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Old 02-28-2016, 06:23 PM   #326
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As I recall two generations told me I should have built a v8

put the studs in and plopped the head on, hopefully it doesn't have to come back off for a while. Would have torqued it down but need to go get a 12-point socket, whoops.

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Old 02-29-2016, 11:31 AM   #327
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...all in the wrist, young grasshopper!
Where did your Dad get his automotive worldliness?
Hi Mike thanks for asking.
I'll provide some of the detail because this is a family site in a lot of ways, and for the fathers and sons that read this, maybe it will be interesting or they will have their own parallels.

My dad, Mike #1, was swapping engines, frenching headlights and tunneling antennas, doing all that stuff when body work was with lead, bee's wax and a paddle in the '50s. He then moved in to the supercharged Studebakers, which were followed by a string corvettes, the most interesting being a 64 fuelie roadster with side pipes, though big block C3s followed. He's an engineer, a real car and aircraft enthusiast who made his side money buying and selling repos from GMAC, eventually partnered in a body shop and at 85 still loves everything automotive, (will still light the tires up on his Lexus SC400) which brings the story to me, Mike #2.

I was always in the garage with him handing him tools, and when cars started going thru garage almost weekly, I became the "company" mechanic when I was about 16, circa 1972. When I got my license, my dad's DD was a 69 pace car Camaro with a 396 and 4 spd, and my mom drove a blue and white stripe W30 442 - I melted a lot of tires! While my friends were pressing shirts for 19 cents each, or working minimum wage for $1.90 an hour, I was making $10/hr for mechanical work (brakes, suspension, exhaust and stuff), $100 for an engine swap, and $25 to shape a car (now called detailing). Of course I had one of the nicest cars when I was in HS, with a motor and tranny built by my dad and I, with the body work and paint done by me (not handed to me by rich parents). 20 years later as my son, Mike #3, was growing up, I was flipping Saabs, and he spent plenty of time handing me wrenches.

Mike #3 really teethed on his dirt bikes, which he eventually ended up racing. We spent countless hours either riding, fixing, or traveling to races. I credit that time for the bond that we have. He had a clone 900 SPG, 9000 Aero and the like, but it was really this Volvo that has brought him to a very accomplished level. As you might read into this, my dad and are both happy and proud to see what he is doing now.

Enough about the family, back to his 242!
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Old 02-29-2016, 11:46 AM   #328
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Hi Mike thanks for asking.
I'll provide some of the detail because this is a family site in a lot of ways, and for the fathers and sons that read this, maybe it will be interesting or they will have their own parallels.

My dad, Mike #1, was swapping engines, frenching headlights and tunneling antennas, doing all that stuff when body work was with lead, bee's wax and a paddle in the '50s. He then moved in to the supercharged Studebakers, which were followed by a string corvettes, the most interesting being a 64 fuelie roadster with side pipes, though big block C3s followed. He's an engineer, a real car and aircraft enthusiast who made his side money buying and selling repos from GMAC, eventually partnered in a body shop and at 85 still loves everything automotive, (will still light the tires up on his Lexus SC400) which brings the story to me, Mike #2.

I was always in the garage with him handing him tools, and when cars started going thru garage almost weekly, I became the "company" mechanic when I was about 16, circa 1972. When I got my license, my dad's DD was a 69 pace car Camaro with a 396 and 4 spd, and my mom drove a blue and white stripe W30 442 - I melted a lot of tires! While my friends were pressing shirts for 19 cents each, or working minimum wage for $1.90 an hour, I was making $10/hr for mechanical work (brakes, suspension, exhaust and stuff), $100 for an engine swap, and $25 to shape a car (now called detailing). Of course I had one of the nicest cars when I was in HS, with a motor and tranny built by my dad and I, with the body work and paint done by me (not handed to me by rich parents). 20 years later as my son, Mike #3, was growing up, I was flipping Saabs, and he spent plenty of time handing me wrenches.

Mike #3 really teethed on his dirt bikes, which he eventually ended up racing. We spent countless hours either riding, fixing, or traveling to races. I credit that time for the bond that we have. He had a clone 900 SPG, 9000 Aero and the like, but it was really this Volvo that has brought him to a very accomplished level. As you might read into this, my dad and are both happy and proud to see what he is doing now.

