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

JerryJS8 10-30-2015 09:20 AM

Olga the Second Revised - 740(SE) Turbo 16V
1991 740(SE) 16v turbo rebuild project

TL;DR Bought Olga the Second in 2004, completed Stage 0 2005, SE bodykit and 16v turbo conversion 2006, put car in family care/storage 2008, sold car 2013, bought car back 2015, imported car to Germany 2016: begin restauration and revision of Olga the Second. Got registered and on the road in Fall 2017, cancelled registration two months later and parked it for repairs and a do88 intercooler plus an M90 swap over the Winter of 2017/2018. Spring 2018 car back together and stage 0 completed, again. Summer 2018 back on the road with Geminis as a daily driver and slowly getting pesky little gremlins sorted out. Fall 2019 - sideswiped by a Fiat Panda. Winter 2019/20 dedicated to ridding chassis of otherwise imminent rust and preparing for bodywork and full repaint. Summer 2020 - Fighting with the bodyshop to get quality results. Winter 2020/21 - The longest puzzle of my life. Spring 2021 - Restauration complete!


Long-time member, now getting back into the game after a many year hiatus.

A little bit about me – born in Florida, now living in Germany. Always driven a Volvo, first car was a 89’ 240 that taught me a lot about problem diagnostics and got me on a first name basis with the local pull-a-part. After that I had about 4 or 5 740’s and a 960 that I fixed up and sold mostly to friends and family. Moved to Europe in 2007 and got an introduction to Volvo’s European counterparts with a 480 "sports car" (at least my insurance argued it being one on paper) and a V40 being prime examples of hodge-podge value chain management and minimum viable rust prevention manufacturing that both ended up being sold for export to countries with governments that don’t have as much to say about regulations concerning transport vehicles.

A bit about my project car – bought the car off eBay in 2004 for around 500 dollars with blown turbo seals, cracked rear window and other busted stuff I can’t remember. Best part was that the motor had been laying a nice thick layer of anti-rust film all the way to rear bumper which lead to not having a spot of rust anywhere on the chassis. The name of the car “Olga the Second” comes from it being the second blue 740 sedan I had owned having the same personality of what I would imagine a Swedish lady with a remarkable half-tank construction would be like.

A bit about the project - years before I had started collecting parts for a 16 valve conversion and by the summer of 2006 I had found an SE body kit in the junkyard, fully upgraded the suspension with Bilstien HD’s, IPD 25/25 swaybars, Lesförd lowering springs (only in the front, the back was squatting with em installed), adjustable panhard rod, aluminum control arms, Virgo rims, lockin diff with 4.10 final ratio, 5-angle valve seats and matched porting on the B234 head etc.. Biggest hurdle was of course the exhaust manifold, but after getting through that being the last piece of the puzzle, the project had to be completed.

In the pics below you can see the progress/final result of the car as it stood back in the summer of 2008.

















The moderately sized but responsive 50 trim T3


A bit about the interim - in 2008 I put the car up for sale, but got cold feet about parting with it for good and was able to convince my family to take care of it for a while.

Link to my sales thread just for fun

In 2013 I ended up selling the car to a buddy of mine cause I had moved to Europe and couldn’t fit it in my carryon luggage, and my family was tired of babysitting it.

There the car proved to be quite a headache for him considering the non-standard build that most of you here are familiar with and those typical Volvo electrical issues. Sad to say, the Florida sun wasn’t kind to the paint and daily life took its toll on both the interior and motor. Last year I contacted him to ask how the car was treating him to find out he was putting it up for sale.

My wife knew how much I loved building that project (cause I often would be sitting at my computer looking at pictures of it or other turbobrick projects) and suggested importing it to Germany. Before she could even think about regretting it I told my buddy we’d take it. It was a long wait, but visiting my parents in the spring gave me the chance to get the car road ready to drive it down to Miami and get it on a boat. Here’s the car as I bought it back in Florida.










And here it is getting off the truck in Germany.



The white hood and door I installed before putting it on the boat for Germany and were from taken from the only 740 in the local junkyards (coincidentally that car also belonged to the former owner). At that point the car didn’t need to look good for shipment, it just needed to be functional.

