The Volvo 242 project thread *UPDATE*

Discussion in 'Gearhead Garage' started by Alex B, Jun 15, 2006.

  1. Alex B

    Alex B Junior Member

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    The intake manifold needed velocity stacks so I had to whip out some brain power to make them myself.

    [​IMG]
    Started with a piece of 1.5" thick, 4" diameter carbon steel round bar and rough turned half of it in to chips and shavings. Then using matlab and excel I generated and printed a list of X,Y coordinates that described an exponential curve 15mm deep and 10mm wide.

    [​IMG]
    Hitting an X coordinate every .25mm is a pretty good middle ground but is still incredibly time consuming even with a good digital readout. In the pic you can see the curve is about half done.

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    The finished press tool with 40mm long pieces of tubing. Also visible is the gratuitous amounts of bearing grease I used on the tool to facilitate pressing and to keep galling to a minimum.

    I'll get some better close up pics when I have the intake manifold welded up complete with runners.
  2. Alex B

    Alex B Junior Member

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    Some parts trickling in. Been scoring an ass load of AN fittings and braided hoses on ebay for cheap. Just need a pressure regulator and the entire AN-10 fuel system is done. Also running -10 on the oil cooler.

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    10 gallon foam filled fuel cell

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    4" thick china intercooler

    Also finished up the intake manifold. Since the 6 cylinder engine is going in the car now I've posted it for sale. There's a guy swinging by on Tuesday to buy it.

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    The header is also shaping up nicely:

    [​IMG]

    [​IMG]
  3. ivanolo

    ivanolo Guest

    This shit fucking nuts! How much money have you spent so far?

    BTW, would you post a picture of a "finished" Volvo 242 that looks like what you're going for?
  4. 86mcss

    86mcss Devouring your Soul

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    D00d freaking awesome work. Keep posting pics! :D
  5. Mr. Ali

    Mr. Ali Junior Member

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    Those welds look so good I want to eat them.
  6. Alex B

    Alex B Junior Member

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    Thanks for the encouragement, it's always fun reading what you guys think of the progress.

    Not sure. Been buying a bunch of necessary parts lately so the dollar amount has been rising. A rough estimate is somewhere between $5000-$7000.

    Here are pictures of two cars I've drawn a lot of inspiration from:

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    In other news:

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    The header is all tacked up.

    [​IMG]
    Got the wastegate. It's a chinese knock-off of a really expensive HKS 60mm wastegate. I've had good experience with the fake ones though so for the price you can't go wrong.
  7. ivanolo

    ivanolo Guest

    Really like the top one. Very clean. Only thing I hate is that thing under the front bumper.
  8. Alex B

    Alex B Junior Member

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    That's acually the stock lower valence that comes on that bumper. It's permanently attached to the bumper cover.

    In other news:

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    H-Beams straight outta china.

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    When you see it, you will shit bricks.

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    Should help the low end some with big laggy turbo.
  9. 86mcss

    86mcss Devouring your Soul

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    your going to dual charge it? why for?
  10. Alex B

    Alex B Junior Member

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    Much better low end, the increased mass flow through the engine will also spool the turbo quicker. After the outlet pressure of the turbo exceeds the outlet pressure of the supercharger, the supercharger will be decoupled to lessen the pumping loss (can be upwards of 200hp at higher rpm). Dumping the supercharger air to atmosphere will also make for an interesting sound.
  11. sims

    sims walls of text

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    You so crazy.

    what snail did you end up going with? I can't believe you're actually dual charging that thing, the concept makes alot of sense, i'm very interested to see how it pan's out.

    whats the supercharger originally from?
  12. 86mcss

    86mcss Devouring your Soul

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    The supercharger looks to be from a early 90s FORD thunderbird.


    Good Luck on that project your doing some awesome work. :cool:
  13. Alex B

    Alex B Junior Member

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  14. tweakmonkey

    tweakmonkey Webmaster Staff Member

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    Sexy... huge tires eh? :D
  15. Alex B

    Alex B Junior Member

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    Got some more goodies for the car:

    [​IMG]

    Started building a floor mount pedal box:

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    [​IMG]
  16. Alex B

    Alex B Junior Member

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    [​IMG]
    Prototype intake manifold mocked up. It's going on a friends car that will be running pretty soon so we can evaluate the functionality of the dual plenum design I shamelessly stole from AUDI.

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    Turned some stainless bearing cups for some weld-in camber plates I'm having a friend of mine laser cut.

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    Billet steel flywheel with the tilton triple plate clutch. Won't have to worry about the stock cast iron flywheel exploding at high rpm any more.

    The driveline for the car (trans adapter, gearbox, driveshaft, etc) is for sale. I'm looking for deals on a new setup right now. The idea is to adapt the torque tube and six speed transaxle from a C5 corvette.
  17. -=Lurker=-

    -=Lurker=- **BANNED**

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    Keep it coming.... Great work so far man!
  18. Alex B

    Alex B Junior Member

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    Picked up some DOM tubing for the cage. Sort of underestimated how long 22' sticks of tubing are. It's just like one of those failure motivational posters you always laugh at. I still managed to get home without impaling anyone.