Enough about the family, back to his 242!
This is really neat.
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Old 02-29-2016, 03:10 PM   #329
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Volvos save lives and bring families together! Yep there's a lot of history, experience and skill in the chain - easy to feel like I'm way behind in that company. I was all bikes until I cared about driving my girlfriends around town, then took a pretty long break from caring about cars until my mid-20's. The foundation was there but this car has been all about learning. I did learn about tapping holes when I got my first KTM though! First bike I had with delicate, light weight 8mm head hardware and boy did I strip everything I touched for a while

Meanwhile, back at the ranch:

I had the RSI flywheel surfaced and it came back perfect. Glad it's not an expensive piece on the scrap pile. I am going to jump in on the YoshiFab group buy for the steel wheel/Clutch Master stuff, but with that being open ended I am anticipating reassembling the car with this wheel and my clutch net stuff. At the least it will get me going so I can get it fired up and put some break-in miles on. Maybe by the time the new setup is in hand I'll be ready to do the hydraulic clutch conversion.



Already March tomorrow? I better buy some tires.
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Old 02-29-2016, 04:51 PM   #330
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Hi Mike thanks for asking.
I'll provide some of the detail because this is a family site in a lot of ways, and for the fathers and sons that read this, maybe it will be interesting or they will have their own parallels.

My dad, Mike #1, was swapping engines, frenching headlights and tunneling antennas, doing all that stuff when body work was with lead, bee's wax and a paddle in the '50s. He then moved in to the supercharged Studebakers, which were followed by a string corvettes, the most interesting being a 64 fuelie roadster with side pipes, though big block C3s followed. He's an engineer, a real car and aircraft enthusiast who made his side money buying and selling repos from GMAC, eventually partnered in a body shop and at 85 still loves everything automotive, (will still light the tires up on his Lexus SC400) which brings the story to me, Mike #2.

I was always in the garage with him handing him tools, and when cars started going thru garage almost weekly, I became the "company" mechanic when I was about 16, circa 1972. When I got my license, my dad's DD was a 69 pace car Camaro with a 396 and 4 spd, and my mom drove a blue and white stripe W30 442 - I melted a lot of tires! While my friends were pressing shirts for 19 cents each, or working minimum wage for $1.90 an hour, I was making $10/hr for mechanical work (brakes, suspension, exhaust and stuff), $100 for an engine swap, and $25 to shape a car (now called detailing). Of course I had one of the nicest cars when I was in HS, with a motor and tranny built by my dad and I, with the body work and paint done by me (not handed to me by rich parents). 20 years later as my son, Mike #3, was growing up, I was flipping Saabs, and he spent plenty of time handing me wrenches.

Mike #3 really teethed on his dirt bikes, which he eventually ended up racing. We spent countless hours either riding, fixing, or traveling to races. I credit that time for the bond that we have. He had a clone 900 SPG, 9000 Aero and the like, but it was really this Volvo that has brought him to a very accomplished level. As you might read into this, my dad and are both happy and proud to see what he is doing now.

Enough about the family, back to his 242!
Awesome family history - thanks for sharing! Reminds me a bit of my dad and grandfather. Both named Earl, both heavily into aircraft & cars, both taught me self-reliance and the right mindset for working on my own projects. My gramps owned an airfield, flew Stearman biplanes, trained pilots for WW2, and later became a gunsmith and designed a few aircraft himself. My dad designed and built his own single-rotor Wankel engine in 1959 when he was 14 years old, and for almost 50 years he has designed and developed experimental optics and systems for submarines with the Navy. I am not Earl #3 in name, but hopefully in spirit!
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Old 03-04-2016, 02:16 AM   #331
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Glad you put those parts to good use! Looks great.
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Old 03-04-2016, 11:29 AM   #332
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Glad you put those parts to good use! Looks great.
Hey, thanks! I cleaned out Paul's garage pretty well. Still have your radiator and e-fan set up to go in as well.

edit: I'm glad I got a good deal on the plating work because I'm going to spend a lot more on blasting and powder coating than I was anticipating... sheesh. Building the car was pretty reasonable, FINISHING the car is proving to be quite expensive.

