1975 242 DL Mods and Upgrades

  #21  
Old 02-01-2014, 06:09 PM
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No turbo on this b20. Though, that would be fun. This engine can handle some good boost.

I have another turbo 16v engine for it.

It is a Holset he351 turbo.
 
  #22  
Old 03-10-2014, 12:50 AM
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Very nice !

What brand are the coil overs ?
 
  #23  
Old 03-10-2014, 03:09 AM
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Thanks,

Kaplhenke Racing LLC

This is the setup from them:
Custom Coilovers F+R (1" shorter strut tubes)
Koni Racing Struts and shocks
roll center/steering spacers
adjustable torque rods and panhard bar
adjustable endlinks
camber plates
 
  #24  
Old 04-27-2014, 11:57 PM
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Looks good. I'm sad that I found the end of the thread, but that means that there's more to come!
 
  #25  
Old 04-29-2014, 04:09 AM
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Thanks.

And I agree. I will have updates next month for sure!
 
  #26  
Old 05-26-2014, 07:04 PM
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Finally have some updates:

Its been a while, but got to work on the car this weekend.

Getting the engine bay ready for the engine:

Brake lines are done in the front of the car. Got the hydraulic clutch lines installed.
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Interior wiring and hoses for the gauges are done. Just have the finish the driver side fuse area and the interior will finally be complete (Well, until the R-sport cluster goes in )

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Clutchnet pressure plate and 8.5" ford t5 clutch disk from yoshifab, M46 Flat Flywheel.

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Fixed the Alternator wiring:

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And then we Dropped the Engine and Trans in.

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Where the T5 transmission lines up in the 240 (not bolted to the cross member yet to check the alignment).



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Also got the rear end out of the car to clean it up and paint it.

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The panhard bolt was rusted and snapped off. It's a good excuse to make a bracket to adjust the panhard bar position.

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Its a stock B20F motor (cleaned up etc...), T5 Transmission from a ford mustang with Hurst short shifter kit....some other stuff.

More next weekend!
 
  #27  
Old 05-31-2014, 06:59 PM
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More Updates:


Finished undercoating the entire car.

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Removed the stock front arm stops for the new bushings

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Cleaned and Painted the Rear end:

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Tomorrow:
We will finish the rear end. (new fluid, modified the panhard bolt. tap the bushing sleeve for a zerk fitting...etc)
Also have to remove the rear brake proportioning valve for the new brake system.
The read end should go in tomorrow. And maybe the gas tank...



More Tomorrow!
 
  #28  
Old 06-01-2014, 11:46 PM
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More Updates:

Got more done on the rear end.

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Still have to install the e brakes, brake lines, and calipers. Also have to find a permanent solution to the panhard bar, but for now, it will be fine.



New shock bolts in and bump stops shorten.

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Made a new bracket for the rear brake line setup. No pics of the bracket. Nothing special.

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Rear proportioning valves out and junction box in.



Should be a better balance to the new front brakes.

Rear end is in, so now we can start tweaking the alignments of the transmission location, driveshaft angels, and ride height....etc.

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Gonna raise the rear of the car up about .5"
maybe a little more.


More Next Weekend.
 

Last edited by TIPSP; 06-01-2014 at 11:49 PM.
  #29  
Old 08-25-2014, 01:01 AM
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Long time since last update...

Got a lot figured out on the car. Some things not pictured, but will post once they are ready.

For starters, we tried to get the one piece driveshaft to work.

Yoshifab adapter plate

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Then mounting it up.



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We noticed the stock lower mounts where tilting the engine and transmission.
It gave us unusable u joint angles with the one piece drive shaft.

So we took the mounts out and figured out a new solution to work with the ride height and drive shaft.

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Also got the new strut brace in and check out for fit.

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Also had to modify the transmission crossmember to fit better.
I also added a skid plate to the front of it.

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Side note:

The rear suspension is finally done (well, still have to mount the panhard bar, and do the pinion angles):

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Finally started to work with the clutch.

I made a clutch stop because Volvo decided not to include one.

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I mounted the reservoir for the clutch
The brace and parts will be painted later. still have some things to do before that is done.

