T5 tranny
-Pro5.0 short shifter
-custom Spec stage 2+ clutch/pp (Volvo pp and clutch with the T5 spline)
-3 inch aluminum driveshaft

Fuel/Ignition:
-MS'nS
-EDIS with Ford coil pack
-Ford CFI injector's
-walbro pump

B21 block fresh from the machine shop




Notice the spots machined for the squirters

Sprayed the garage down with a hose to keep the dust down


Test fitting the squirters




rods, pistons, oil pump installed



finished short block




the light! (40mm exhaust valve)


seam welding


painted bay


preparing to drop in the motor




ready to go in


motor in, test fitting header with junk head

body still needs a lot of work



engine bay




The new motor has been run through 3 sessions of stealth's run in procedure. When I was almost finished with the 3rd session I blew a freeze plug. I wasn't sure if this was due to the coolant system getting pressurized from a slight leak in the headgasket or if the machine shop installed the freeze plugs incorrectly. The blown freeze plug was replaced with one of the rubber expandable plugs and the head gasket replaced. If another one blows the motor is coming out and all of the plugs are going to be replaced(JB will be involved). The motor did sound great and sounded really smooth after the 2nd session.
I'm heading back to Colorado tomorrow, so I won't see the car for a few months. The plan is to get a bunch of little parts needed while I'm away. Hopefully get the car painted over springbreak or the beginning of summer. Once the body is painted the 93 block cloth interior(that's sitting in the basement) is going in the car. Then a few test drives (I smell Missouri) and if all goes well it'll get registered.
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Old 01-15-2007, 12:01 AM   #2
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OMG I wet myself!.. that is killer! good lighting on the engine bay pic's!

Last edited by Delfosse; 01-15-2007 at 12:26 AM..
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Old 01-15-2007, 12:03 AM   #3
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Gorgeous car! Very nice work!
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Old 01-15-2007, 12:06 AM   #4
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DOnt do anything to the outside!

SLEEPA POWA!

EDIT: I spy Eikers! What rubber are you gonna put on them?
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Old 01-15-2007, 12:25 AM   #5
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Quote:
Originally Posted by Yeliwmots View Post
DOnt do anything to the outside!

SLEEPA POWA!

EDIT: I spy Eikers! What rubber are you gonna put on them?

Those aren't crappy eikers, they are the real things.

BTW, way to go davo!
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Old 01-15-2007, 12:56 AM   #6
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Thanks for all the complements guys!

Quote:
Originally Posted by Yeliwmots View Post
DOnt do anything to the outside!

SLEEPA POWA!
Originally that's the attitude the project took on, screw all the looks and just make it fast. Now I'm going for just a great all around car: handles great, plenty of power, nice interior, clean factory looks on the outside but nothing that says look at me.
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Old 01-15-2007, 01:06 AM   #7
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Just a thought, some after-market water pumps if not shaped like the oem blade can cause freeze plugs to pop. Not sure what it has on it but just in case you didn't know
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Old 01-15-2007, 01:15 AM   #8
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Originally Posted by edicius View Post
Just a thought, some after-market water pumps if not shaped like the oem blade can cause freeze plugs to pop. Not sure what it has on it but just in case you didn't know
I read the stories about the stamped impellers and made sure to get the one with cast impeller.
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Old 01-15-2007, 08:31 AM   #9
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I love everywhere this project is going. Well done.
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Old 01-15-2007, 09:09 AM   #10
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Amazing, the work put into that is huge!
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Old 01-15-2007, 09:16 AM   #11
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Now THATS what I'm talking about!
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Old 01-15-2007, 11:31 AM   #12
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very nice work!
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Old 01-22-2007, 11:56 PM   #13
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Very nice Dave. I've seen the car in person and "helped" a bit. I like where it is going and can't wait to ride around in it. This project is being done like it should, on a budget nonetheless.
The lighting is very high tech too!
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Last edited by Homer; 01-23-2007 at 12:01 AM..
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Old 01-23-2007, 12:02 AM   #14
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What did you do for a WG?
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Old 01-23-2007, 12:09 AM   #15
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awesome awesome, yah im curious about the wastegate and manifold myself
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Old 01-23-2007, 12:15 AM   #16
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i see an internal flapper on the back of the turbo
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Old 01-23-2007, 12:18 AM   #17
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this project has been in the dark, this the first time you've posted anything on it?
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Old 01-23-2007, 02:57 AM   #18
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Quote:
Originally Posted by Homer View Post
Very nice Dave. I've seen the car in person and "helped" a bit. I like where it is going and can't wait to ride around in it. This project is being done like it should, on a budget nonetheless.
The lighting is very high tech too!
Without the parts hook up and the motivation to do it clean it wouldn't be where it is now man!

Quote:
Originally Posted by impulse922 View Post
this project has been in the dark, this the first time you've posted anything on it?
I've made a few threads about it in the past, but not since last summer when I totally tore it down.

Quote:
Originally Posted by str8krewzn View Post
What did you do for a WG?
Two summers ago I ran the stock wastegate and it held a consistent 19psi(which it was I think the original actuator opens up at). Now I ported the hell out of the wastegate, and I'm planning on fabricating something similiar to atp's ultimate wastegate over springbreak with an internal wastegate I can get different springs for. Eventually I'll get a the header setup for twin wastegates with a nice twin scroll turbo.

Last edited by DavoS40; 01-23-2007 at 10:18 AM.. Reason: grammer, i was tanked when i originally wrote this
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Old 01-23-2007, 12:46 PM   #19
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is that block orange? or is that just a bad digital camera?
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Old 01-23-2007, 12:58 PM   #20
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You and Lee really make me miss 240's (and REALLY hate living in smog states)

amazing job man!
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Old 01-23-2007, 04:50 PM   #21
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Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.
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Old 01-23-2007, 05:06 PM   #22
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Quote:
Originally Posted by blackbrick82 View Post
Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.
Not sure I am now :*( /thread jack
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Old 01-23-2007, 05:21 PM   #23
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that engine bay looks godly
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1981-1982 Euro style 242, with GLT trim, rules over all other 240's.
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Old 01-23-2007, 05:26 PM   #24
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Quote:
Originally Posted by homer1300 View Post
is that block orange? or is that just a bad digital camera?
It's chevy red-orange it turned out more orange than I wanted though.

Quote:
Originally Posted by Hank Scorpio View Post
You and Lee really make me miss 240's (and REALLY hate living in smog states)

amazing job man!
Thanks dude, it was your old project that really got me motivated to take it this far!

Quote:
Originally Posted by blackbrick82 View Post
Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.
Thanks, when are we going to get some updates on your 242?
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Old 01-23-2007, 06:18 PM   #25
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Your engine gives me big wood.

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Originally Posted by DavoS40 View Post
Thanks, when are we going to get some updates on your 242?
He's turned it into a 120 wagon
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Not sure I am now :*( /thread jack
Start new thread now! Must hear details! Can't wait month to talk! Unless you're still going to hooters...
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