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Old 07-18-2006, 12:33 AM   #1
dturbo
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Default 81' 242 TI Build Up

Ok a bit of history:

Bought my first volvo in 04' 98 s70 T5 SE. loved it, joined VS and tbricks right away. learned alot about FWD and what not. got bored with the FWD after a year and decided to look for a RWD. Found my:

1981
242 Turbo Intercooled
106k original miles
4spd w/OD
silver exterior
White interior
BONE Stock

I purchased the car from a 40 y/o lady about an hour south of Seattle in Olympia. She purchased the car 6months earlier for her daughter who wanted a jetta not a volvo. so She drove it for 6months from home to work 4 miles a day round trip. She bought the car from Topping Volvo in Olympia who had had the car since 1981 and kept it as their 'shop/grocery getter'. The dealer added the Intercooler.

I purchased the car for $3,000 in October of 2005. Car was kept stock for a while, did some minor cosmetic things, painted bezels black, black virgos etc.... Put the car up for sale in january cuz i just didnt see myself doing much to it. Then i went out and purchased iPD Sways and fell in love. Met Doug Kauer in Summer of 2005 when he and T came to Seattle for vacation. I had admired his work on his famous red 242 and figured heck why not rip into my car. SPring 2006 came around and Doug mentioned that he was going to be moving to seattle for the summer. i thought this was a great opertunity to learn more about RWD, and build my car at the same time.

Doug and I tore into the car in the end of June and are Mid way on teh project.

THE MOD LIST:

Phantom II Oil Pressure, Boost, Volts, EGT
Sparco Ring Steering Wheel
Sparco Hud adapter
Innovate XD-16
iPD Sways
iPD Turbo Camshaft
B21F intake manifold
SRT4 550cc injectors
EVO VIII Intercooler
Walbro 255
S60R kkk24 Turbo
2.5" IC piping
Forge BOV
Megasquirt
90+ Exhaust Manifold
Hose Techniques Vac Lines
Mallory 6-AL Box
SIngle Mount Fuel Pump Switch
New Gasket Kit
Tial 38/40 Hybrid External Wastegate FOR SALE!!!!!

First Day:


Black Bezels:


Black Virgos:

'Paint Booth'




Phantom II's:



Stock Engine Bay:



Torn Apart:




B21F:



90+ Exhaust Manifold:



KKK24:




KJet UNinstalled:


EVO VIII Intercooler:











How It 'SHould' Look After:


How It 'Looks' Now(Picture will Change with Each Day Spent on it):
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Old 07-18-2006, 01:36 AM   #2
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Looks great bud! I'll get you added to the list!

Im in a couple shots there hit and miss lol
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Old 07-18-2006, 02:03 PM   #3
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Looks great man!!!! Can wait to see her done, and running!!!

This build along with dougs has inspired me to do something similar to my 78 242GT!!!! Now i just need some cash, hahahaha
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Old 07-18-2006, 02:58 PM   #4
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That is a really clean 242!
Does it have the really cool black on white velour 81 GLT interior? I love that combo.
Only thing glaring that I would ever change is deleting the commando bumpers...it makes an old 240 look a few decades newer.
Funny, the shot of the gauges is really neat, but it is also cool how the silver looks just like the gold metallic in that light.
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Old 07-18-2006, 03:12 PM   #5
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looking forward to seeing this one!
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Old 07-23-2006, 06:52 PM   #6
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Ok so doug and i did ALOT more work this weekend on the 242. things went very very smoothly.

srt4 550cc injectors. no drilling needed.

They plugg right in

Love these things so far, now only if i could drive the car.



Almost done with the Cold side of the motor. fuel rail....



The remote oil filter kit from jeggs. mounts so clean, and makes oil changes a breeze so i was happy with that

where the filter use to be...

and where it is now. (no its not too close to the down pipe guyshahaha)

Mallory 6-AL and MS mounted up.

mallory is upside down for a reason, the rev limitor switch is on the side facing the rear of the car so for easy access to change, it had to be mounted this way.

And my favorite. the IC stuff came out AWESOME!!!!! i am very very happy with the way its coming, its going to be welded tomorrow and everything. doug and i have been amped on the IC project part since the beginning, and both of us think that thats going to be the high light of this car.


