home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > projects & restorations

Reply
 
Thread Tools Display Modes
Old 01-06-2019, 01:21 AM   #676
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

The front seats are back in and feel excellent.

__________________
-Tom 1980 242 T5
The Full Banana is offline   Reply With Quote
Old 01-06-2019, 01:30 AM   #677
Harlard
80/20 speed parts club
 
Harlard's Avatar
 
Join Date: May 2007
Location: PDX
Default

Baller
__________________


Herr Harlard am Erstens

1979 242 DL

Quote:
Originally Posted by t8fanning View Post
My knob has a big chunk of steel on it
Harlard is offline   Reply With Quote
Old 01-06-2019, 03:19 PM   #678
soclosenotnear
Board Member
 
Join Date: Oct 2011
Location: summerville, south carolina
Default

Looks awesome
soclosenotnear is offline   Reply With Quote
Old 06-06-2019, 05:39 PM   #679
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

Long story short, I was wrong about having solved the oil consumption issue (at least in part). I pulled the engine and found one melted piston (infamous cylinder #4) along with all other pistons having broken ring lands. I won't get deep into the why, but effectively, the cause is believed to be oil induced detonation over a long period of time, compounded on top of the fact that these pistons already had 240k on them.

Time to rebuild it better than before. Thanks largely to the generosity of Alex and Doug, I will be piecing together a refreshed block built with h-beams and Wiseco pistons.














Might as well repaint the engine bay while things are apart.

Disassemble


Sand


Prime


Basecoat (Volvo 477 electric silver metallic to match the exterior)


Clearcoat







I wish it was as easy as this short series of photos makes it look.

Next step: block machine work.

Last edited by The Full Banana; 06-26-2019 at 10:46 AM..
The Full Banana is offline   Reply With Quote
Old 06-06-2019, 06:26 PM   #680
Vol242vo
Board Member
 
Vol242vo's Avatar
 
Join Date: Feb 2005
Location: Spokane, WA
Default

Sorry to hear about the engine, the replacement will be sure to bring smiles. Fresh painted bay looks fantastic, eager to do the same soon. What gun are you using?
__________________


Derek - 1980 242
Vol242vo is offline   Reply With Quote
Old 06-06-2019, 06:50 PM   #681
Stiggy Pop
Board Member
 
Stiggy Pop's Avatar
 
Join Date: Feb 2011
Location: Granville, MA
Default

Painting is fun
__________________
'79 242
943 pickup
Stiggy Pop is offline   Reply With Quote
Old 06-06-2019, 07:28 PM   #682
Duder
His Dudeness, El Duderino
 
Duder's Avatar
 
Join Date: Dec 2009
Location: Torrance, CA
Default

That engine bay is looking fresh! Nice job. It only took about 30 seconds as far as I'm concerned

Your new block looks super clean too; I had a sneaky peek at it. I'm sure you'll be happy with it.
Duder is offline   Reply With Quote
Old 06-06-2019, 10:15 PM   #683
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

Quote:
Originally Posted by Vol242vo View Post
Sorry to hear about the engine, the replacement will be sure to bring smiles. Fresh painted bay looks fantastic, eager to do the same soon. What gun are you using?
I bought this kit last year when I ceramic coated the exhaust manifold and turbine housing.

PowRyte 4-Piece HVLP Gravity Feed Air Spray Gun Kit https://www.amazon.com/dp/B0762M9LCK..._wDC-CbGGWPFZ3

Ended up using the detail/touch up gun for both that and spraying the engine bay this time. I donít really know what Iím doing with these, but it worked just fine in both cases.

Quote:
Originally Posted by Duder View Post
That engine bay is looking fresh! Nice job. It only took about 30 seconds as far as I'm concerned

Your new block looks super clean too; I had a sneaky peek at it. I'm sure you'll be happy with it.
I canít wait to check it out when it arrives! Looked practically new in the photos. Itís about time I get to give this GTX a workoutónot long now.
The Full Banana is offline   Reply With Quote
Old 06-07-2019, 09:53 AM   #684
DET17
Reformed SAABaholic
 
Join Date: Nov 2009
Location: NW Georgia
Default

Quote:
Originally Posted by The Full Banana View Post
Long story short, I was wrong about having solved the oil consumption issue (at least in part). I pulled the engine and found one melted piston (infamous cylinder #4) along with all other pistons having broken ring lands.....

