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-   -   1980 242 GT. A reasonable project. (https://forums.turbobricks.com/showthread.php?t=284730)

The Full Banana 09-14-2013 09:51 PM

1980 242 GT. A reasonable project.
 
Most recent picture:

https://live.staticflickr.com/65535/...729bb9d7_b.jpg

Current setup:

Engine
99 T5 b5234t block with liners "shimmed"
98 T5 b5234t head lightly ported, stock cams
ME7 intake manifold with plenum shortened to clear PS pump, bung for IAC, brackets for 240 b230 throttle spool
960 3" throttle body
modified S70 fuel rail
850 turbo 3 bar FPR
ceramic coated ATP C30 cast exhaust manifold
38mm external wastegate dumping into exhaust
Garrett GTX3067R with ceramic coated .82 A/R turbine housing
CX racing SRT4 2.5" intercooler
Gates Racing kevlar timing belt
Volvo 260 Diesel passenger side engine mounts
960 e-fan
full 3" TIG welded 304SS exhaust with a cat and 2 Vibrant mufflers
92+ 940 NA radiator
Mann Provent oil separator
Bosch FR7DPP+ spark plugs


Engine Management
MS3x w/ knock module, 4 bar MAP, dual VR conditioner added in

Driveline
Getrag 265 transmission
One-off adapter plate
Volvo 960 bellhousing
e46 M3 transmission mounts
Sachs 240mm full-faced clutch disc from BMW e34 M5
e36 M3 / e34 M5 guibo
lengthened m47 front driveshaft
j9fab 740 turbo driveshaft support bracket
j9fab getrag 265 shifter bracket and linkage
BMW e60 shifter
Condor racing tall weighted shift knob
Tilton 60-1100 hydraulic release bearing with custom lines


Suspension
Front
GAZ Gold coilovers
336lb x 8" springs
6" helper springs
Homerbuchka camber plates and spring hats
control arms boxed with Yoshifab plates
polyurethane control arm bushings
Kaplhenke V2 QSRC spacers with adjustable Ackerman
GT firewall braces
cravingboost big strut brace
iPd (volvo-style) lower chassis braces
STS machining 28mm drop swaybar


Rear

Shortened trailing arms (20mm shorter)
Speedway 5" adjustable spring perches
200lb x 5" x 9.5" main springs
Gaz adjustable shocks, 40mm shorter than factory spec
factory rear swaybar
Kaplhenke hybrid torque rods with Volvo bushings
iPd adjustable panhard bar
Genuine Volvo front trailing arm bushings
SuperPro polyurethane larger trailing arm bushings


Brakes
94 Ford Mustang Master Cylinder

Front
2005 Cayenne V8 front calipers
S60R 330mm rotors
Homer's caliper adapters
iPd braided stainless lines
Bosch Quietcast pads


Rear
2005 Cayenne V8 rear calipers
Homer's caliper adapters
iPd braided stainless lines + Homer's adapter banjo lines
S60R 330mm rotors
Bosch Quietcast pads


Wheel/Tires
Current:

BBS RC305 17x9 et32 w/ motorsporttech adapters (38mm front, 32mm rear)
245/40R17 Pirelli P Zero Nero GT

Alternatives:

BBS RC304 17x8 et38 w/ motorsporttech adapters (38mm front, 32mm rear)
235/40R17 Falken RT615K

OE BMW DS1 17x7.5 et40 wrapped in Michelin Pilot Sports w/ motorsporttech adapters (38mm front, 32mm rear)

Interior
Recaro LS-B from mkII VW reupholstered in black leather
GT door cards
flocked '87 dash
Momo Mod 69 350mm suede steering wheel on Momo hub with 2.5” spacer
Rattletrap (sound deadener) below 1/8" closed-cell foam (decoupler) below 1lb/sq ft mass-loaded vinyl (sound barrier) below carpet (comfy)


Exterior
7" round H4 ecodes with relayed 12 gauge harness
GT fogs with relayed 12 gauge harness and 100w bulbs


------------


Previous setup:

Engine
95 b230ft - stock longblock resealed
b21f intake manifold w/ added fuel injector bungs
nathaninwa fuel rail
960 3" throttle body
TD04HL-20T w/ 11 blade billet compressor wheel, T3 wastegate actuator, ported straight turbine housing with a 3" vband outlet
90+ exhaust manifold w/ ported outlet
Grainger valve MBC @ 20 psi
CX racing SRT4 2.5" intercooler
NGK BPR6ES spark plugs
RSI Stage II turbo cam w/ RSI adjustable cam gear (timed straight up)
Gates Racing kevlar timing belt
91+ 240 power steering pump mounted on custom bracket
240 OE diesel engine mounts
960 e-fan
full 3" 409SS exhaust with 1 dynomax ultra-flo muffler in the rear
92+ 940 NA radiator
Mann Provent oil separator
Yoshifab vented oil cap


Engine Management
LH2.4
954 ECU with TLAO 6800rpm chip
EZK with Buchka wasted spark board and TLAO chip
Mitsubishi J702T ignition amplifier
Bosch Motorsport 2x2 coil
012 3" MAF
Bosch 42lb injectors (S60R green giants)


Driveline
Getrag 265 transmission
240 flat flywheel w/ 60-2 pattern
Sachs 240mm pressure plate from Saab 9000 aero
Sachs 240mm full-faced clutch disc from BMW e34 M5
j9fab getrag adapter plate & centering ring
e36 M3 / e34 M5 guibo
m47 driveshaft (unmodified)
m47 bellhousing & clutch fork w/ BMW TO bearing
clutch cable
j9fab 740 turbo driveshaft support bracket
BMW e46 330xi shifter & knob


Suspension
Front
DIY Short Strut Coilovers - 240 strut tubes sectioned 3" shorter
A1 Racing coilover sleeves & adjusters
Kaplhenke spring hats
Eibach 450lb x 8" springs
~100lb x 4" tender springs
Koni Race struts (p/n 8610-1437)
scottyd camber plates
control arms boxed with Yoshifab plates
polyurethane control arm and swaybar endlink bushings
Kaplhenke roll correction spacers
GT firewall braces
cravingboost big strut brace
Yoshifab lower chassis braces


Rear

Shortened trailing arms (20mm shorter)
DIY adjustable 2.5" spring perches (ebay accord coil-over kit with custom machined retainer)
250lb x 8" main springs
~100lb x 4" tender springs
Koni Race shocks (p/n 30-5436)
no rear swaybar
iPd adjustable torque rods
iPd adjustable panhard bar
Genuine Volvo front trailing arm bushings
SuperPro polyurethane larger trailing arm bushings


Brakes
94 Ford Mustang Master Cylinder

Front
2005 Cayenne V8 front calipers
S60R 330mm rotors
Homer's caliper adapters
iPd braided stainless lines
OE Pagid pads


Rear
2005 Cayenne V8 rear calipers
Homer's caliper adapters
iPd braided stainless lines + Homer's adapter banjo lines
S60R 330mm rotors
Wearever Gold pads


Wheel/Tires
BBS RC304 17x8 et38 w/ motorsporttech adapters (38mm front, 32mm rear)
235/40R17 Falken RT615K

OE BMW DS1 17x7.5 et40 wrapped in Michelin Pilot Sports

Interior
Recaro LS-B from mkII VW
GT door cards
flocked '87 dash
Momo Mod 69 350mm suede steering wheel
Rattletrap (sound deadener) below 1/8" closed-cell foam (decoupler) below 1lb/sq ft mass-loaded vinyl (sound barrier) below carpet (comfy)


Exterior
7" round H4 ecodes with relayed 12 gauge harness
GT fogs with relayed 12 gauge harness and 100w bulbs
black GT grille & headlight buckets


------------

New car, new thread.

This will be the continuation of my wagon project which you can see here --> http://forums.turbobricks.com/showthread.php?t=257147. Pretty much everything from that car will be swapped into this shell. The primary difference is that now I incorporate the goals of having a nice interior and body.

My goal:
The car needs to do everything as I personally expect it should to make for an enjoyable driving experience. If something stands out as being subpar, I will attempt to fix it to make it good. This is my all-inclusive, wholly subjective metric.