Cuttin the piping to fit.

COldside, goes right under the battery mount platform.

then bends around the wheel well where it hits into a 45* ilicone elbow, then 90's up into a hump coupler then onto the throttlebody.


And the hott side. we had to use the old turbo and clock it to the position that the new turbo is going to be at.(k24 is with ben having oilfeed adapters made)


and with an intake, Darn this engine bay is gonna be sexors.

Then i had to cut out a bit of the reenforcement that the bumper bolts to so i can get some more flow on the IC. turned out really well. let me know what u think guys.


and the pride and joy of the project. the IC!!!!!!!!
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Old 07-23-2006, 07:17 PM   #7
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AWESOME JOB!!! Cant wait to see this when its done....
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Old 07-23-2006, 08:18 PM   #8
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The only complaint I have... Is why did you mount the IC right behind the bumper? Is it not going to block flow to what looks like 70% of the IC? Why not just flip the IC over (have the IC pipes in the same location) but the IC up wehre the stock one was? Thats my only question.
But otherwise, that looks damn nice. Wish I could be working on my car!

Jordan
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Old 07-23-2006, 10:09 PM   #9
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Quote:
Originally Posted by GTJordan
The only complaint I have... Is why did you mount the IC right behind the bumper? Is it not going to block flow to what looks like 70% of the IC? Why not just flip the IC over (have the IC pipes in the same location) but the IC up wehre the stock one was? Thats my only question.
But otherwise, that looks damn nice. Wish I could be working on my car!

Jordan
oh just wait, 70% of it wont be blocked hahaha. custom front bumper in the worx FTW!!!
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Old 07-23-2006, 10:55 PM   #10
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Werd

Awsome, thats all I was wondering, looking sweet!

Jordan
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Old 07-23-2006, 10:59 PM   #11
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Quote:
Originally Posted by GTJordan
Werd

Awsome, thats all I was wondering, looking sweet!

Jordan
thanks man. yeh when we first threw tha IC on and the bumper was on i liked it and all, and i knew itd get enough flow, jsut cuz thered be enough air circulating anyway through there. but then doug reminded me about a certain bumper idea and so my paint and body guy has lets see......3 front airdams and a euro bumper that he will be fabing up a front bumper+lip/airdam for the car once i can get it running and up to his shop. im hoping itll come out ok, he usually pulls through pretty well. thanks again jordan

brian
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Old 07-24-2006, 12:31 AM   #12
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Even if we just hack the bumper for now that'd work brian.

That being said, my FMIC has maybe 1/5th the exposed air yours has and it works fantastic. Was extremely consistent pull to pull on the dyno.
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Old 07-24-2006, 02:16 PM   #13
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what throttle body are you using on the b21f manilfold?
got any plans to convert to a flathood?
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Old 07-24-2006, 03:23 PM   #14
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If you slice carefully, removing most of where the license plate goes on a skinny bumper can actually look just fine. I plan to trim mine to put the oil cooler on my 240NA...that or delete the airbox and put it there, which I am reluctant to do since I like the paper filter for off road and in general. If you have some sheet aluminum you can also pretty easily build an air guide from the inlets on the deeper front airdam that comes on skinny bumper turbo cars (can you tell I dispise commandos yet?).
Anyway, looks great! Tho, isn't a K24 a bit tiny...I mean...you do have Doug helping you...there is a certain lack of holset I feel that is required with B21F intake 550cc injector fun.
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Old 07-25-2006, 02:08 AM   #15
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Quote:
Originally Posted by 945ti
If you slice carefully, removing most of where the license plate goes on a skinny bumper can actually look just fine. I plan to trim mine to put the oil cooler on my 240NA...that or delete the airbox and put it there, which I am reluctant to do since I like the paper filter for off road and in general. If you have some sheet aluminum you can also pretty easily build an air guide from the inlets on the deeper front airdam that comes on skinny bumper turbo cars (can you tell I dispise commandos yet?).
Anyway, looks great! Tho, isn't a K24 a bit tiny...I mean...you do have Doug helping you...there is a certain lack of holset I feel that is required with B21F intake 550cc injector fun.
the bumper and FMIC are going to be the highlights of this car so....doug and i have a great plan for what is gonna happen, i also have an OUTSTANDING bodyshop guy that is doing mine for free so ill post pics in a few weeks when i get it on.

i also think the injectors might be a BIT big but i think they will work out fine. as for the k24, that bicth is gonna spool up pretty damn quickly so...we will see how it comes out.
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Old 07-25-2006, 08:07 PM   #16
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*drools* really, many more progress pics and pics when finished especially, that looks like teh sex already. Very nice car, I love it.
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Old 07-28-2006, 04:30 AM   #17
dturbo
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UPDATE!!!!!!