Next step: block machine work.
Will the next 5 cyl. block be the small bore type? What is your engine management system?
__________________
Project "cheap thrills" build thread: http://forums.turbobricks.com/showth...67#post4211467

Feedback thread: http://forums.turbobricks.com/showthread.php?t=198746
DET17 is offline   Reply With Quote
Old 06-07-2019, 03:10 PM   #685
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

Quote:
Originally Posted by DET17 View Post
Will the next 5 cyl. block be the small bore type? What is your engine management system?
Next block is a 81mm bore 2.3l from a 1999 T5. I'm using MS3x
The Full Banana is offline   Reply With Quote
Old 06-07-2019, 10:11 PM   #686
DET17
Reformed SAABaholic
 
Join Date: Nov 2009
Location: NW Georgia
Default

Quote:
Originally Posted by The Full Banana View Post
Next block is a 81mm bore 2.3l from a 1999 T5. I'm using MS3x
I understand the 81mm is the bore of choice; I hope to follow your lead with MS3x.
DET17 is offline   Reply With Quote
Old 06-17-2019, 01:26 PM   #687
Chuck W
Board Member
 
Chuck W's Avatar
 
Join Date: Apr 2008
Location: Indpls, IN
Default

This build is an inspiration!
__________________
'80 264GLE - (B21FT-MS'ed/M46)
'97 854 T5 (Eventually to be 5spd)
'77 242DL (B21F/M45) - SOLD '75 245DL SOLD '85 244GLT DEAD
'83 Tbird Turbo (2.3T/T5/MegaSquirt)
My feedback thread
Chuck W is offline   Reply With Quote
Old 06-17-2019, 03:00 PM   #688
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

Update!

Thanks to Alex Buchka doing all the legwork, a fresh block arrived to serve as a base for the new engine. This block came from a '99 T5 and appears to be identical to my 98 block with the exception that it has the factory-machined windows in the crankcase walls between cylinders. The block was cleaned and media blasted before Alex shipped it to me.








Some nice Wiseco pistons also arrived, huge thanks to Doug Kauer. At 81.2mm, these necessitated a slight overbore to the block.




Accordingly, the block and pistons went off to the machine shop to be matched. They ended up boring the block and resurfacing the deck.




After a shocking 2.5 days, I had them back from the shop and ready to go. At the same time, the last parts showed up so I geared up for a weekend assembly party.

The bottom end parts list includes
  • Maxspeeding chinesium h-beam rods
  • King main and rod bearings
  • Wiseco 81.2mm pistons sold by RSI back in the day
  • Total Seal rings
  • ARP 2000 rod bolts
  • new OE headbolts and reused OE bolts everywhere else





Thanks to a ton of help on Saturday, the fresh bottom end is assembled.



We continued on to get the head and pan on, and get everything timed.



I should have this sitting in the car within the next week. From there, the goal is to have it back on the road in early July.

I have a batch of fresh powdercoating being done on a bunch of things throughout the engine bay to change things up a tad. Should both look and perform like it's brand new!

The first part is done... the rest should be done in the next week:






Huge thanks to Alex (Alex Buchka), Doug (Hank Scorpio), Justus (justlie), Art (elpress) and Jay for all of their help so far. The quality and expediency of this rebuild is totally thanks to the generosity and direct efforts of those guys.