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Here is the lower clutch fork stop we made to get the fork at the right setting.

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Here it is mounted

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We calculated a lot of stuff for the suspension, drive shaft and engine and transmission angles. With all that information we are now making new lower engine mounts to lower the engine to give us a proper drive line alignment. We determined that the one piece drive shaft would not work without serious manipulation of the tunnel in the car, so I am having a custom 2 piece driveshaft made for the car. It should be done early next week.

Car is soooo close to a first test drive.

More to come later!
 
  #30  
Old 08-26-2014, 04:47 PM
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Picked up the new driveshaft and also bought a T6 aluminum block for the motor mounts.

Here is the 6"x6"x10" 35.3# of aluminum:

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Cutting this block in half will give us the 2 piece we need to CNC mill the lower mounts, so we can have workable u-joint angles.

Here is the new drive shaft for the car.

Its a nice piece made by the guys at Coast Driveline in Ventura, CA.
Awesome staff, decent pricing, and fast turn around.
Here is their link: Coast Driveline & Gear

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Gonna make a new center bearing bracket this weekend for it, and get it installed.

Getting pretty excited now! The car is coming along now, and hope to drive it very soon.
 
  #31  
Old 09-10-2014, 08:00 PM
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Small update.

Got the drive shaft installed for the most part. Made the new center support for the new type of bearing (better than the junk Volvo used).

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Modified the clutch fork to handle a stiffer pressure plate.

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We also Tested out the clutch and are now looking for a way to get more throw out of it. Probably just going to get a wilwood master and adapt that with a slightly larger bore size. That or sleeve the slave for a smaller bore size.

After getting the clutch finished up, all that is major left to do is make the new fuel lines, and put it all back together. Motor mount 3d model is almost done, and basically ready to CNC that aluminum block.

Edit:

Got a new set of rims for the car. (used that need to be refinished).

HRE 525 17"x8" 5x108 et is something like 21mm-25mm

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When installing them, found out that the R brake caliper adapter was not centered. Going to have to shave off some of the ears to get the caliper centered.
 

Last edited by TIPSP; 09-14-2014 at 04:49 PM.
  #32  
Old 09-30-2014, 09:29 PM
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So... Some small updates.

Finished shaving some of the ears of the RSI adapters so the Calipers would be centered of the rotor. Also, got the front back together.

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Didn't get enough throw from the Stock Master, so I picked up a new MC:

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Spacing plate and pin holder made out of T6 Aluminum. (I still need to pick up one more 5/16th fine pitch nut for the rod).

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Final got some 3d printed pieces of the motor mount files done so we can test and then mill the final out of that big block of T6 I picked up.
These are either 1.25" or 1.5" shorter than the stock mounts (I don't remember right now). Should now be able to get proper Ujoint angles with the lower profile.

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And Last but not least, I picked up some material to do a cheap exhaust for the car.

Test fitting a Header (terrible collector, but whatever...Going for a cheap temp setup.)
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I've got the rest of the exhaust stuff in boxes. Going to make it either this weekend, or the following weekends... Not sure yet. It will be a 2.5" system with one 13" muffler. Not 100% sure where I will end it. Still waiting for a couple of small parts to finish the new clutch line.

That's all for now...
 

Last edited by TIPSP; 09-30-2014 at 09:31 PM.
  #33  
Old 10-06-2014, 02:24 AM
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Simple and cheap exhaust... Getting it test fitted right now.

Over the Axle.

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Where the muffler is going.

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Lower than I wanted it... Unfortunately, The cross member doesn't allow for good vertical clearance for the exhaust.

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It's actually over 1 inch higher than the old turbo 240.
So I will not have an issue with this setup.
Pretty happy about that.

Oh... Testing the 3d printed mounts...

Works pretty good! just some slight changes, and then that chunk of Aluminum will be beautiful billet mounts.



More next weekend... Should hopefully have it all fitted and ready to fully weld it. Have some final piece coming in next week to finish it.
 

Last edited by TIPSP; 10-06-2014 at 07:13 PM.
  #34  
Old 10-19-2014, 09:32 PM
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So finally finished the exhaust this weekend. Only thing left to do is wrap the header with titanium wrap.