And now the project “Olga the Second Revised” begins

First things first – blue door. The white hood doesn’t bother me so much, but that ther’ stock-car racing deal ain’t gonna work. So I found some local enthusiasts parting out a blue 740 and had an impromptu party getting to meet the gang while filling up on spare parts.


Next improvement – my current daily driver is a 1989 16v 740 SW which originally comes with the 3” throttle body so I swapped manifolds :oogle:

After that I converted to an e-fan, but I’ll need to update with a pic of that since I can’t find any on my phone right now…

Dem Eyes so sad – much better with E-Codes





In all my (revised)project planning, I decided the turbo is too small, and that before I get a new one, it would only make sense to first have a larger air filter. So what I’m currently up to is fabricating a stock-ish looking airbox to furnish a huge air filter. Bigger box needs moar space, so I relocated the stock wiper fluid reservoir, and relocated the battery to accommodate it.



So my winter project is to fabricate said air filter box, and spiff up the interior with said collected spare interior parts from said cannibalized former enthusiast owned Volvo 740. Before springtime I need to also (re)complete Stage 0 for the import registration in Germany. Meanwhile I’ve been having some fun with some 3-D concepts for a bigger turbo. Someone say EFR 6758 Twin scroll?



Coupid 10-30-2015 11:16 AM

What a total sleeper! That's awesome that you get to reconditioning it after the person you sold it to ruined it. There are a few cars I've sold that I wish I could have helped out like that...

JerryJS8 10-30-2015 11:40 AM


Just means I get more project for old my project car :) But I wouldn't go as far as saying he ruined it. Just missing a bit of its old glanz ;-)

okoye 10-30-2015 08:36 PM

I met the guy who bought this car . He was telling me the story on it. Glad to see its back in good hands and being restored to its former glory.

JerryJS8 10-31-2015 10:51 AM

Got to swapping the Virgos to my DD and the Remotecs on the project 744.


Not sure how I like the look of these... but they are 7.5 inches wide, which makes them interesting.

Kinda up in the air on these or a set of Geminis, even though a 225/55 tire would go on Geminis just fine.

okoye 10-31-2015 12:10 PM

keep the remotecs and lower the car.

JerryJS8 10-31-2015 12:38 PM

Well the car is lowered already, and with the streets here in town I'd be afraid of going any lower.

Also got these hanging out in the garage.


But the remotecs with new paint are kinda growing on me.

Coupid 10-31-2015 01:48 PM

Use the Gems

amerbritcan 10-31-2015 11:18 PM

I love those remotecs on the car, but gems are my favorite OEM wheels. Tough choice.

JerryJS8 11-11-2015 05:22 AM

Found a good reason to use the Gemini rims.


Always aggravated me how quickly a new set of stock rotors started warping... :grrr:
Hopefully some 302mm brakes will be the end of that.

+Kardboard+ 11-11-2015 05:59 PM

Very nice!

MadDog_945 12-24-2015 04:41 AM

Whoa awesome... So im not the only 16v turbo guy in germany anymore? :) i think we need to phone some day about 16v's n stuff :) !!

JerryJS8 01-03-2016 03:33 PM


Originally Posted by MadDog_945 (Post 5304339)
Whoa awesome... So im not the only 16v turbo guy in germany anymore? :) i think we need to phone some day about 16v's n stuff :) !!

Sounds like a plan! But at the moment you may be the only owner of a registered 16v turbo ;-)

nordmaschine 01-03-2016 04:03 PM

Senn was one of my favourite people on the board, as you can see from my sig. lol

Good to see it's getting reborn.

Glass sunroof?

JerryJS8 01-03-2016 05:36 PM


Originally Posted by nordmaschine (Post 5310438)
Glass sunroof?

Yeah, I grabbed a glass sunroof some years ago in a junkyard, should have swapped the headliner as well... I'm missing that optional sliding shade!

JerryJS8 01-19-2016 11:36 AM

The mailman brought me a new present today! The car has made it this far on a square-toothed belt...


And since this had been a Florida car probably all its life, this might be the first time it's seen snow!


Jack 01-19-2016 12:06 PM

looking good.

I always thought the P80 chassis front calipers would work. Nice cheap upgrade!

also how much for your "old" header?

