The Buchka 242 Fake Racecar

[HiSPL]

Where's the update on the fake streetcar!

[Karl Buchka]

Originally Posted by HiSPL

Where's the update on the fake streetcar!

It seems I misspoke. Alex cleaned up at Davis with his DD whiteblock swapped 242. The fake street car is dead, but the engine will live on. I'll post an update once there's progress worth reporting on.

[Alex Buchka]

Originally Posted by agent008

Hi there. Found this thread while researching for my project - I challenged myself to build a "Locost" (Lotus Seven Replica) and want it to be B8444S powered. Ironically in Brazil, which is where I'm from, this engine, while not cheap, is much less expensive than any other respectable small-block V8 and for being narrower than a 90 degreee V8, will fit into my chassis easier.
After reading the whole thread here I felt compelled to register to the forum and follow it because so much goodness and also it has already given me a few answers for my own project. To the Buchkas I can only say well done and congratulations for your craftiness and ability with various workshop tools and jobs. Mind blown by, for example, the bellhousing and various other stuff accomplished already.

Well, presentation made, I ask if you have any news for us regarding the build. Also have you considered going with the original Volvo ECU? Any ideas as to what parts that'd need? I'm thinking at least original ECU, loom, keys & keyhole, immobiliser antenna ring, not sure on the instrument panel (DIM)?

EDIT: Maybe also the chassis/body ECU (not sure whats the name, BCM I think)?

Cheers

Hey bud, thank you for the kind words. Your locost sounds like a fun project, I've considered building one myself but I've been able to live vicariously through a friend and his Caterham project. The B8444S will definitely be a very tight squeeze in a locost. I think you'll find the height of the engine difficult to accommodate. The narrower V-angle and DOHC configuration both drive up the total height compared to an LS style engine and you might find yourself needing a pretty substantial bump in the hood to cover it up.

The original ECU was never really something Karl or I entertained. Neither of us were interested in jumping through a bunch of hoops to fool the immobilizer and other interconnected chassis signals only to be left with an unmodifiable engine calibration. I know there is at least one guy in Sweden who successfully ran the engine on an old Haltech E11v2 standalone by deleting the VVT functionality and converting to a cable actuated throttle body.

Things are happening on the car slowly but surely. The drivers seat and harness mounts are 100% complete so we've been able to strap in and make engine noises while turning the steering wheel. This was a big milestone.

I wasn't happy with the steering column mounts so they got some revisions. Built a box section to hold the forward shaft collar in place. Also re-arranged the tubing supporting the rear shaft collar and added a removable strut down to the pedal box mount. I only have a few pictures of the box section, will post more later. All of this greatly improved the vertical and lateral stiffness of the column and actually allow for mounting of master cylinders (probably important that those fit )



Added some taco braces to the knee bar to give more shear area in that region in case of a frontal impact. Also added a few up by the windshield bar for a small stiffness gain.

[agent008]

Originally Posted by Alex Buchka

Hey bud, thank you for the kind words. Your locost sounds like a fun project, I've considered building one myself but I've been able to live vicariously through a friend and his Caterham project. The B8444S will definitely be a very tight squeeze in a locost. I think you'll find the height of the engine difficult to accommodate. The narrower V-angle and DOHC configuration both drive up the total height compared to an LS style engine and you might find yourself needing a pretty substantial bump in the hood to cover it up.

Thanks for the quick answer! I see, the plan is to make a +442E chassis which is 4 inches wider, 4 inches longer and 2 inches taller. Not sure whether the extra 2 inches will be enough but man... that engine has got the best of me when I heard the sound. If I'm doing something crazy, why limit it to a more mundane engine? It's not like we have any race regulations here as there isn't any Locost championships etc. so we don't need to be constrained by any rules except those of physics of course.