Silicone came in today, and had the IC piping welded......

Love it or hate it, my buddy Bailey and I tiger striped the ISH outta the IC piping, it looks really raw and awesome i love it.


Hawtness

holy HUGE front mount batman



my buddy blake on the left with his english bulldog 'Moki' and the stud Bailey, master mind behind the IC striping

T clamps, only way to go


ANd the Tiger Striping, its super dead sexy if u ask me bailey or joseph.

The hawt side


and the cold side u can kinda see.




OK well after, 3 different trys to fit the IC w/ the 90* coupilers, we got it in, and having to run the dye grinder at 1230 at night, it was a fun night, just messing around on the car. more updates saturday and sunday guys, thanksa again


Brian
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Old 07-28-2006, 05:00 AM   #18
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Looking GREAT! Can't wait to see the finished product.
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Old 07-28-2006, 05:14 AM   #19
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one question, if i may. i check performance like twice a week at least, and have never seen/heard anyone talk about converting from a b23 intake mani to a b21. what is the reasoning behind this?

fast progress, it seems, nice work!
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Old 07-28-2006, 08:33 AM   #20
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Quote:
Originally Posted by nate_bass
one question, if i may. i check performance like twice a week at least, and have never seen/heard anyone talk about converting from a b23 intake mani to a b21. what is the reasoning behind this?

fast progress, it seems, nice work!
all 240 turbos came with b21fts - the intake manifolds are totally different from the b23's, the b21f intake is the one pictured , I reckon the theory is longer runner, a lil more bottom end torque.

It's been done a few times - (ie John, Aspirator)

Great build up guys!
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Old 07-28-2006, 10:53 AM   #21
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thats the money shot right there!

Dont forget we need to put something around the openings they pass through, once we do they will be golden.
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Old 07-28-2006, 11:57 AM   #22
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Quote:
Originally Posted by Hank Scorpio

thats the money shot right there!

Dont forget we need to put something around the openings they pass through, once we do they will be golden.
split vacuum tubing does the trick.
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Old 07-28-2006, 01:59 PM   #23
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Quote:
Originally Posted by Hank Scorpio


thats the money shot right there!

Dont forget we need to put something around the openings they pass through, once we do they will be golden.
Ye doug about that. we are gonna have to cut back the holes that the 90*s go through because its jsut waay too tight of a fit, i did one side lsatnight, 1230 at night running the dye grinder, that didnt go over too well with the rents hahaha. but i think i got it figured out, ull see it on sunday im hoping to have the IC all straightened out and mounted for when u come over. thanks for the comments guys. yeh the project is going really fast, it helps when u have ALOT of steady income.
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Old 07-28-2006, 03:56 PM   #24
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Quote:
Originally Posted by quinn_volvo
split vacuum tubing does the trick.
UPDATE!!!!!!

After lastnighs lil latenight work party this morning i decided to finish up and get the IC mounted perfectly and have it be done with. had to cut out some notches so the 90*s wouldnt rub through the holes.

And the cold side....

Had to cut some Vac hose to wrap around the edges so there wont be any chance of a puncture

Clears it by just enough, i love how it turned out.

Ok now the hawt side....

turned out great, flawless on this side since it was the second one i did, i had it down pat.

Happiness comes in the form of Tclamps


more hawt side ish

View from the turbo and the IC piping coming back. lovin' the tiger stripes sooo much.


Ok thanks guys, look for more updates tonight and tomorrow, thanks.


Bdazzler
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Old 07-28-2006, 10:50 PM   #25
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Nicely done brian I've got you harness mostly figured out.
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