-It needs enough power to get out of it's own way and justify the suspension. ~230-250rwhp should be plenty, but that yet remains to be seen.
-It must handle well, but also be street-able enough for me to happily drive to work in the summer, around town casually, and on a long trip to iPd.
-It has to look 'good', but in doing so also give minimal concessions to drivability (no scraping, no rubbing, etc).
-The interior needs to be a nice place to be (quiet-ish, comfortable, and pleasing to look at).



Anyways, this was Brian's (2fast242gt) old shell that was graciously donated to me. A huge thanks to him for this, and for saving me from wallowing in my rusty-shelled misery.

Here is my starting point, after rolling off the trailer and a quick wash.

http://i254.photobucket.com/albums/h...ps92712d87.jpg




With that, the work begins.

Pulled the front apart to begin prepping the engine bay for paint. It was rattlecanned black, and was in really poor shape.
https://lh3.googleusercontent.com/-d...4/IMG_3648.jpg

https://lh3.googleusercontent.com/-l...4/IMG_3655.jpg

Spent a good portion of the day removing the paint. Not fun.
https://lh5.googleusercontent.com/-c...4/IMG_3668.jpg

https://lh5.googleusercontent.com/-h...4/IMG_3669.jpg

I pulled the dash the other night. I will be swapping in the dash from the 87 after I fix it up.
https://lh3.googleusercontent.com/-l...4/IMG_3650.jpg

And now it's time to replace the destroyed window scrapers. Thanks Ken for shipping so quickly.
https://lh5.googleusercontent.com/-8...4/IMG_3677.jpg

slow240 09-14-2013 09:59 PM

I'm excited to see Brian's 242 live on, but I reeeeally love your wagon.... That color/wheels/ overall fitment, it's just right.

Good luck with this beastie, ill keep an eye out for this

fortbrick 09-14-2013 10:38 PM

This is gonna be good.

2fast242gt 09-15-2013 12:33 AM

Yeah the rattle can job sucked. I just touched it up as I scratched it.
That car is a engine slut. Is this your basic goal? It was a fun setup.
<a href=http://s265.photobucket.com/albums/ii234/2fast242gt/?action=view&current=PICT0002-1.jpg target=_blank><img src=http://i265.photobucket.com/albums/ii234/2fast242gt/PICT0002-1.jpg border=0 alt=></a>

doucheNozzle 09-16-2013 01:18 AM

Subscribed

Old Iron 09-16-2013 09:46 AM

This will be a cool project! What's wrong with the wagon.

Benjam83 09-16-2013 10:34 AM

I like the shave-ed-ness on the exterior.

smith_t240 09-20-2013 01:47 PM

Great angle in the pics. Keep that hood up and fender off, haha.

Let me know when you need a hand with the engine and stuff!

Also, what happened to 50 shades of grey as the thread title?

The Full Banana 09-20-2013 10:34 PM

Quote:

Originally Posted by Old Iron (Post 4686397)
This will be a cool project! What's wrong with the wagon.

Rust and just a generally haggard shell.

Quote:

Originally Posted by smith_t240 (Post 4690535)
Great angle in the pics. Keep that hood up and fender off, haha.

Let me know when you need a hand with the engine and stuff!

Also, what happened to 50 shades of grey as the thread title?

Yeah, that just reminded me to order paint. Thanks for your help with the initial work in getting the car. I'll let you know when I'm thinking it's time for the engine to go in--probably a couple weekends from now. 50 shades of grey was swept under the rug after I decided to make paint a higher priority.


Anyways, cleaned up and painted the valve cover. This was in this car the last time it had a 8v redblock in it. Brian modified it to work with a 530 head years ago.
https://lh6.googleusercontent.com/-P...4/IMG_3692.jpg

I took Redwood Chair's advice and ordered SprayMax 2k primer and clear coat. I used the POR Prep & Ready to take care of some flash rust that showed up in the past couple days. I'll reapply it to prep before priming.
https://lh5.googleusercontent.com/-D...4/IMG_3682.jpg

I used the clear coat on the GT grille and headlight surrounds after repainting them black just now. That stuff is pretty great.

Tomorrow I'll finish prepping the engine bay, and then lay down the SprayMax 2K epoxy primer.

doucheNozzle 09-20-2013 10:36 PM

Sand off the Volvo letters. That'll make that valve cover bitchin'

The Full Banana 09-20-2013 10:49 PM

I'm thinking about it.