The original ECU was never really something Karl or I entertained. Neither of us were interested in jumping through a bunch of hoops to fool the immobilizer and other interconnected chassis signals only to be left with an unmodifiable engine calibration. I know there is at least one guy in Sweden who successfully ran the engine on an old Haltech E11v2 standalone by deleting the VVT functionality and converting to a cable actuated throttle body.

Yeah, If I end up not using OEM those would be my reasons exactly, but either path isn't without its difficulties. I know you had to talk even to Volvo engineers to get the info, so after going such lengths to achieve your goals I understand one might not feel like giving away the treasure so easily, but I'll ask -- In case I'd go with an aftermarket ECU, would you mind sharing the info you have on eg. how to drive the CVVT solenoids, possible maps etc.? Thanks

Things are happening on the car slowly but surely. The drivers seat and harness mounts are 100% complete so we've been able to strap in and make engine noises while turning the steering wheel. This was a big milestone.

I wasn't happy with the steering column mounts so they got some revisions. Built a box section to hold the forward shaft collar in place. Also re-arranged the tubing supporting the rear shaft collar and added a removable strut down to the pedal box mount. I only have a few pictures of the box section, will post more later. All of this greatly improved the vertical and lateral stiffness of the column and actually allow for mounting of master cylinders (probably important that those fit )

Added some taco braces to the knee bar to give more shear area in that region in case of a frontal impact. Also added a few up by the windshield bar for a small stiffness gain.

Great to see project's still alive and having good progress. Keep up the good stuff. Following this thread with great interest.

Cheers

[Karl Buchka]

Originally Posted by agent008

Yeah, If I end up not using OEM those would be my reasons exactly, but either path isn't without its difficulties. I know you had to talk even to Volvo engineers to get the info, so after going such lengths to achieve your goals I understand one might not feel like giving away the treasure so easily, but I'll ask -- In case I'd go with an aftermarket ECU, would you mind sharing the info you have on eg. how to drive the CVVT solenoids, possible maps etc.? Thanks

As mentioned earlier in the thread, we're planning on using a Link G4+T to control the engine. The engine uses fairly conventional engine-oil fed cam phasors for VVT that requires closed loop control of the solenoids. The G4+T supports this strategy on four cams with user-definable trigger patterns. The jury is still out on if the stock cam trigger wheels can be properly translated to the Link configs, but we're hopeful. In the worst case we will have to modify the trigger wheels.

We have no maps or other info at this time. The talking we did with Volvo engineers was pretty superficial and never ended up going anywhere, so there really isn't any secret sauce to share there.

I would have no problem sharing any maps or calibrations we end up with. Secrecy is dumb. Just be aware that they will be of limited utility unless you have an almost identical engine setup.

[Alex Buchka]

Here are a couple of photos of the updated steering column mount. The lower removable strut is made from a piece of aluminum hex stock with right and left hand threaded rod ends. Probably going to run a compact reservoir on the clutch as pictured and some remote reservoir masters for the brakes.

Also vaguely visible are the keenserts i installed in the pedal box to allow for bolting it on from underneath.

[doucheNozzle]

Ooo yea, drink that C-

[Duder]

Originally Posted by doucheNozzle

Ooo yea, drink that C-

Hehe. We keep Diet Coors around the shop because it's low ABV, cheap, and inoffensive. Seems to work well when you want a refreshment but also want to Keep On Wrenchin! (TM) and not kill your productivity.

I sat in the FRC last night and tried out the new steering situation. Column feels super stiff and should stand up to reacting the multiple lateral g's this thing will pull in the corners. Many triangles, much race.

[agent008]

Originally Posted by Karl Buchka

As mentioned earlier in the thread, we're planning on using a Link G4+T to control the engine. The engine uses fairly conventional engine-oil fed cam phasors for VVT that requires closed loop control of the solenoids. The G4+T supports this strategy on four cams with user-definable trigger patterns. The jury is still out on if the stock cam trigger wheels can be properly translated to the Link configs, but we're hopeful. In the worst case we will have to modify the trigger wheels.