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Old 03-04-2016, 06:29 PM   #333
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Hey, thanks! I cleaned out Paul's garage pretty well. Still have your radiator and e-fan set up to go in as well.

edit: I'm glad I got a good deal on the plating work because I'm going to spend a lot more on blasting and powder coating than I was anticipating... sheesh. Building the car was pretty reasonable, FINISHING the car is proving to be quite expensive.
Thats exactly where I flopped. Getting all that stuff ceramic coated was about $1000 if I remember right
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Old 03-04-2016, 06:37 PM   #334
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Thats exactly where I flopped. Getting all that stuff ceramic coated was about $1000 if I remember right
Ouch, yeah I can definitely see how it would add up like that. Well think of it this way: I spared you the pain of watching it turn brown and flake in a few spots Most of it held up well though, the turbo still looks really good. The powder guy actually talked me out of doing ceramic on the intake manifold and doing regular PC instead... said it would hold up better over time.
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Old 03-06-2016, 07:32 PM   #335
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I put a few coats of etch primer on the barrels of the wheels, will get finished in silver.



I finally managed to finish the first lip, I think I have between 15-20 hours into this. The next ones will go a bit quicker since I know to go straight to 100 grit, but it is definitely a time consuming process. Satisfying though!

Once I got up to 800 I could start seeing the light at the end of the tunnel.



Last sanding step was 2000, at which point you're starting to put a polish into it.



Finally time to fire up the polisher. This is brown tripoli compound on a stitched cotton wheel, run in a 'cut' motion: move part against the rotation of the wheel with medium pressure.



pretty pleased with this.



Next I used a white diamond compound on a loose leaf cotton wheel, in a 'color' motion: move the part with the direction of the wheel with light pressure. This really puts the deeper shine into it. It was a little tricky to keep the wheel from building up compound and leaving black deposits on the part but I got the hang of it. Last and final step was a nice firm rubdown with Mother's aluminum polish and a hand buff.

Yes! This is what I wanted.



Here is the finished lip next to an unfinished one for comparison. Not bad for a 31 year old wheel.



One down, three to go. Can't wait to assemble a wheel once the centers are back from coating.
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Old 03-06-2016, 07:35 PM   #336
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wow, great work on the polishing!
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Old 03-07-2016, 10:31 AM   #337
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wow, great work on the polishing!
Thanks, I'm really happy with the results. I've done some polishing in the past but this is the first time I've used a machine to finish it and it made all of the difference. I think I paid like $33 for the bench polisher from Harbor Freight.
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Old 03-07-2016, 12:28 PM   #338
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Get some Zoops on those to keep the polish nice
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Old 03-07-2016, 12:41 PM   #339
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Get some Zoops on those to keep the polish nice
Thanks for the tip, I'll do some research on it. Otherwise I'll be doing a whole lot of touch up polishing with the Mother's. Not totally unreasonable since it's a limited-use car but it'd be nice to maintain this finish. I had thought about clear powder or anodize but I feel like any clear coat is just going to yellow and haze over time? It'd also be a shame to do all the work and lose some of the 'wow' shine to the top coat.
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Old 03-07-2016, 01:00 PM   #340
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Thanks for the tip, I'll do some research on it. Otherwise I'll be doing a whole lot of touch up polishing with the Mother's. Not totally unreasonable since it's a limited-use car but it'd be nice to maintain this finish. I had thought about clear powder or anodize but I feel like any clear coat is just going to yellow and haze over time? It'd also be a shame to do all the work and lose some of the 'wow' shine to the top coat.
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Old 03-13-2016, 07:06 PM   #341
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It was 81 degrees and sunny here on Wednesday and I'm getting the itch to drive the car. I also have to really start busting my ass if I want to bring it to the eeuro show on May 1. Getting the wheels done is a priority, I need to get them assembled and make sure they're all sealed properly and ready to roll. Should have powder coating back this week, and I'm trying to spend a few hours every day sanding to get the lips ready.

I torqued the head down to 90ft lbs using the ARP lube, it's definitely not going to fall off. Started putting shtuff on the block, it would be nice to be putting the engine in two weeks from now.

Before oil pan pics since it will never be so clean again.