JerryJS8 01-21-2016 09:46 AM


Originally Posted by Jack (Post 5321150)
looking good.

I always thought the P80 chassis front calipers would work. Nice cheap upgrade!

also how much for your "old" header?

I got a lot of other stuff to do to get it registered and made into a reliable daily driver before I start on the twin scroll upgrade.

okoye 01-21-2016 10:03 AM

let me buy those remotecs!

JerryJS8 01-22-2016 02:59 AM


Originally Posted by okoye (Post 5322752)
let me buy those remotecs!

Ok, but you also pay shipping from Germany...

JerryJS8 02-15-2016 06:37 AM

So, the weather finally got warm enough to be able to work outside, so I took the chance to do some work before the snow rolls back in. Was working on cleaning up the motor from all the oil leaks and replacing the gaskets one by one when my garage neighbor asked why I wasn't just pulling the motor if I had so much on my to-do list.

Me: I don't have a crane to pull the motor.
Him: I do, so now what's your excuse?
Me: ... I need a beer, then I'll be over to get the crane

And so the fun begins...


Nastyness in the engine bay, gotta take car of that before the motor goes back in


Source of nastyness in the engine bay, gotta take care of that before the motor goes back in


Then I pulled the head to see what the past 10+ years have done to it.



#4 - Nice grooves man...


#3 - More groovyness


#2 - And the song continues


#1 - Ah sweet! No grooves, just rust....

So it's not what was wrong with cyl#1, but what happened to 2,3 and 4... Guess I'll be needing a new block, since I don't think they'll be gone with the next bore up and already running once overbored.

On a side note, this is why we don't like the stock 16v intake on boosted motors



So fortunately I just happen to have a low mileage b230f block laying around the garage. Just needs a light hone and drilling all the oil lines for the turbo.


Still happy with the exhaust manifold though, held up to a lot of abuse with those ugly welds...




So now I'm ordering gaskets and such, getting my shopping list together. While the weather's cold again, at least I got part of my project in the garage next to the heater :)

MadDog_945 02-15-2016 06:50 AM

Ask FT-Albert.de for parts... Give him a greet from me ;) Or... No.. dont... Just say to him dass er die Dichtungen nicht knicken soll, damit sie in den umschlag passen ;)

he's the best source for parts in .de

I like the manifold.. What material and dimensions? Selfmade?

JerryJS8 02-15-2016 07:01 AM


Originally Posted by MadDog_945 (Post 5338653)
Ask FT-Albert.de for parts... Give him a greet from me ;) Or... No.. dont... Just say to him dass er die Dichtungen nicht knicken soll, damit sie in den umschlag passen ;)

Funny you said that, look what recently came in the mail...




Manfold is self made from mild steel elbows and a sheet of old metal I had laying around the shop back then. Cutting out those flanges with an acetalyne torch then rounding em out with a dremel took a good amount of time...

MadDog_945 02-15-2016 07:08 AM

HE DIDNT ?!!!!! Gerhard... You Prick!! :D

JerryJS8 02-15-2016 07:18 AM


Originally Posted by MadDog_945 (Post 5338660)
HE DIDNT ?!!!!! Gerhard... You Prick!! :D

Ruhig Blut! I didn't order it from him, some eBay shop out of the UK.

MadDog_945 02-15-2016 07:38 AM

... Just things which woulndt have wondered me ;)

It's an insider.. To everyone hes a good parts supplier.. Just me he jackasses with crimped gaskets all the time... Because he can... ...prick...

JerryJS8 02-28-2016 01:33 PM

So I had some time to play around with the laser cutter at work to get my header flange dialed in. Although welding a new manifold is not on my immediate list of things to do, I already had the 3D-model and time on my hands. Exporting a DXF and tweaking it to the ports was easy enough.

Laser cutter in action checking the specs on some scrap wood.


More meat around the studs, just cause, and the hypothetical warpage that may occur during welding. :-P
Notice the weight saving slots! :lol:


Flange DXF that's floating around the internet for comparison. Decent fit if anyone was curious, just requires some "minor" porting to get it to match the flange.


Trial and error for the perfect fit!


JerryJS8 03-10-2016 06:49 AM

Small update, small setback

Took a saturday morning cleaning up parts, sorting out stuff. Got the cylinder head looking somewhat spiffy


And then noticed a small problem with the valve faces...





