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-   -   Olga the Second Revised (https://forums.turbobricks.com/showthread.php?t=314945)

JerryJS8 04-19-2017 10:39 AM

Got back to the workshop Monday afternoon, didn't get the motor buttoned up cause I spent most of the afternoon chasing a leak in the trunk. Ended up having to rip out the carpet and wash everything cause of the mold that had been building up... I hope it's fixed now!!!


Resistor pack delete for the delphi 42lb injectors (01D030x).


Trying my best to use old volvo intercooler piping to make the build look like nuthin's special here.


Still looks....




And then it started snowing, in the middle of April... :grrr:


JerryJS8 04-23-2017 07:50 AM

Installing the 3" MAF on the stock air filter box I needed a 70mm to 80mm adapter hose. So in the spirit of Turbobricks, I said forget ordering online (piece of hose costs 23€ shipped), I'll make one!



Got some new material for the printer a while ago and was dying to try it out. Thermoplastic Polyurethane is both oil and solvent resistant as well as heat resistant up to 95°C (203°F).


Four hours later I had my adapter freshly made. See how this stuff holds out, but it's looking good so far!



Got to cleaning out the car, now it feels like I'm working on a Volvo and not a storage container. Swapped out the glovebox and center console with spares that weren't broken, starting to come together nicely!


And finally got the chipped 984 ECU installed that will be regulating the e-fan conversion. Pins 10 and 11 wern't populated on the factory harness, so I robbed some cables with connectors from a broken side view mirror harness to tap in with. On the front I still got the A/C condensor fan on the stock circuit, so I should be pretty much good in the cooling department.


JerryJS8 05-01-2017 08:24 PM

It's been a successful day at the shop!

As I said I couldn't leave the blue, so I used a high performance remedy...




Printed some new nylon bushings for the throttle cable roller


The ugly PCB inlet work till I get a decent connection printed and installed...



After that I got everything buttoned up and started it up for the first time.

First start after complete rebuild:

<iframe width="854" height="480" src="https://www.youtube.com/embed/HXSOjow_cq8" frameborder="0" allowfullscreen></iframe>

First drive under own power after full warmup:

<iframe width="854" height="480" src="https://www.youtube.com/embed/UBt1Bk46bg4" frameborder="0" allowfullscreen></iframe>

Took awhile for the hydrolifters to pump up, but then she sounded pretty good :)

Today's end result! Still going for that no obvious thrills look.



stick70 05-01-2017 08:38 PM

That's pretty damn slick with the printed intercooler hose. I wasn't aware they had material with those specifications.

Love the project, it's really interesting to see how it aged and what you had to repair.

JerryJS8 05-02-2017 02:09 AM

Yeah, I'm really impressed with the material as well. It's amazing how many options are available for 3d printing filament.

Glad you enjoy it, also been fun for me to see what held up and what not.

MadDog_945 05-02-2017 02:35 AM

video doesnt work.. this build must be Fake !!

JerryJS8 05-02-2017 02:43 AM


Originally Posted by MadDog_945 (Post 5604517)
video doesnt work.. this build must be Fake !!

YouTube work not fast enough, aber jetzt geht's!!!! :-P

JerryJS8 05-15-2017 03:52 AM

Spent the past few saturdays day chasing gremlins, both electrical and mechanical.

Silly things like:
Sunroof would open, but not close --> cleaned switch
Horn would not work --> chased it down to a grounded connection
Low charging voltage --> swapped in spare alternator
Knock control signal absent --> swapped in spare knock sensor
Small oil leak somewhere around the turbocharger --> tightened the oil feed banjo bolt 1/8 of a turn
Throttle cable was fraying --> new used installed
Brake light was permanently on --> adjusted switch contact point with a hammer
Exhaust leak at the turbocharger --> retorqued the wastegate flange bolts
Idle was sporatic --> cleaned idle control valve
Missing interior panels --> found, cleaned and installed interior pieces
Missing euro plate holders --> mounted euro plate holders
Bad windshield wipers --> installed new ones
Faulty front left turn signal --> put new bulbs on the shopping list
Ugly brass PCB Inlet --> installed new inlet adapter
Computer was having a hard time adapting to the 3" MAF --> revert back to the 016 MAF till after registration