I like the letters sanded on the newer style valve covers with the larger lettering, but on these old covers with small lettering I think it might be best as-is.

Old Iron 09-20-2013 11:54 PM

Dang, whats the address, I am shipping you a valve cover for you do do for me! Look forward to more from this thread!

2fast242gt 09-21-2013 01:54 AM

where did the car get flash rust? engine bay? i have some ooolldd pictures of this car and I when i was like 17, so I may photobomb this thread sometime. if you need help anytime or just want to hang out let me know! id love to help.

The Full Banana 09-21-2013 02:22 AM

Quote:

Originally Posted by Old Iron (Post 4691021)
Dang, whats the address, I am shipping you a valve cover for you do do for me! Look forward to more from this thread!

Maybe if I get bored I'll use the extra paint on a spare 530 valve cover. If I do, I'll shoot you a PM.

Quote:

Originally Posted by 2fast242gt (Post 4691065)
where did the car get flash rust? engine bay? i have some ooolldd pictures of this car and I when i was like 17, so I may photobomb this thread sometime. if you need help anytime or just want to hang out let me know! id love to help.

Yeah, just a tiny bit in the engine bay which was to be expected. I will be finishing up the rest of the engine bay prep and priming tomorrow. I would definitely appreciate some help when it gets to be time to drop the engine in the car, but that will be a little while yet. I'll probably be working on it pretty much every weekend, with a little tinkering on weeknights. Stop on over!

I've been ordering so much stuff for this lately. Lots of little stuff, but quite a steady stream. Excited to get everything in!

The Full Banana 09-21-2013 11:53 PM

Car is now safely tucked away in the garage.
https://lh5.googleusercontent.com/-4...4/IMG_3702.jpg

Almost time to put that Spray Max epoxy primer to work.
https://lh3.googleusercontent.com/-L...4/IMG_3737.jpg


The pile of parts in queue is growing:
https://lh4.googleusercontent.com/-x...921_113111.jpg

2fast242gt 09-22-2013 03:48 AM

Awsome! Did you score a new grill? Or did you paint my old one? Looks very nice I like the progress.

smith_t240 09-22-2013 11:22 AM

Quote:

Originally Posted by The Full Banana (Post 4691084)
tinkering on weeknights

The foundation to greatness.

Great progress on stripping the bay and getting some stuff painted. Should we do a double header engine swap weekend? I am finally getting what I need for the new longblock.

volvobrage 09-22-2013 12:19 PM

Really nice job!:)Keep on going!

The rust/crash fix on the driver side doesnt look so nice, planning on changing that while your at it?

The Full Banana 09-22-2013 01:06 PM

Quote:

Originally Posted by 2fast242gt (Post 4691827)
Awsome! Did you score a new grill? Or did you paint my old one? Looks very nice I like the progress.

Same old grille, just cleaned up and painted

Quote:

Originally Posted by smith_t240 (Post 4691943)
The foundation to greatness.

Great progress on stripping the bay and getting some stuff painted. Should we do a double header engine swap weekend? I am finally getting what I need for the new longblock.

Thanks. Double header sounds rough... but yeah, let's get cranking. The whole non-running car thing is lame.

Quote:

Originally Posted by volvobrage (Post 4691981)
Really nice job!:)Keep on going!

The rust/crash fix on the driver side doesnt look so nice, planning on changing that while your at it?

Thanks! I would like to change it, just trying to figure out the best way to go about it. Some day I will have to buy a welder and learn to use it.

volvobrage 09-23-2013 02:19 AM

Quote:

Originally Posted by The Full Banana (Post 4692007)
Thanks! I would like to change it, just trying to figure out the best way to go about it. Some day I will have to buy a welder and learn to use it.

Look how I did it in my project thread:)If you take good time dismounting and have a donor car its actually a quite easy job!
But ofcourse you need a welding machine first:-P

Keep on going!

2fast242gt 09-23-2013 02:36 AM

If you get a new innerfender I'd be glad to repair that the right way for you. Its always bothered me, that repaor was done when I was 17 by a local guy I knew. It would be easy to make it look like nothing ever happend.

550 09-24-2013 12:56 PM

Diggin it!

