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Old 03-29-2003, 05:04 AM   #101
Hank Scorpio
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Well... time to unveil my secert. It's a bit early as I have the dyno tomorrow but didn't have time to wire up the AIC yet. So its going to have to be on low boost.

Ok, now that disclaimer is DONE time for the good news:

HOLSETS WORK ON A STOCK MANIFOLD AND A B21FT!!! :D

Now, this is a quickie write up as well. I'll be writing an article on the swap asap here but heres my thoughts:

Over all, quite a responsive turbo. I've been having problems sorting out some bugs so I kept my MBC down (and haven't been able to romp it much yet) but Im seeing peak boost (only 14 at the moment) in first gear by about 3500 rpm ish. Now, its really hard to say because when it hits, it HITS. After sending the elbow off the turbo into the hood I've been kind of reluctant to try to hammer it, but I solved the problem and decided to try again. All I have to say is it hauls ass.

Now, as for the install, its involved but not to bad. I'll post some pics, but you'll have to bear with me as all the silicone adapters I ordered (last week) still aren't here so I had to get "creative".

So, what have we learned? b21ft's will spool a holset WH1C!

Now, for the bad news. I really think that the head work, cam (now you can see what I choose what I choose) and intercooler is a must. Obviously extra fuel is too, though its still doing ok at 14psi. With out being willing to put in some over all effort a Holset is a waste of time.

Also, next time around Im getting an HX35 that already has the wastegate actuator point out the front, not the side. I had to make a "bracket" (I will use that term loosely).

Ok guys, debate that one all you want. Tomorrow I'll get some real info up (now that things aren't flying off the motor)







(dont worry the blue hose goes away soon)
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History: Car 1 (242) | Car 2 (t5r) | Car 3 (255)
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Old 03-29-2003, 05:07 AM   #102
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I also installed an NPR intercooler, the K15 cam too. I didn't get to wire up the AIC yet so thats still on the list.

Heres the IC


The stock location for the oil cooler doesn't fit with the new IC so I mounted it horizontal on the strut tower. Came out good I think:


And the latest pics!



Doug
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Old 03-29-2003, 05:08 AM   #103
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Oh, some good sound/video clips:
http://kauerkreations.com/MVI_0499.avi
http://kauerkreations.com/MVI_0496.avi

Doug
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Old 03-30-2003, 01:05 PM   #104
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Went to the dyno yesterday, couldn't even keep the hoses on so I crossed my fingers and hope'd it would hold.

Well it did and exposed a new problem. That turbo is sucking so hard its completely colapsing my k-jet snorkel, even with the supports.

So the verdict is in, I'm ordering up a MegaSquirt EMS system tomorrow with 58lb injectors. This should really simpilfy things and I get a new toy to play with.

So I bet your wondering, how bad did it to. Try 140 hp. As soon it started to make power and boost it would just try to kill itself. I was also having problems with the wastegate trying to open early, so I'm getting an EBC (haven't decided what brand yet) to help. If after that I'm still not happy I'll start spraying with a 50shot of the line to help spool up :D

The dyno sheet is pretty funny to look at. It's really lackluster below 4k (once again, alot of that is due to the wastegate again) but it doubles its hp in 500 rpm before it just fell on its face. I've got issues, but I'm getting a handle on them.

So its getting there... its really got most of the pieces in place for some serious HP just have to uncork it.

Doug

(ok don't laugh)
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Old 03-31-2003, 04:25 AM   #105
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Here guys, took some pictures... heres my favs:





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Old 04-04-2003, 08:25 PM   #106
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Updates!

Got the wing back on it, looks pretty sharp still!

Also, parts are starting to show up again. I ordered a Megasquirt EMS (engine management system), MSD6al, Blitz SBC-S electronic boost controller and a bunch of other odds and ends.

So heres a few pics (the EBC is at the bottom)

Doug



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Old 04-08-2003, 01:36 AM   #107
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Well, got started on my Megasquirt DIY EMS system.

Thought I'd share ;)

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Old 04-12-2003, 08:41 PM   #108
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Well, finished building up my Megasquirt EMS. I love it, it was not only a kick in the butt to build, it was pretty straight forward.

I'm also learning to use the software, its pretty slick too.

Anyways, heres some pictures:


Using the software


hahaah I had to customize the case a bit ;) Course I did use green LED's instead of the ones that came with it.

Doug
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Old 04-19-2003, 10:03 PM   #109
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Well, after a week where I just couldn't touch the car, started back on it today. Got everything on the engine wired, except the distributor. Got the MSD boxes mounted, but just wore out before I could wire it up.

So, really just have to get the fuel pump relays up and running, MSD box running and get my fuel injectors figured out. Had some lucas 53 lb/hr injectors but I just cant come up with a way to make them fit. So, it may go the week on stock Turbo injectors... but eventually something bigger.

Have the Davis (BIG) volvo car show next weekend, should be intresting.

So enjoy!


Adapter a 850 TPS switch needed for use with EMS


Test fitting of HKS turbo timer and Blitz SBC-S boost controller

Mounting of hte MSD boxes
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Old 04-19-2003, 10:07 PM   #110
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Oh, I just wanted to add a little update on the big picture on the car. So far, since august, Im 10k into the car :eek: but its getting there!

Also, really wanted to thank ipd (ofcourse) and ATP Turbo (www.atpturbo) for being outrageously helpful, and being great about my 20 changed orders!

Also, Dave Lot, John Parker (v-performance.com) and countless others. Less than a year, and the cars almost done!

Doug
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Old 04-23-2003, 10:08 AM   #111
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Engine harness is done and all hooked up. Actually, everything is, except the injectors leak like crazy (trying to adapt some Lucas 53lb/hr injectors) so I'm headed out to a junkyard today to find some low impedence temporary injectors.