Pics of the inlet adapter, 3D printed of course with a polycarbonate body and polyurethane gaskets

<iframe width="640" height="360" src="https://www.youtube.com/embed/FnPcPYjRBVI" frameborder="0" allowfullscreen></iframe>





To Do List:
Install new blinker bulbs
Faulty rear fog light --> dunno, gotta see what I have to work with. Rear fog lights are required in Europe...
Shifter reverse lock out and bushings --> install shortened shifter and new bushings
Call and make an appointment for technical inspection!!!

I'd like to be up and running within the next few weeks, but the next few weekends I'm out of town. Not much of a problem since it's light outside until 9:30 p.m. :-D


On a side note I finally got a choice turbo. Was wanting a disco potato, but they're still quite expensive even on the used market. Last night I caught this beauty on eBay for 100 Euronen shipped! A .48 T3 "cosworth" hotside with a T4 something (later identified as a V-trim).





Been looking for a good turbo for the past two years, but everything kept slipping through my fingers. Have a Volvo K24 on the shelf, but it's the later model where the output tilts towards the back and would run the piping too close to the exhaust manifold...

Even though the currently installed turbo is already a tight fit, looking at this comparison photo of a T3 next to a T34 leads me to think the swap won't be too problematic... Sure I'll need a new downpipe, but I was planing on that anyway.


After the restauration and registration I'll be looking forward to beginning the next stage with the cossie turbo!

12david34 05-15-2017 04:28 AM


Originally Posted by JerryJS8 (Post 5604318)


JerryJS8 05-15-2017 09:42 AM


Originally Posted by 12david34 (Post 5611134)


JerryJS8 05-17-2017 01:13 PM

Found the electrical problem for the lights! TLDR; found a clipped signal wire behind the radio...

I had completely forgotten that the headlight switch was botched up, and only worked in the park position (haven't driven the car in a few years, and I think it was even like that when I originally purchased the car back in 2004...). Had a few extra light switches and relays laying around, but nothing helped so I got out the electrical plans.

The white and yellow wire coming from pin 4 on the light switch and going to pin 4 on the light relay makes a detour going through the radio harness. Behind the radio the signal wire from the switch was leading into the harness, but not leading back out!

Tip of the day: If your headlights don't work except in the park position, check to see if your radio install properly continued to route the illumination wire to the light relay :oops:

JerryJS8 05-21-2017 05:41 PM

Finally got around to getting my short shifter installed. 3D Modelled the reverse lockout plastic thingy and cut 30mm out of the middle. Pics are of the install I did last week to my daily driver with the part printed in polycarbonate, but it broke pretty quickly. New part is printed using Taulman 910 Nylon and along with being flexible it seems to be a lot stronger! After I've put a few miles on it I'll be able to say if it's a winner.

These are pictures of the install on my DD, but the same happened in the project car as well ;-)

Da big stick


Lockout strap in polycarbonate


Shortened chrome part


New unit ready to go back in


Shortened non-chrome part


Completed in the "short" version


Went down to the local car parts store to get some orange blinker bulbs for the front and they didn't have any in stock. Had to order them online, but as soon as they're in I'm ready to roll! Just waiting to get an appointment for the technical inspection to complete the importation process and I'm back in the game :cool:

okoye 05-22-2017 11:37 AM

Hey question do you think you could 3d print a shifter bushing for an m90?

Sander 05-22-2017 12:28 PM

Good luck with the TüV, Germany needs more nicely modded Volvo's like this.

oldschoolvolvo 05-22-2017 01:03 PM

nice work! love the "no-nonsense" look under the hood

also jealous of your wheels :)

JerryJS8 05-22-2017 02:45 PM


Originally Posted by okoye (Post 5614361)
Hey question do you think you could 3d print a shifter bushing for an m90?