The Full Banana 09-26-2013 08:53 AM

This stuff showed up:

https://lh6.googleusercontent.com/-5...8/IMG_3747.jpg

https://lh3.googleusercontent.com/-7...4/IMG_3742.jpg

50 sq ft of Fat Mat Rattle Trap & 100 sq ft of Mass Loaded Vinyl.

Started on the passenger door. 25% minimum coverage is all I am shooting for with the Rattle Trap.
https://lh4.googleusercontent.com/-M...4/IMG_3749.jpg

Josepilove 09-26-2013 09:03 AM

http://www.youtube.com/watch?v=NMwB5uIWOOI

The Full Banana 09-29-2013 10:34 PM

More progress this weekend.

Measured and cut out the strut tower opening to make room for camber plate adjustment.
https://lh4.googleusercontent.com/-4...4/IMG_3757.JPG

https://lh6.googleusercontent.com/-2...4/IMG_3775.JPG

https://lh4.googleusercontent.com/-h...4/IMG_3770.JPG

Finally wrapped up the prep and sprayed the engine bay with Spray Max 2K epoxy primer. For an aerosol can, this stuff is pretty great.
https://lh6.googleusercontent.com/-3...4/IMG_3788.JPG

https://lh3.googleusercontent.com/--...4/IMG_3785.JPG

https://lh4.googleusercontent.com/-f...4/IMG_3806.JPG

Then I pulled the dash out of the wagon. This is in way worse condition than I realized. Not sure what I'll end up doing with this.
https://lh3.googleusercontent.com/-T...4/IMG_3826.JPG

https://lh5.googleusercontent.com/-Q...4/IMG_3824.JPG

I'll be using some of the blue interior trim from the wagon for this car, so I tried out Duplicolor interior paint. Seems to be pretty good.
https://lh3.googleusercontent.com/-k...4/IMG_3836.JPG

2fast242gt 09-30-2013 01:23 AM

Arnt you cutting that innerfender out so I can weld it???

2fast242gt 09-30-2013 01:24 AM

Swapping from the almost mint early dash :(?

Josh 09-30-2013 03:09 AM

I used some of that duplicolor interior paint on my kick panels and it turned sorta dull and white-ish in about a year. I've had much better luck with the sem paint Ipd offers.

NChoy 09-30-2013 04:56 AM

Quote:

Originally Posted by Josh (Post 4698937)
I used some of that duplicolor interior paint on my kick panels and it turned sorta dull and white-ish in about a year. I've had much better luck with the sem paint Ipd offers.

Josh,

Check out Industrial Finishes, or Bob's Paintland in Vancouver. Their prices on SEM trim paint are way better than IPD's. Also, Bob's Paintland can color match anything you bring them. I've had very good success with them.

Crazychopstick 09-30-2013 12:26 PM

Make sure you apply paint pretty quickly after the 2k primer. Otherwise you may lose adhesion qualities and may need to resand in order to get it to stick.

Hank Scorpio 09-30-2013 02:14 PM

Quote:

Originally Posted by Crazychopstick (Post 4699233)
Make sure you apply paint pretty quickly after the 2k primer. Otherwise you may lose adhesion qualities and may need to resand in order to get it to stick.

Personally, with primer I'd scuff regardless.

The Full Banana 09-30-2013 06:23 PM

Quote:

Originally Posted by 2fast242gt (Post 4698863)
Arnt you cutting that innerfender out so I can weld it???

Swapping from the almost mint early dash :(?

I'll save the inner fender from the wagon in case I want to replace it, but for right now this is fine. It looks way better than I expected it would, and this isn't going to be a show car.

I prefer the later dash, and as an added bonus it already has an electric speedo.

Quote:

Originally Posted by Josh (Post 4698937)
I used some of that duplicolor interior paint on my kick panels and it turned sorta dull and white-ish in about a year. I've had much better luck with the sem paint Ipd offers.

Thanks for the heads up. I'll have to order some SEM paint.

Quote:

Originally Posted by Crazychopstick (Post 4699233)
Make sure you apply paint pretty quickly after the 2k primer. Otherwise you may lose adhesion qualities and may need to resand in order to get it to stick.