All welded up.

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Still need practice, but getting better.



Front section

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All painted and ready to go in

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Got it installed

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Nice and tight fit to the body

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Installed some lower bracing from Yoshifab




Ground clearance check

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A lot better ground clearance then the 240 turbo. The downpipe was only 2.5inches from the ground. That car way lower than this car mostly due to smaller diameter tires. Plus that was a 3inch system.

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Almost done with the hydraulic clutch setup. Next weekend.






The car is sooooo close to being done now. Just going to finish the clutch stuff next weekend and start the fuel lines. Then it's a simple matter of installing the rest of the misc and wiring stuff.
 
  #35  
Old 10-26-2014, 08:55 PM
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Small update:


Got the Clutch hard line done this weekend:
It's still not in the car yet as we are installing a hood release. Had to get some parts to fit, so the Clutch master is still out.

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Had to make a new support bracket as the header hit the stock one.
Made this one out of some Aluminum. It is .25" plate and 1", .125" wall tube.

Test fitting it all

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Here it is after some sanding:

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Here it is next to stock one:

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That was my first time making something out of Aluminum. I made a clevis pin holder for the clutch master, but we made a billet one as seen above.
I painted the bracket black and waiting to install it later when everything else goes back in.



///Edit:
Here it is painted:

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Header is back out getting some titanium wrap.

Recent shot of the car. Still have to roll the rear fenders for the new rims and tires.




That's all for now. More next weekend.

///Edit 2:

Went ahead and did the header. It was a slow processes, but the end result should be great. Less heat soaking.

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Last edited by TIPSP; 10-30-2014 at 01:16 AM.
  #36  
Old 10-31-2014, 08:08 PM
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That header is so beautiful. It almost makes me sad that you wrapped it.
 
  #37  
Old 10-31-2014, 10:39 PM
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Originally Posted by Blue91SL View Post
That header is so beautiful. It almost makes me sad that you wrapped it.
It's not bad for the money. but the wrap will definitely keep the temps in control. The coating on the header would probably burn off in a couple years anyways :wink:


Edit:///

Tested the modification made to the model. Looks like a perfect fit.

Version 2.0!

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Just need to get them CNC machined and we are good to roll!

Got a New hood release for it. The stock one was loose and so was the new one. Had to come up with a way to hold the housing in the firewall.





This is what we came up with...The plastic piece threads into the brass piece while the brass piece clamps the firewall.
Works Great since these parts didn't work at all. The stock one and replacement didn't grab the firewall.

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It isn't that exactly, but looks very similar. There is a brass cap and orings we used to clamp the firewall, which is not pictured.

Installed:

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Last edited by TIPSP; 12-11-2014 at 05:01 AM.
  #38  
Old 12-09-2014, 06:51 PM
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So, its been a while....

We have been working on it getting some things figured out.

Pulled the gastank out. Putting new fuel lines in the car. So removed it work on some stuff...etc. Also got the Panhard bar done. Simple fix, but it should work great now.

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Made a new throttle cable holder. It's the little things that are slowing down the project.

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Because the Aluminum mounts will take God knows how long, I made some steel ones so I can drive the car till they are made.

Cutting the Plates and drilling holes.

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Made a jig to line up the parts.

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Then I welded them up. (might add a gusset to it, but probably not. They should be plenty strong as is)

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Took the engine out to make some space and get better ujoint angles. We basically shifted the entire engine and trans assembly over ~5/16".


Best part. I didn't even have to remove the strut brace to remove the engine and trans. That is a very nice part!

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Now, We can lower the engine and trans back in and put the car back together!

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Put some paint on them:

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It is sooooo close now to becoming completely done.

Working on fuel lines, right now. just have to order a couple new fittings for them as the old ones are way to rust to use.
 

Last edited by TIPSP; 12-11-2014 at 05:08 AM.
  #39  
Old 12-14-2014, 08:06 PM
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I just found and read this entire thread.

WOW
 
  #40  
Old 12-15-2014, 02:42 PM
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Originally Posted by geosar View Post
I just found and read this entire thread.

WOW
thanks.

the car should be done beginning of January.
 

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