242 Build

DavoS40 · 01-15-2007, 12:54 AM

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.

Delfosse · 01-15-2007, 01:01 AM

OMG I wet myself!.. that is killer! good lighting on the engine bay pic's!

Nick · 01-15-2007, 01:03 AM

Gorgeous car! Very nice work!

Tom Wiley · 01-15-2007, 01:06 AM

DOnt do anything to the outside!

SLEEPA POWA!

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

blkaplan · 01-15-2007, 01:25 AM

Quote:

Originally Posted by Yeliwmots

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!

DavoS40 · 01-15-2007, 01:56 AM

Thanks for all the complements guys!

Quote:

Originally Posted by Yeliwmots

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.

edicius · 01-15-2007, 02:06 AM

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

DavoS40 · 01-15-2007, 02:15 AM

Quote:

Originally Posted by edicius

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.

01-15-2007, 09:31 AM

I love everywhere this project is going. Well done.

VQ · 01-15-2007, 10:09 AM

Amazing, the work put into that is huge!

suterman · 01-15-2007, 10:16 AM

Now THATS what I'm talking about!

oldschoolvolvo · 01-15-2007, 12:31 PM

very nice work!

Homer · 01-23-2007, 12:56 AM

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!

str8krewzn · 01-23-2007, 01:02 AM

What did you do for a WG?

oxity · 01-23-2007, 01:09 AM

awesome awesome, yah im curious about the wastegate and manifold myself

stylngle2003 · 01-23-2007, 01:15 AM

i see an internal flapper on the back of the turbo

impulse922 · 01-23-2007, 01:18 AM

this project has been in the dark, this the first time you've posted anything on it?

DavoS40 · 01-23-2007, 03:57 AM

Quote:

Originally Posted by Homer

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

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

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.

homer1300 · 01-23-2007, 01:46 PM

is that block orange? or is that just a bad digital camera?

Hank Scorpio · 01-23-2007, 01:58 PM

You and Lee really make me miss 240's (and REALLY hate living in smog states)

amazing job man!

Blackbrick · 01-23-2007, 05:50 PM

Another beautiful 242 in the making. kudos man.

Doug, life will get a lot easier when you get out of Cali.

Hank Scorpio · 01-23-2007, 06:06 PM

Quote:

Originally Posted by blackbrick82

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

Chrisco · 01-23-2007, 06:21 PM

that engine bay looks godly

DavoS40 · 01-23-2007, 06:26 PM

Quote:

Originally Posted by homer1300

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

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

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?

Big Lan · 01-23-2007, 07:18 PM

Your engine gives me big wood.

Quote:

Originally Posted by DavoS40

Thanks, when are we going to get some updates on your 242?

He's turned it into a 120 wagon

Quote:

Originally Posted by Hank Scorpio

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...

01-15-2007, 12:54 AM	#1
DavoS40 Board Member Join Date: Nov 2002 Location: Fort Collins, CO	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. __________________ 1983 245DL, 2011 WRX, 1978 SR500

01-15-2007, 01:01 AM	#2
Delfosse VFL Join Date: May 2006	OMG I wet myself!.. that is killer! good lighting on the engine bay pic's! Last edited by Delfosse; 01-15-2007 at 01:26 AM..

01-15-2007, 01:03 AM	#3
Nick Board Member Join Date: Jan 2004 Location: Winter Park, FL	Gorgeous car! Very nice work! __________________ -Nick S30 & E30 No mas Volvo.

01-15-2007, 02:06 AM	#7
edicius Super Moose! Join Date: Apr 2005 Location: Calgary, Alberta, Canada	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 __________________ 2006 Subaru Sti

01-15-2007, 10:09 AM	#10
VQ Not such a PRVert Anymore Join Date: Oct 2005 Location: Melbourne, Australia	Amazing, the work put into that is huge! __________________ 264 GLE RIP 88 740T wagon 1964 122s 88 760GLE RIP

01-15-2007, 01:06 AM	#4
Tom Wiley Board Member Join Date: May 2006	DOnt do anything to the outside! SLEEPA POWA! EDIT: I spy Eikers! What rubber are you gonna put on them?

01-15-2007, 09:31 AM	#9
740ATL Guest	I love everywhere this project is going. Well done.

01-15-2007, 10:16 AM	#11
suterman Board Member Join Date: Jun 2005 Location: UK	Now THATS what I'm talking about! __________________ 1985 Bedford cf. B230e aw71L 1990 240 turbo. b230ft m47 chips

01-15-2007, 12:31 PM	#12
oldschoolvolvo Board Member Join Date: Mar 2004 Location: Lancaster, PA	very nice work! __________________ -Mike ~~1998 V70 T5~~ 1979 242 DL 16v \|Feedback\|

01-23-2007, 12:56 AM	#13
Homer OEMplus++ Join Date: Aug 2003 Location: Bay Area, CA	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! __________________ -Jacob: 1990 240 - 5 Cyl Whiteblocked. 2006 A4 - Comfy DD Need something TIG welded? Give me a shout. Last edited by Homer; 01-23-2007 at 01:01 AM..

01-23-2007, 01:02 AM	#14
str8krewzn Board Member Join Date: Mar 2005 Location: Maryland	What did you do for a WG?

01-23-2007, 01:09 AM	#15
oxity Board Member Join Date: Feb 2006 Location: Richmond, VA	awesome awesome, yah im curious about the wastegate and manifold myself __________________

01-23-2007, 01:15 AM	#16
stylngle2003 Board Member Join Date: Nov 2002 Location: Two Up, Two Down	i see an internal flapper on the back of the turbo __________________ -Billy Volvoless for the first time since 1990... 2002 Toyota Avalon XLS (comfy gradma car) 1996 Chevrolet Tahoe LS 2WD (hauls ass) 1990 Mazda Miata (track toy)

01-23-2007, 01:18 AM	#17
impulse922 Board Member Join Date: Dec 2005 Location: satx	this project has been in the dark, this the first time you've posted anything on it? __________________ -Matt '90 780 and '03 s60 T5M

01-23-2007, 01:46 PM	#19
homer1300 Board Member Join Date: Mar 2005 Location: Portland, OR	is that block orange? or is that just a bad digital camera? __________________ 1983 244 Turbo 1995 944 Turbo

01-23-2007, 01:58 PM	#20
Hank Scorpio Chubfest 2009 Survivor Join Date: Nov 2002 Location: The neighborhood with the ******* guitar player.	You and Lee really make me miss 240's (and REALLY hate living in smog states) amazing job man! __________________ Hank Scorpio is from the Simpsons. You can call me Doug ;) Will trade guitars/guitar parts for go fast goodies or stuff I need. Just PM. www.kauerguitars.com the second best way to upset neighbors and alienate people. History: Car 1 (242) \| Car 2 (t5r) \| Car 3 (255)

01-23-2007, 05:50 PM	#21
Blackbrick Grandpa Join Date: Nov 2002 Location: Ocala, FL.	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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