Quote:

Originally Posted by Hank Scorpio (Post 4699339)
Personally, with primer I'd scuff regardless.

Thanks for the tip. The manufacturer recommended scuffing if you topcoat after 12 hours, so I will definitely be scuffing it tonight before I paint it.

The Full Banana 10-02-2013 10:52 PM

More progress in the engine bay. It's about half done now.

https://lh4.googleusercontent.com/-M...4/IMG_3861.JPG

fortbrick 10-02-2013 11:22 PM

Exceptional work. Keep it up. :)

2fast242gt 10-03-2013 02:05 AM

that looks white... lol sure looks nice. makes me want to stitch weld my new one's bay.

760T man 10-07-2013 12:51 PM

Tom, that 87 dash is in better shape than my 244's dash by a long shot. Mine easily has 10 more cracks above the instrumentation alone, not to mention the rest of the thing. I might be interested, if you're willing to hang on to it for a bit (nature of my job and all) and assuming you're not going to use it.

The 75-80 dash is better anyway. :nod:

The Full Banana 10-13-2013 09:57 PM

Quote:

Originally Posted by 1989volvo740gl (Post 4702581)
Exceptional work. Keep it up. :)

Thanks!

Quote:

Originally Posted by 760T man (Post 4706524)
Tom, that 87 dash is in better shape than my 244's dash by a long shot. Mine easily has 10 more cracks above the instrumentation alone, not to mention the rest of the thing. I might be interested, if you're willing to hang on to it for a bit (nature of my job and all) and assuming you're not going to use it.

The 75-80 dash is better anyway. :nod:

The 87 dash is going in the car. I went ahead and spent quite a bit of time repairing all of the cracks in the dash with Bondo/3M flexible bumper repair kits. It took two kits to fix everything. If you are interested in the early dash, shoot me a PM.


Two quick pictures: (I will update this week as more significant things are completed)

https://lh5.googleusercontent.com/-a...4/IMG_3872.jpg

https://lh4.googleusercontent.com/-z...4/IMG_3911.JPG

I've been spending a lot of time cleaning, prepping, and painting. I can't wait to be beyond this part of the project. Very rewarding, but very tedious.

The Full Banana 10-15-2013 12:57 AM

After the clearcoat fully cured, I took my harbor freight DA to it to clean it up some.

This is really hard to capture in pictures because the lighting is crap on this side of the garage, but I'm really happy with how it turned out.

https://lh6.googleusercontent.com/-w...4/IMG_3969.jpg

The Full Banana 10-18-2013 11:25 PM

crawling along...

https://lh4.googleusercontent.com/-y...4/IMG_3974.JPG

https://lh6.googleusercontent.com/-z...4/IMG_3995.JPG

Beachee 10-19-2013 06:30 AM

Looking good!!!

wisturbo 10-21-2013 09:10 AM

Excellent work , Tom. What garage are you working out of?

The Full Banana 10-21-2013 10:57 AM

Thanks!

Joel, my parents bought a new house with a sizeable detached workshop. That's where the car is. Heater goes in soon! :nod:

760T man 10-21-2013 11:27 AM

Are you flocking the whole upper dash like the glovebox is done? (At least the black *looks* flocked...)

The Full Banana 10-21-2013 11:31 AM

The upper half, yes.

760T man 10-21-2013 11:39 AM

Giving me ideas...

Also, I spy blue. Still got the front seats from the 245? My interior is blue cloth, but the front seats are tan vinyl... :grrr: Granted they're in amazing shape, but the color mismatch is a little more than I can handle.

The Full Banana 10-21-2013 05:55 PM

Front seats are long gone, and were vinyl not cloth.

The Full Banana 10-21-2013 09:20 PM

I never want to do this part again. It was so tempting to cut it, but I managed to resist.

https://lh4.googleusercontent.com/-v...4/IMG_3998.JPG

wisturbo 10-21-2013 09:25 PM

That would require an extra beer or two. Wooof!

The Full Banana 10-21-2013 09:39 PM

Maybe that's my problem... I need more garage beer.

wisturbo 10-21-2013 09:55 PM

How far away did the folks move? That's a stellar garage setup you're working in. Have em put compressed air and a lift in there, you know.... for good measure. ;)


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