The Volvo 242 project thread *UPDATE*

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

  1. ninefivezero

    ninefivezero infinite resolution

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    Lame, we have to wait that long for updates?!?

    Great work as usual.
  2. Alex B

    Alex B Junior Member

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    Heading back the 12th so we're still making some progress. Got some more tubes in the car:

    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SnZgDFCO_DI/AAAAAAAAW04/DjAGjK4xDGM/s800/IMG_6595.jpg" />

    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SnZgEVQhviI/AAAAAAAAW1A/SRhn_IYMMK4/s800/IMG_6597.jpg" />

    We're pretty satisfied with how the fit-up is coming out.
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SnZgFJtzwHI/AAAAAAAAW1I/GUDiMVqMzK0/s800/IMG_6598.jpg" />

    Still need to add the upper window brace, the roof x, the rest of the door bars, and the a-pillar braces.
  3. Alex B

    Alex B Junior Member

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    My brother picked up a 1.5:1 steering quickener from summit. It's just a 1.5:1 gearbox that goes on the steering column to "quicken" the steering action.

    [​IMG]
  4. -=Lurker=-

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    What kind of tube is that? Looks like 1 5/8" DOM...

    Nice work. Keep it coming. ;)
  5. tweakmonkey

    tweakmonkey Webmaster Staff Member

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  7. Alex B

    Alex B Junior Member

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    Thanks man. It's 1.75" .095" wall cold rolled DOM. Really nice stuff to work with. I can't praise the JD-Squared bender and notcher enough. They are awesome tools and make this tube work a snap.

    That's painful to watch. Especially considering it's the top of the line 280bhp twin-turbo six they are killing :(
  8. Octane91

    Octane91 <smartass comment> Staff Member

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  9. Alex B

    Alex B Junior Member

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    [​IMG]

    Pushed the car outside while prepping it for storage. It looks pretty terrible in the current state.

    [​IMG]

    [​IMG]

    Built a 2.5" straight through aluminum muffler that's destined for the wastegate outlet. Will probably do basically nothing to muffle the sound but it's good practice for the real muffler i'm going to build later.
  10. Alex B

    Alex B Junior Member

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    Some progress. My brother and I spent a few days on and off making this thing. Finished it last night. It's a blow-off valve made from two Zenith-Stromberg carburettor float bowl covers.

    Broken down:
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SrL5Q8RsTNI/AAAAAAAAXGU/KDUkfEY-SUk/s800/DSC00086.jpg" />

    The top of the upper cover has been turned down and threaded:
    <img src="http://lh5.ggpht.com/_7EUAij74Ycw/SrL5Wlbg3lI/AAAAAAAAXG0/ELcESykPWtM/s800/DSC00088.jpg" />

    The inside has also been turned down to hold a spring:
    <img src="http://lh6.ggpht.com/_7EUAij74Ycw/SrL5fiABtpI/AAAAAAAAXHM/8hI2WaW5YeU/s800/DSC00091.jpg" />

    Bottom cover has been mostly hacked apart and also has some slits along the perimeter:
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SrL5ZtKDu5I/AAAAAAAAXG8/CKR1VEUGcoE/s800/DSC00089.jpg" />

    The tube has a snap ring that places it flush with the face of the bottom cover:
    <img src="http://lh3.ggpht.com/_7EUAij74Ycw/SrL5lcHHvAI/AAAAAAAAXHc/O-aXGKHoqvw/s800/DSC00094.jpg" />

    Nylon reinforced rubber membrane with a spring perch/50mm disc:
    <img src="http://lh3.ggpht.com/_7EUAij74Ycw/SrL5dK0A90I/AAAAAAAAXHE/sOVqhsP7MSg/s800/DSC00090.jpg" />

    Tube goes inside the bottom cover, membrane goes on top:
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SrL5La0kZeI/AAAAAAAAXGE/7YXLSgx5638/s800/DSC00084.jpg" />

    Then with the spring on the membrane's perch followed by the top cover and the threaded bushing, you end up with this:
    <img src="http://lh4.ggpht.com/_7EUAij74Ycw/SrL5FEQpbBI/AAAAAAAAXF0/PMhdN3Dh3rI/s800/DSC00082.jpg" />

    Weld the tube to your charge pipe and run a vac signal to the bolt and that's it. Hopefully it sounds ok. At least it'll look different.
  11. Alex B

    Alex B Junior Member

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    This thread is in need of some serious updating. 56k, go back to your abacuses:

    Bought a gearbox. M12 six speed manual pulled from a flooded, but low miles, C5 Z06. The 5-6 cluster is trashed. Looks like someone dropped it on the floor. Other than that all the gears and engagement teeth look to be in good, usable condition. They're rusty, but with some bead blasting, a rebuild kit, and a new 5-6 cluster it should be good as new.
    [​IMG]

    Been working on a pedalbox for a while. Karl drew one up and then we fired up the cnc mill:

    [​IMG]

    Brake pedal:
    [​IMG]

    Clutch pedal:
    [​IMG]

    [​IMG]