So, new valves all around added to the shopping cart. Starting to think it won't be ready by April :grrr:


But I did recieve some chips from Hi-Tuning (i.e. Fred's chips) in the mail :spin:

Custom 1 is the 16 valve turbo version, custom 2 experiemental secret sauce ;-)


Decided to go this route since the car needs to pass inspection for the import process without any road time, and for my power goals and required reliability as a daily driver I'll be more than satisfied with what LH can offer.

JerryJS8 04-23-2016 02:47 PM

In the past month I've been busy with getting the little ducks in a row to get the motor refurbed. Took the old N/A block I had laying around and drilled the holes for the piston squirters, oil feed line and cleaned it up to send it out to get bored.

Other than that, not much to post what's happened lately. Got the chips installed with the eprom board (not worthy of pictures), cleaned up some wiring in the engine bay, ordered a pile of parts currently laying around in boxes (not worthy of pictures), and got parts cleaned up and sorted for assembly (also not yet worthy of pictures).

JerryJS8 06-06-2016 06:28 AM

Machine shop called, after almost 6 weeks they're still not done boring the cylinders and resurfacing the valve seats. They're going to plane the head as well since they measured it being warped by 2mm :oops: Oh well, higher compression!

But doesn't bother me a bit, work has me tied up pretty well anyway...

On a side note I found some Galaxies and put em on the DD. :-P


JerryJS8 10-31-2016 09:25 AM

Updates! Finally got the head and block all buttoned up, slowing putting it together as I have time... Maybe it'll be together and on the road for the good springtime weather :-)


Money shot with forged rods (Pun intended)


Thought I had a piston ring compressor, had to order one...


Oil return with 3/4" NPT threads


This paint is spot on with the stock color, some kind of boat motor stuff. Kinda pricey, but hardened up like a champ!


Another good find on eBay, 1998 m90 from a crashed car. Just a bummer they cut through all the auxilliaries I still need... Will give it an overhaul during the winter.


JerryJS8 11-08-2016 12:22 PM

Oil squirters from a Smart ForTwo



Getting there, slowly...
Head shaved, valve seats reground and then reassembled with new valves and ford 4.6L springs.




JerryJS8 04-01-2017 03:20 PM

So over the winter haven't had much time to get a lot done, but the motor is finally finished! Today was the first day of nice weather where I could really get some work done. Should have shot some pictures of the motor, but I was busy doing the brakes and didn't think about it. Next time I'm in the shop I'll have to get some. Motor looks great again :cool:

Got new seals for the M90 and cleaned it up.

Replaced some interior parts and the front door panels.

Brakes went pretty well... just had a small problem removing the brake lines. Wanted to do all new lines front and back since they're still the original lines, but I couldn't get em off the rear. Orderd a new flange tool to redo the brakeline ends (after cutting off the old ones) and will get the new ones mounted soon.

Also wanted to replace all the suspension bushings while I'm at it so I went ahead and ordered a set front and rear. Removed the control arms and noticed I had already done that some years ago and forgot... Oh well, it was fun putting them back in with the peace of mind that won't be bothering me anytime soon.

Recently got a sandblaster, so I started refurbishing things. All calipers got new pistons and seals cause the old ones had been sitting so long they had begun to rust.


Should have painted them black, the silver paint has already absorbed some grease and won't get clean...



All new rotors, pads, bolts and studs on all corners

302mm discs on the front


281mm rears


Found a second set of Geminis with tires for a steal on eBay, cheaper than buying new tires and mounting them on the black set I have. Europe is great, so many good parts that are otherwise really hard to get in the states.

The white hood is growing on me...


At some point we had a small impromtu Volvo meet at the garage :)


JerryJS8 04-02-2017 09:57 AM

Motor pics



Not much room to spare



Diesel motor pucks and the earlier style mounts gave me some more much needed room for the turbo oil return. Will also make my life a heck of a lot easier when I swap the turbo later.

Hydro mounts before


Solid mounts after


MadDog_945 04-06-2017 07:14 AM

so nice to have a B234FT pal over here :)

JerryJS8 04-06-2017 10:41 AM

I still got to make it over to HH and meet up with you guys. Maybe that'll be my first major roadtrip!