Could, but they are the same bushings for the m46 and m47 trannys. That is if you mean these bushings. http://www.skandix.de/en/spare-parts...r-kit/1014858/

Otherwise the ones for the stabilizing arm going to the shift collumn wouldn't be a problem, but then at 4.45 Euros I'd probably just buy em outright. http://www.skandix.de/en/spare-parts...lever/1040272/

If you need a special bushing cause you changed something or whatever, I could still help out. But I first got to print out a couple of Gemini tools when the 3d printer calms down again...


Originally Posted by Sander (Post 5614400)
Good luck with the TüV, Germany needs more nicely modded Volvo's like this.

Thanks! Can't say I'm not nervous what they'll start complaining about first... cause they will find everything they want if they're in the mood :oops:

And Sander, excited to see your build finished, you got a niiiice project :nod:


Originally Posted by oldschoolvolvo (Post 5614422)
nice work! love the "no-nonsense" look under the hood

also jealous of your wheels :)

My neighbors are all into the VW tuning scene, big rims, shiny paint and all. Their freinds sometimes walk by the shop and start poking fun at my poor old Volvo...

Those who don't want to know, don't need to know!

And yeah, I gotta hold myself back from buying more rims...

okoye 05-22-2017 02:51 PM


This bushing. It seems that they're now available for sale. They weren't year.

JerryJS8 05-22-2017 02:57 PM

Ah, super!

volvonyc 05-26-2017 12:35 PM

very nice work saving your old car

JerryJS8 06-23-2017 07:16 AM


Got Olga registered with temporary tags to have a few days to get the technical control finished and iron out any bugs before they expire. Was kinda adventurous, but got everything checked off and now I'm only waiting for a certificate of conformity to be able to finally register it.


So ready to get this car on the road!!!!

JerryJS8 06-23-2017 05:16 PM

Also got around to identifying that turbo. Ends up being a v-trim compressor. Not a perfect fit, but it'll do if I don't pick up something else in the meantime.

okoye 06-25-2017 07:18 AM

Any thoughts on respraying the car in the original colour

Edit: what did you use for the tensioner for the main belt?

JerryJS8 06-25-2017 08:21 AM


Originally Posted by okoye (Post 5631227)
Any thoughts on respraying the car in the original colour

Edit: what did you use for the tensioner for the main belt?

When I re-re-paint the car, it'll only be in the original color. Thought about other colors, but there's merit in keeping the car looking original. When that'll happen, no idea!

EDIT: The original color of the car was already blue if that's what you're getting at. I just painted and installed an SE kit, it's not a true SE ;-)

The tensioner is from an Audi 80 VW Golf T4 Vento 1,6 1,9 D TD type thing. Drilled and tapped the head for a 10mm bolt and put a washer underneath to space it out.

JerryJS8 06-26-2017 02:08 PM


Originally Posted by JerryJS8 (Post 5630469)
got everything checked off and now I'm only waiting for a certificate of conformity to be able to finally register it.

Seems like this last step might be more of a task than anticipated. Tried getting the CoC online but ended up only getting a reply telling me they were unsuccessful and I should contact the manufacturer directly. Last week I talked to the Volvo dealer and he said it would take 6 weeks to get it. Just emailed Volvo directly and hope they can help out a bit more than it's been going thus far.

Worst case scenario, the car sits around till mid August. Been a few years already, what's another month or two going to hurt :woowoo:

Guess I'll just have to put the waiting time to good use :-D

JerryJS8 07-02-2017 12:13 AM

Back to getting the small things done while I'm waiting on the papers! Mostly just quality of life items.

-- Brighter headlight bulbs
-- Gas shocks for the trunk lid (goodbye wooden prop stick!)
-- Ignition switch replaced since it was sometimes hard to get the starter to engage

Wanted to get to some other stuff checked off this weekend, but I kinda got caught up in getting "famous" (big sarcastic grin).


Yep, that's me on TV!!!


And there I am again, just lurking :ninja:

Stuff I still got to do:

-- Replace rear brake hoses (just not looking forward to it since the brass fittings rounded off)
-- Replace handbrake cable (was looking kinda sketch and finally broke during those adventurous technical inspection times)
-- Find a way to reglue the headliner that's sagging over the back seat without having to remove the headliner completely, and have it not look... improvised
-- Install radio and audio system

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