Heres some pictures: (Oh, still waiting on the elbows to come for the turbo to IC piping, I ordered to big DOH)




Just for visual's sake on that pipe

Doug
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Old 04-24-2003, 12:43 AM   #112
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Car is fantastic Doug, Is that air filter permanent? Dan242tic
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Old 04-24-2003, 01:25 AM   #113
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Thanks man!! The filter is permant, the location isn't yet. Though, my air intake temps didn't show any difference after almost of an hour of the car running tonight.

Which brings me to my point, ITS ALIVE!!! From k-jet to EMS in two weeks :D

Heres a completed pic, sorry its blury. Tomorrow the rest of the dash goes back together then the fun begins!
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Old 04-26-2003, 12:19 AM   #114
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Alrightie!! It's detailed and finally at a point where I think I can say "its done for a week!"

Heres some pics!






Sorry they are dark, just finished tonight getting it ready for the show this weekend.
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Old 05-01-2003, 02:43 AM   #115
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Weekend Update ;)

Alrightie!!! Well, made it through the much awaited for Davis Golden Gate/Sacramento VCOA chapter Volvo Show and the car made it there under its OWN power :D :D!

Babied the car to get it there... but today I decided to see how she goes, and I must say, QUITE well!! Current injectors are maxed at 100% duty cycle by 10 psi though :eek: thats always fun. So I'll be getting bigger injectors soon, but over all, the car runs great!

I think Im going to try advancing the cam 2*, just bring that power down a bit, comes on about 3k right now, but really comes alive at 4k. If I can get it to about 3500-3700 that should just be ideal. Course, Im not really winding the car out to the desired 7500 yet either ;)

Picking up new wheels for the car this weekend, 17X7 Moda R6's and I am PUMPED! So look forward to pictures of those hopefully on the car saturday.

Next project, has to be the T5 swap. My rear main is leaking again (long story) and I refuse to pull it just to put an m46 back in. Then, injectors, then roll cage, Crossdrilled rotors and then maybe, just maybe I'll be almost done ;) From August last year till now, (about 8-9 months) I've come this far, I just may finish this car in a year!

... course, that depends on what you consider finished. I still may (probably will) through a 50shot of NOS at the car too.. for spool up ;)

Thanks guys,

Doug
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Old 05-01-2003, 02:44 AM   #116
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Oh btw, heres a nice pic (just like to take pics!)
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Old 05-03-2003, 10:12 PM   #117
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Got a new set of "toys" ;). Moda R6 in 17X7 with 225/45/17 P7000's on them... not my ideal choice of tire but I'll take em :D

Anyways, need to space them out just a hair more, one of them is rubbing but over all I looooooove them!



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Old 05-15-2003, 08:31 PM   #118
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T5 adapters via John Parker came in today!! I've got the motor out of the 242 again to help test fit the tranny, and to do a bunch of other stuff I have planned. :D The next two months are going to be another whirlwind guys, keep an eye on this thread!





Doug
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Old 05-17-2003, 07:53 PM   #119
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So in a wierd form of Deja Vu here ya guys go!




So begins the start of the end ;) Last phases of the project is stripping all the parts and painting the entire chasis and engine bay the same color as the body of the car. Also going to pull the dash out and make a custom facia and use nothing but Autometer Carbon Fiber faced gauges!

Should be pretty slick, so stay tunned! Also have some last new surprizes on the motor as well!

Doug
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Old 05-30-2003, 07:49 PM   #120
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So Idecided enough manual labor for a day, time to do something fun. So first try on our CNC at work, got this damn near perfect!

So, should I (when I do the final one) paint it to match the car, mill it out of Aluminum or Carbon Fiber (provided I can get a sheet of it).

Also, cleaned the chasis, but after a few days I realized with out sandblasting I was never going to get it clean enough to do what I wanted. So, alas the next one will have the perfectly detailed chasis.

Thanks guys enjoy!


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Old 05-31-2003, 06:37 PM   #121
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Today got under the hood preped and primed, just have to go get the paint in the next day or two and start spraying!

Also got the motor stripped down to a long block again. I think I'll leave the cylinder head off untill I get closer to putting it back in (help keep dust out of the motor), basicly just cleaning it (looked pretty nasty again), fix a bunch of oil leaks and do a few other things.

Heres a couple pics

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Old 06-01-2003, 12:07 PM   #122
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Pbase must be down for now. I saw the pics earlier. Looks really
good, bud. Just love Project 242ti!! :thumbsup:
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1982 242 turbo. 340k miles. MVP coilovers and 3" exhaust. Flowed 405 with a V15. Cossie turbine housing with upgraded compressor housing. 90+, IPD remote oil filter. Some other goodness, too. Been lots of fun over 25 years. Restored in 2k. Now ready for a 2nd restoration.

1993 245 Classic, 430k miles, enem V15. IPD bars and chassis braces. Simons sport exhaust from Scandix. sbabbs ezk chip. Been a good road warrior. Genuine Volvo rebuilt leaky M47.
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Old 06-01-2003, 04:24 PM   #123
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Thanks bud! :D Pbase has been hit and miss the last couple weeks, so if no pictures show up, check it in an hour ;)

Doug
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Old 06-03-2003, 08:56 PM   #124
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:D Not bad I think. Got the first coats on tonight, do some color sanding tomorrow-thursday and hopefully get some clear coat on it by this weekend!

Woo Im proud of myself lol




Keeping the blue motor, just wanted to see if I still liked it (still do). I also need to use one of our smaller guns for up under the strut towers and such... maybe actually mask off the a-arms this time DOH

lol, still not bad I think

Doug
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Old 06-06-2003, 09:16 PM   #125
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All done:
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