Since I got some Geminis with center caps, gotta make sure they stay on there. So this morning I modelled and 3D printed an 86mm nut to be able to torque em down good.

Little workhorse



Fits just fine!


skjarlie 04-06-2017 11:13 AM

If you are interested in making gemeni nuts for sale, I'd be interested in buying :)

Tfrasca 04-06-2017 11:18 AM

What material are you printing with?

JerryJS8 04-06-2017 11:30 AM

If you need a gemini tool, wouldn't cost much to ship em overseas I suppose. Easy enough to print, just going to test mine out first and see where I might need to add some reinforcement.

Printed with ABS. Also have nylon, polycarbonate and carbon fiber filament, but ABS should be just fine for what it needs to do.

skjarlie 04-06-2017 12:05 PM

I live in norway, so shipping cost won't be to high :)

JerryJS8 04-06-2017 12:07 PM


Originally Posted by skjarlie (Post 5590308)
I live in norway, so shipping cost won't be to high :)

Wonderful! :-D
I'll shoot you a PM as soon as I get one ready to ship out.

swedishiron.com 04-06-2017 11:07 PM


Originally Posted by JerryJS8 (Post 5590287)
If you need a gemini tool, wouldn't cost much to ship em overseas I suppose. Easy enough to print, just going to test mine out first and see where I might need to add some reinforcement.

Printed with ABS. Also have nylon, polycarbonate and carbon fiber filament, but ABS should be just fine for what it needs to do.

Can you make a couple more and send them to me in the USA?

JerryJS8 04-06-2017 11:45 PM


Originally Posted by swedishiron.com (Post 5590780)
Can you make a couple more and send them to me in the USA?

Sure, looks like I got a list going now

skjarlie 04-07-2017 04:16 AM


Originally Posted by JerryJS8 (Post 5590309)
Wonderful! :-D
I'll shoot you a PM as soon as I get one ready to ship out.

Perfect :)

JerryJS8 04-16-2017 12:18 PM

New Gemini center cap tool has been tested to 50 ft/lbs, more than enough to keep the centers put. I probably will only torque them down to 20 ft/lbs though, with the o-rings, that should be enough to keep them from coming off. Just remember to apply copper paste to the threads before installing!


Stress marks after 50 ft/lbs


You guys are welcome to take the .stl file and gets it printed for personal use.
Here is a link to the file: http://www.thingiverse.com/thing:2252575

JerryJS8 04-16-2017 12:41 PM

And on to the car! As I was mulling around the shop I found a stash of old parts and a lightly used clutchnet fiber disk.


Since it was Easter weekend I was able to get away on Saturday and get the motor dropped in :-) Finally!!!!


Barebones as I left on Saturday


Original Volvo lower chassis brace. Leaving in the M46 to get the car registered with, while in the meantime I'm still scraping the necessary parts together for the M90 swap.


Electric fan conversion


Just enough clearance to make it work!


Here there's also just enough clearance...


How the motor is now just waiting on the turbo plumbing. I'm not leaving the blue silicone hose...


okoye 04-16-2017 01:34 PM

looks like it's coming together great! Why E-fan vs mechanical fan? Personally I prefer mechanical fan and wanted to convert my 960 turbo to use the mechanical fan.

JerryJS8 04-16-2017 01:53 PM


Originally Posted by okoye (Post 5596010)
looks like it's coming together great!

Thanks! Now that it's coming together quickly I'm anxious to get out on the streets!


Originally Posted by okoye (Post 5596010)
Why E-fan vs mechanical fan? Personally I prefer mechanical fan and wanted to convert my 960 turbo to use the mechanical fan.

Cause I just don't like the sound of the mechanical fan. The amount of noise it adds just drives me crazy on my 740 wagon. Also I like things shutting on and off automatically :-P

okoye 04-16-2017 01:55 PM

The reason I have an issue with it is because of what I use my car for (drifting) so the car sits on the limiter for a few minutes and after a run that will cook the engine if the fan fails. That being said I'm not sure I can fit a mechanical fan with the tightness of my engine bay.

JerryJS8 04-16-2017 02:11 PM

To each his own :-)

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