Last edited by The Full Banana; 06-17-2019 at 03:10 PM..
The Full Banana is offline   Reply With Quote
Old 06-17-2019, 06:48 PM   #689
elpress
Board Member
 
Join Date: Jun 2008
Location: Chicago, IL
Default

__________________
Previous:
2000 Volvo V40
2004 Volvo S60R
2011 Subaru STI

Current:
1984 Volvo 242 DL +T
2005 Volvo S60R
elpress is offline   Reply With Quote
Old 06-17-2019, 08:08 PM   #690
Stiggy Pop
Board Member
 
Stiggy Pop's Avatar
 
Join Date: Feb 2011
Location: Granville, MA
Default

This is going to be great
Stiggy Pop is offline   Reply With Quote
Old 06-17-2019, 09:04 PM   #691
Hank Scorpio
Chubfest 2009 Survivor
 
Hank Scorpio's Avatar
 
Join Date: Nov 2002
Location: The neighborhood with the ******* guitar player.
Default

Can’t wait to see it back on the road! Thanks for clearing some storage space in my garage for me
__________________
Hank Scorpio is from the Simpsons. You can call me Doug ;)
Will trade guitars/guitar parts for go fast goodies or stuff I need. Just PM.
www.kauerguitars.com the second best way to upset neighbors and alienate people.
History: Car 1 (242) | Car 2 (t5r) | Car 3 (255)
Hank Scorpio is offline   Reply With Quote
Old 06-26-2019, 10:40 AM   #692
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

Parts came back from powdercoat, so I got the engine ready to go back in the bay. If all goes well, it should be sitting back on the mounts tonight. Posting pictures because it makes me happy when things are this clean, and I know it won't stay that way .













The Full Banana is offline   Reply With Quote
Old 06-26-2019, 10:44 AM   #693
Stiggy Pop
Board Member
 
Stiggy Pop's Avatar
 
Join Date: Feb 2011
Location: Granville, MA
Default

stealthy
Stiggy Pop is offline   Reply With Quote
Old 06-26-2019, 11:38 AM   #694
Harlard
80/20 speed parts club
 
Harlard's Avatar
 
Join Date: May 2007
Location: PDX
Default

Noice.
Harlard is offline   Reply With Quote
Old 06-26-2019, 12:01 PM   #695
Chuck W
Board Member
 
Chuck W's Avatar
 
Join Date: Apr 2008
Location: Indpls, IN
Default

Damn. That's a nice-looking mill.
Chuck W is offline   Reply With Quote
Old 06-26-2019, 12:15 PM   #696
+Kardboard+
Chinese guy/Swedish rides
 
+Kardboard+'s Avatar
 
Join Date: Aug 2008
Location: Vancouver, Canada
Default

NSFW
__________________
'88 245DL Uncle Sven|'95 945T Darth Haul|'82 242GLT B23E Lumpy the Angry Viking (sold)|'77 244DL, red/sold.|'90 744T C3P-LOL, gold/sold

mtd240: I suspect "the wives" have a super-secret forum to discuss whether or not they will let us buy Volvo parts.
DavidSamuels: Not a website, a panel discussion/reality show. Real Housewives of Gothenburg.

-Feedback-
+Kardboard+ is offline   Reply With Quote
Old 06-26-2019, 04:07 PM   #697
Duder
His Dudeness, El Duderino
 
Duder's Avatar
 
Join Date: Dec 2009
Location: Torrance, CA
Default

Like I always say, a murdered out T5 is a sexy T5.
Duder is offline   Reply With Quote
Old 06-26-2019, 10:39 PM   #698
The Full Banana
not yet good enough
 
The Full Banana's Avatar
 
Join Date: Apr 2007
Location: Jackson, WI
Default

Thanks all! Engine is in as of an hour ago.



The Full Banana is offline   Reply With Quote
Old 06-27-2019, 01:02 AM   #699
Dirk242
Board Member
 
Join Date: Jun 2008
Location: The Netherlands
Default

Nice
__________________
Ď81 245
Dirk242 is offline   Reply With Quote
Old 06-27-2019, 01:07 AM   #700
NONHOG
equal opportunity car guy
 
NONHOG's Avatar
 
Join Date: Oct 2008
Location: Tacoma ish
Default

Man! that looks great!
__________________
_____________________________________________
80 Bertone (part-time driver) learn how to 5.0-Volvo here.... http://forums.turbobricks.com/showthread.php?t=250257
B20 sound! https://www.youtube.com/watch?v=6FpMWALskko
242, https://forums.turbobricks.com/showthread.php?t=344891
NONHOG is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


All times are GMT -4. The time now is 05:54 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.