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-   -   Project '82 Volvo 242 (https://www.lateral-g.net/forums/showthread.php?t=21742)

krptonite 12-29-2012 04:03 PM

^^^^^^^^^^^^^^^^^^^^^^
you have got to be kidding me! are you sure you aren't a rocket scientist? lol, seriously, to be able to design and build that board is awesome, :thumbsup:

Karl Buchka 12-29-2012 07:08 PM

Haha, thanks. I won't offend rocket scientists by claiming this is on their level, but in my defense, embedded systems design is what I do for work when I'm not at school. :thumbsup:

Karl Buchka 12-31-2012 09:02 AM

Dropped the engine in the bay last night. It's within a few millimeters of the intended position. Looks like the cowl area is going to need some modifying to fit the intake manifold. Firewall will also come back a bit to make room for the coolant manifold that bolts to the back of the heads.

https://lh4.googleusercontent.com/-9...hoto%25203.JPG

The front two cylinders line up with the front axle centerline. Not quite mid engine. :(

https://lh3.googleusercontent.com/-4...hoto%25204.JPG

This pic shows how the exhaust ports are offset from the bores. The front one is especially bad. "Fixing" it would be a pretty ****ty task that neither of us is interested in doing. Hopefully we can get a head on a flow bench to see how it matches the other ports.

https://lh5.googleusercontent.com/-t...hoto%25201.JPG

WSSix 12-31-2012 12:57 PM

Talk about engine set back! This is going to be cool as hell.

Karl Buchka 01-01-2013 09:21 PM

Quote:

Originally Posted by WSSix (Post 454591)
Talk about engine set back! This is going to be cool as hell.

Thanks!

After years of removing material, we finally added some.

https://lh6.googleusercontent.com/-y...hoto%25202.JPG

TIG welding, complete with a costume change.

https://lh5.googleusercontent.com/-9...hoto%25203.JPG

Once they're welded up they'll support the front end structural tubes that run back to the safety cage.

https://lh5.googleusercontent.com/-W...hoto%25204.JPG

coolwelder62 01-02-2013 03:52 PM

Quote:

Originally Posted by Karl Buchka (Post 454920)
Thanks!

After years of removing material, we finally added some.

https://lh6.googleusercontent.com/-y...hoto%25202.JPG

TIG welding, complete with a costume change.

https://lh5.googleusercontent.com/-9...hoto%25203.JPG

Once they're welded up they'll support the front end structural tubes that run back to the safety cage.

https://lh5.googleusercontent.com/-W...hoto%25204.JPG

Very cool build thread.Love the Jayhawk motorsports t shirt.I help w/KU SAE team all the time.:thumbsup:

Karl Buchka 01-02-2013 06:46 PM

Quote:

Originally Posted by coolwelder62 (Post 455069)
Very cool build thread.Love the Jayhawk motorsports t shirt.I help w/KU SAE team all the time.:thumbsup:

Small world! We've got friends that are former and current members.

Got some new tubes in the car! These will ultimately support the upper control arm mounts and damper mounts:

https://lh3.googleusercontent.com/-I...hoto%25201.JPG

MoparCar 01-02-2013 07:48 PM

This is one of the coolest and truly innovative builds on this site! Wow! Pro-Build quality all the way. Wow again!

I love the updates.

Wes

bonecrrusher 01-03-2013 06:05 PM

Had to go back quite a bit - nice unique Volvo motor you have there!

Karl Buchka 01-09-2013 02:16 PM

Quote:

Originally Posted by MoparCar (Post 455116)
This is one of the coolest and truly innovative builds on this site! Wow! Pro-Build quality all the way. Wow again!

I love the updates.

Wes

Quote:

Originally Posted by bonecrrusher (Post 455353)
Had to go back quite a bit - nice unique Volvo motor you have there!

Thank you for the kind words guys. It really means a lot!

I'm back in Sweden getting an early start to the semester. I'll be starting my bachelor's thesis in a couple of weeks. Really looking forward to it.

My brother decided to stay with the car for a little while longer and he just put the finishing touches on a killer upgrade for the TIG machine we picked up last year. He's done a little write-up with pics, so I'll just hand it over to him:

Bought a new torch for the TIG welder last summer but didn't had time to hook it all up until now. It's a water cooled WeldTec WT-20 with a 25ft hose setup.

Made up a ~4 gallon reservoir out of 0.63" 6061-T6 sheet:

https://lh5.googleusercontent.com/-l...2014.30.14.jpg

Tacked up the tank. From front to back the fittings are for filling, suction from the bottom through the tube, and return from the torch.

https://lh4.googleusercontent.com/-C...2017.05.42.jpg

https://lh3.googleusercontent.com/-8...2018.12.14.jpg

https://lh3.googleusercontent.com/-Q...2018.12.25.jpg

Pretty happy with the penetration:

https://lh6.googleusercontent.com/-J...2018.15.06.jpg

Pump bracket:

https://lh3.googleusercontent.com/-9...2018.13.28.jpg

Mounted up with the sight tube:

https://lh4.googleusercontent.com/-_...2012.40.44.jpg

In place and hooked up. The wiring was just temporary for testing.

https://lh5.googleusercontent.com/-6...2018.13.24.jpg

Made up a ballistic nylon hose sheath and joined it to the handle with a piece of glue lined heat shrink.

https://lh5.googleusercontent.com/-3...2014.30.03.jpg

Size comparison between the old busted down air cooled 26-series torch and the new one.

https://lh5.googleusercontent.com/-i...2018.55.18.jpg

All in all, really happy with the new setup. The reservoir is big enough that there shouldn't be any issues with temps. If it turns out that it needs a radiator it'll be easy to add one. Right now I have to plug the pump in manually when I want to run it but Karl is working on a pump controller that'll be the bees knees.


The pump itself was salvaged from an old industrial-type espresso maker. I believe the line pressure is set to about 50psi.


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