We have no maps or other info at this time. The talking we did with Volvo engineers was pretty superficial and never ended up going anywhere, so there really isn't any secret sauce to share there.

I would have no problem sharing any maps or calibrations we end up with. Secrecy is dumb. Just be aware that they will be of limited utility unless you have an almost identical engine setup.

Great! On to google "closed loop solenoid control" and learn about it.

Still talking about the engine, and how you said it would be a tight fit in my proposed car's engine compartment. I've googled a lot and couldn't find any dimensional drawings for the B8444S. Wikipedia says it's 754mm long and 635mm wide. What's this thing's height from the bottom of the oil pan to the top of the intake plenum?

[MadDog_945]

Originally Posted by Duder

Hehe. We keep Diet Coors around the shop because it's low ABV, cheap, and inoffensive. Seems to work well when you want a refreshment but also want to Keep On Wrenchin! (TM) and not kill your productivity.

I sat in the FRC last night and tried out the new steering situation. Column feels super stiff and should stand up to reacting the multiple lateral g's this thing will pull in the corners. Many triangles, much race.

We only keep 3 different kinds of Beer in the Garage which kills the produtivity every****ingtime :D

[DNAsEqUeNcE]

just checking in to see progress and say hello.

[SquareD]

Man this is so awesome, you guys drink Coors Light too.

[Karl Buchka]

Decided to drop the body down on to the frame today.

The cowl panel needed some notching to get it low enough.



The front of the body still needs to be dropped another 15mm or so in this photo, so it's slightly raked right now.



The body has been lifted almost 8" off the frame for almost a year, so it was super cool to see it closer to its final position.

[volvo # 240 -86]

Hi I looking for a volvo 240 -86 tail light in good used condition thanks.

[Karl Buchka]

Originally Posted by volvo # 240 -86

Hi I looking for a volvo 240 -86 tail light in good used condition thanks.

Sorry man, I don't have anything like that.

[HiSPL]

Thats not fair Karl. With your priveledge you could build this guy a new taillight.

[moise]

ho nice!

[Duder]

Body drop!

Soon...

[Alex Buchka]

Got a few hours in this weekend. Got the door bars and a-pillar braces tacked in place. Also notched and fit tubes for the main hoop/front main stay supports (helmet crushers) but didn't have time to weld them in.

[mopar318]

What kind of racing is the plan for this car? Road racing? Will you be doing HPDE or is some sort of class? Can't wait to see the finished product.

[Alex Buchka]

Originally Posted by mopar318

What kind of racing is the plan for this car? Road racing? Will you be doing HPDE or is some sort of class? Can't wait to see the finished product.

Mostly track days, maybe some hill climb and time attack. The tube chassis puts it in the Global Time Attack Pro/Comp class where it won't even be close to competitive so that would just be for the hell of it.

[Stiggy Pop]

I can't wait to see it sitting on wheels.

[rijk]

Originally Posted by Stiggy Pop

I can't wait to see it sitting on wheels.

But not without every extensively documented, breathtaking step in between, please.

[TheLost]

Reading your build threads is like a gripping novel. I love it. This thing is the coolest thing since sliced bread. Rad.

[Alex Buchka]

Originally Posted by Stiggy Pop

I can't wait to see it sitting on wheels.

Dude, me too. The excitement is building.

Originally Posted by TheLost

Reading your build threads is like a gripping novel. I love it. This thing is the coolest thing since sliced bread. Rad.

Thanks man, really appreciate the kind words.

Lifted the body off the chassis and got a good look at it for the first time. It's a bit comical to me how there's almost 36" of overhang front and rear from the extents of the frame. Ample room up front to package the cooling system, ample room in the back for... something?





Hit a big milestone this weekend. Karl and I fabricated the roof X brace and tack welded it in. This marks the completion of all the tubes on the entire main structure of the car. Now there's just lots of welding left, some more taco gussets, then the suspension hardpoints can go on.