    Got one of these, just need three more. ~380mm mount-to-mount, 100mm travel, adjustable for rebound and compression, and wonderfully rebuildable.
    [​IMG]

    Karl got a smokin deal on a 2.5l 960 engine. Tore it down, washed it, and tossed a bunch of parts. Here's what's left, ready for surgery:
    [​IMG]

    Made up some rotor hats for the front rotors. 8mm 7075-T6. The slots get T-nuts with about 0.0005" play so the rotors have the ability to expand when they get hot. This is before deburring so don't mind the sharp edges:
    [​IMG]

    Got started on the big project for this summer, all new new front suspension. We're working our way in so we started with the centerlock adapters for the wheels. Bought some large pieces of 7075-T6 aluminum round stock and started making chips:
    [​IMG]

    Getting the big boy drill out:
    [​IMG]

    After one setup:
    [​IMG]

    Backs all done:
    [​IMG]

    Also finished the centering rings for the centerlug adapters. The angled face contacts the nut and should also keep the wheels from deforming when we torque the nuts. They're out for black anodizing now.
    [​IMG]

    [​IMG]

    Finished all the turning operations on the first adapter. Still needs to go in the mill for the bolt pattern and some lightening pockets.
    [​IMG]

    [​IMG]

    [​IMG]

    *Insert obligatory nut joke here*

    Ended up with an M60x1.75 thread (60mm dia, 1.75mm pitch). Going to need a 75mm socket for the nuts. Snap-on wants over $180 for one so I think we're just going to make one of those as well. Will also need a long breaker bar for tightening and removal. Installation torque should be somewhere in the 360ftlb range.

    [​IMG]

    [​IMG]

    Missing the centering ring underneath the nut, should end up looking something like this when it's all stacked on there.
    [​IMG]

    Large nuts or small hands? You be the judge.
    [​IMG]

    Well that brings us to the present. Going to finish the rest of the centerlock stuff early this coming week, then get going on the front uprights. Let me know what you guys think so far.
  12. -=Lurker=-

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    Damn you guys are doing some incredible work. Keep it up man.
  13. fornik8her

    fornik8her Junior Member

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    Awesome work
  14. -=Lurker=-

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    Any updates on this Alex? Please? :)
  15. ninefivezero

    ninefivezero infinite resolution

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    He hasn't been around for aaaagggeeeeess.

    But I'm also curious.
  16. -=Lurker=-

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    Still waiting to see what came of this project! :D
  17. Commissar Smersh

    Commissar Smersh 2020 Staff Member

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    Holy necrobump. Maybe you and Giggity are made for each other!
  18. Alex B

    Alex B Junior Member

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    Holy shit, this place is still around? I'll write an update for you guys tonight when I get home from the shop.
  19. mistawiskas

    mistawiskas kik n a and takin names

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    Now this is an epic bump!
  20. Alex B

    Alex B Junior Member

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    The project is still going on, but progress has been very slow. Life has gotten in the way; got a job, moved to Los Angeles, got involved with a 24hrs of Lemons team, engine swaps on other cars, girlfriend, etc.

    The car is in massachusetts right now but is slated to be picked up by a truck next week, shipping it out here to LA where we can actually finish the damn thing. A lot of design work has happened, the chassis and suspension hardpoints are all frozen now and won't change, I'm pretty happy with the layout

    Here's a quick run-down of the current status:

    Engine is now a 4.4l DOHC V8 out of a Volvo XC90 SUV. Stock rated at 300-ish horsepower, should be a good starting point. The project snowballed so much that a tube chassis felt like the proper thing to do. Tube frame has a lot of benefits, mainly being able to make good design decisions ahead of time instead of being stuck with a big compromise that would have uncertain results in the end.

    [​IMG]

    Fabricated some driveline bits, flywheel, trigger wheel, clutch release adapter, bellhousing:

    [​IMG]

    Using a reverse-mount starter from some NASCAR roundy-round application:
    [​IMG]

    Got a complete set of creme-de-la-creme NASCAR brake calipers and rotors. These things are comically huge:
    [​IMG]

    Did a bunch of design and analysis:

    [​IMG]

    [​IMG]
    [​IMG]
    [​IMG]

    Started making bits:

    [​IMG]

    [​IMG]
    [​IMG]
    [​IMG]

    This pretty much brings us current in the timeline. Both my brother and I have been pretty uninterested in this thing for a while but now the motivation is back in force. Getting the car shipped to LA is really exciting and I'm really looking forward to making some solid progress on the chassis and suspension parts.
    Commissar Smersh says thanks for this.
  21. hans5849

    hans5849 Serious as a heart attack

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    Neat. Now fucking finish it.
  22. -=Lurker=-

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    That's pretty badass. Love all of the fab work and nascar bits. Keep going!

    For those wondering I saw a bunch of videos of drag 242s yesterday and was reminded of this thread hence the necrobump. :)
  23. funkgab

    funkgab Junior Member

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    holy crap, thats alot of fab! and thats a nice shop you work in, can i hire you to build me some parts haha
  24. -=Lurker=-

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