We made a mark on the cam gear at 180* from the TDC mark and made a stainless steel plate to mount to the head with an alignment hole. Will work for lining the cam up without the upper portion of the belt cover.



We're going to try and make a brace for the header this week. Looks like coming from the alternator block bracket up to the underside of the collector should work. Then this weekend I'd like to get some wiring done, then have the engine dressed and ready to put the transmission on and drop it in the following weekend.
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Old 03-18-2016, 06:16 PM   #342
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pow pow powder coat.





I finished polishing the next lip last night so I had to mock it up. So happy with this. Glad I did the black zinc hardware. Now chrome or black lug nuts...



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Old 03-19-2016, 04:15 AM   #343
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Aw man those wheels
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Old 03-19-2016, 04:40 AM   #344
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I get more and more jealous every time you update!
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Old 03-19-2016, 11:23 AM   #345
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Great googly moogly. This is incredible. I swear someday I'll work on my 242 lol
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Old 03-19-2016, 05:21 PM   #346
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Thanks guys!

Everything takes so much longer than expected. I basically just spent today making stuff fit. First I had to nip the ends off of my new oil pressure sender because the oil return hose snakes right behind it and I needed some more room. I need to get some small nuts for it, the thumb screws that came with it are way too big for the room I have.



Oh speaking of the oil return hose... it's a -12 aeroquip hose with a DEI fire sleeve over it. One part of the hose sits against a header tube, no way to avoid it. It had melted the fire sleeve so I figured it had done it's job. I was actually about to wrap some DEI heat shield tape around it to kind of bolster the fire sleeve when I went to rotate the melted spot around towards the back. Looked closer and, whoa! Hose was totally cooked through. I can only assume that because the hole was facing upwards that the oil was just drooling along the bottom of the hose, and that's why I didn't get a leak from it. Still, no bueno. I'm going to make a new hose and put as much heat shielding **** on it as I possibly can, but I think making some kind of hard line for the section through the header is going to be the eventual long-term solution.



Believe it or not I didn't test fit the valve cover before I sent it off to powder.. I know, I know. Put it on today and found it was hitting the cam cap and nose of the lobe. I worked it with a small ball peen hammer and shaped it for clearance. Checked clearance on the cam and cap with clay and got myself plenty of clearance... phew.



Had to shorten one of the exhaust studs because of the way the header tube bends.



And because I obviously like clean shiny things I bought some stainless steel acorns for the valve cover to replace the ugly stock ones. Well they aren't as deep as the stock ones so I had to shorten valve cover studs to just the right length to get them to pull down.



You can see how smoked the coating on the header is, that's after not even 5k miles driving. It's a bummer because everything else is so clean and new looking, but it's going to be at least $300 to have it and the downpipe re-done and with the way I'm spending money on the car right now I am just going to put it off. I'd also hate to get another aluminum based coating done and have it turn into this in another year. I might look into the 2000* silicone based coatings.

Pushing on. We made a brace for the header that goes from the bottom of the flange to the alternator block bracket. That means I've got to lay the alternator out further to clear the new brace, so we are going to extend the alt adjustment bracket tomorrow. I'm hoping that's the last of the unplanned changes so I can get my wiring done and get the thing in the car.
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Old 03-19-2016, 05:39 PM   #347
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Stove Bright wood stove paint is the best/cheapest coating for headers. I've never seen anything last longer, even expensive coatings. The Stovebright holds up better than coatings if applied to bare metal. TrueValue/Ace Hardware stores usually carry it or you can order it online.

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Old 03-19-2016, 06:54 PM   #348
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i have 0 faith in coatings on turbo headers. Just use SS when building it and be done with it.
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Old 03-19-2016, 07:44 PM   #349
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Pat I've heard good things about that paint lasting.

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i have 0 faith in coatings on turbo headers. Just use SS when building it and be done with it.
Yeah, it is SS it'd fine raw. I still kinda cling to the ceramic because of the huge amount of heat this thing kicks into the bay. That said I have no idea how much it really helps.
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Old 03-19-2016, 07:49 PM   #350
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i have 0 faith in coatings on turbo headers. Just use SS when building it and be done with it.
Still gray 20 something years later...

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