    [​IMG]
  19. Alex B

    Alex B Junior Member

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    Finished patching the firewall:
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SlK25nHopLI/AAAAAAAAWYc/aBzKPvHYsR8/s800/IMG_6553.jpg" />

    Mounted one of the carbon/kevlar buckets:
    <img src="http://lh3.ggpht.com/_7EUAij74Ycw/SlK22eXn5yI/AAAAAAAAWXs/z3CJy8UCEqo/s800/IMG_6549.jpg" />

    Not bad for being an angle-grinder special.
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SlK22-9W3mI/AAAAAAAAWX0/dT9MsV1XQnM/s800/IMG_6550.jpg" />

    Grotesque is really the only word I can think of:
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SlK23tQZvWI/AAAAAAAAWX8/e4glQIrzU88/s800/IMG_6551.jpg" />

    Should be wide enough. 335/30R18 on 18"x13" ET25 rears and 285/30R18 on 18"x11" ET20 fronts.
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SlK24Sdm1nI/AAAAAAAAWYU/vaKJEMOrdTM/s800/IMG_6552.jpg" />

    12" ruler:
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SlK20taI7vI/AAAAAAAAWXU/wBn3JO1QTKQ/s800/IMG_6545.jpg" />

    Might need some more fender clearance:
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SlK21Cw1voI/AAAAAAAAWXc/5XfKXHO-Pow/s800/IMG_6546.jpg" />[/QUOTE]
  20. tweakmonkey

    tweakmonkey Webmaster Staff Member

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    This is such an awesome project, one of the coolest I've seen on -any- forum. Keep up the great work man.
  21. Alex B

    Alex B Junior Member

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    Thanks man! I appreciate the positive comments. Gives me a boost of motivation to get working.

    Got the baseplates for the main hoop and front lateral bars welded in. Made from .125" cold rolled mild steel sheet. Both the front and rear sections add up to about 300cm2 of area each which is nearly double the minimum FIA requirement.

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  22. -=Lurker=-

    -=Lurker=- **BANNED**

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    I like the dimple die work. :)

    Looking good man. Keep it coming...
  23. randomtask

    randomtask Chimp.

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    wow, humongous tires!!
  24. smirnoff

    smirnoff Curmudgeon

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    Yeah, those are mad. Can't wait to see more. :)
  25. Alex B

    Alex B Junior Member

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    I wish I had the cash to lay out for a set of good dimple dies. All those holes come stamped like that from the factory.

    I'm heading back to sweden in a while so we're getting ready to store the car until at least December.

    I cleaned up the garage and took some new pics of the car. We were hoping to bring it to the VCOA meet in Ipswich a few days ago, but time was tight and it was pouring rain on the morning of the show. The result of wanting to bring it out is that it's down on four wheels and has a bunch of other crap bolted on.

    Maybe not that low considering, but this is the first time in over two years its been less than 14" off the ground. The front suspension is all stock with bottomed out shocks, and the rear end is about 4" from bottoming out.
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SmOKPe7szpI/AAAAAAAAWrU/-hUnHXMsIcs/s800/IMG_6573.jpg" />

    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SmOKSubO1JI/AAAAAAAAWr4/VYqamX-G2o8/s800/IMG_6580.jpg" />

    Tacked up the wastegate.
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SmOKQDhCO-I/AAAAAAAAWrc/Y_i9iLSfya8/s800/IMG_6574.jpg" />

    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SmOKRW6PDuI/AAAAAAAAWrk/e1Dn7v2PLNI/s800/IMG_6576.jpg" />

    This puts the engine position somewhat in perspective. The (stock positioned) steering column passes over the engine mount.
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SmOKRyyed_I/AAAAAAAAWrw/zWwi3Ad8S0s/s800/IMG_6577.jpg" />

    Mounted the other seat and spraybombed the dash.
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SmOKUyoh5dI/AAAAAAAAWsQ/ugmo-Ia30dU/s800/IMG_6583.jpg" />

    Main-hoop tacked in.
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SmOKVtNucgI/AAAAAAAAWsY/3c-2VtK0tQg/s800/IMG_6584.jpg" />

    Pretty damn happy with the fit, especially considering it's the first one we've ever done.
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SmOKWFjxZ-I/AAAAAAAAWsg/a-BqUxyGHeU/s800/IMG_6585.jpg" />

    Hung the intercooler.
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SmOKYkGjs-I/AAAAAAAAWsw/CW2gO2H48z4/s800/IMG_6588.jpg" />

    I turned out some lower mount brackets for it.
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SmOKXTlN45I/AAAAAAAAWso/shIs2PLb378/s800/IMG_6587.jpg" />

    Ass shot. Had to put the 40mm spacers on the front to clear the strut tubes, so the 30mm spacers went on the back. This put the rear wheels in a weird looking position.
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SmOKZIDqn0I/AAAAAAAAWs4/65JoRjOTgaU/s800/IMG_6590.jpg" />[/QUOTE]