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In terms of aftermarket for this engine, there might be cold air intakes and catback exhausts out there. That's it. There is nothing else. We're probably going to salvage the connectors from the harness and make everything else from scratch. The aftermarket ECU connectors are different anyway, so the stock harness is really of limited use. There has actually been some progress. My brother and I have spent most of the last couple of summers renovating a workshop with our dad. We put in all the labor in exchange for keeping the car in the shop once the reno was finished. The previous owner was a carpenter and he had very little in the way of dust collection equipment. This, coupled with a raised wooden floor, water creeping in under the roll-up door, and some dubious cleaning practices over the years resulted in hundreds of pounds of putrid sawdust on the floor and an equal amount of sawdust covering every horizontal surface in the entire shop. The shop is about 1000sqf with a mezzanine and a small office. A small half bath is tucked into the corner of the ground level: https://lh6.googleusercontent.com/-a...8-IMG_7411.jpg https://lh5.googleusercontent.com/-S...2-IMG_7397.jpg We started by tearing out the raised floor to uncover the concrete and let it dry out properly https://lh4.googleusercontent.com/-e...0/IMG_1193.JPG https://lh6.googleusercontent.com/-X...0/IMG_1200.JPG https://lh4.googleusercontent.com/-g...0/IMG_1207.JPG Painted the walls: https://lh5.googleusercontent.com/-d...0/PICT1517.JPG Installed studs under the beams supporting the mezzanine: https://lh3.googleusercontent.com/-T...0/IMG_1210.JPG Built a small closet under the stairs to house the compressor: https://lh4.googleusercontent.com/-j...0/IMG_1217.JPG Drywall: https://lh4.googleusercontent.com/-c...0/IMG_1224.JPG All new wiring pulled through EMT with 220v outlets for hooking up welders: https://lh4.googleusercontent.com/-C...0/PICT1522.JPG Replaced all the outdated T12 fixtures with T8's and electronic ballasts. They're a little more expensive than magnetic ballasts but they raise the efficiency of the bulbs and don't have any annoying hum. All in all, ended up being about 4kw of lighting, it's really bright in there now and it's awesome. https://lh4.googleusercontent.com/-8...0/PICT1589.JPG https://lh3.googleusercontent.com/-K...0/PICT1585.JPG Got a used, dealer trade-in two post lift: https://lh3.googleusercontent.com/-O...0/PICT1575.JPG Swapped a set of wheels for a lot of industrial shelving. The mezzanine is now geared for parts and junk storage: https://lh6.googleusercontent.com/-j...0/PICT1545.JPG |
Ground the floor and laid down epoxy coat. Thought about spreading those flake things to pretty it up but if you drop a small bolt or washer on there it becomes impossible to find:
https://lh5.googleusercontent.com/-S...hoto%25203.JPG Ran copper pipe for compressed air outlets around the shop, along with a 50ft hose reel mounted on the lift. Completely gutted the bathroom and installed hex mosaic tile flooring, recessed lights, new fixtures, and a utility sink. We picked up a Miller Syncrowave 250 TIG at the start of this summer. https://lh5.googleusercontent.com/-L...hoto%25201.JPG Moved in some workbenches that I put steel tops on, along with some storage cabinets. https://lh4.googleusercontent.com/-8...s800/photo.JPG There's always tons of fiddly stuff to take care of but all in all, I'd say the shop is nearing completion. Before we dragged the 242 over from hibernation, my brother put together a makeshift chassis table for it. Building one out of steel was outside the budget so it ended up being 2x6 framing with 3/4" poplar ply on both sides, standing on 4x4 legs with adjustable feet. Final size is 4'x10' so it covers the wheelbase of the car with some room to spare on both ends. It's not perfectly flat by any stretch, but much better than the old concrete floor, and it gets the car off the ground for a more comfortable working height. https://lh5.googleusercontent.com/-s...hoto%25202.JPG https://lh6.googleusercontent.com/-m...hoto%25203.JPG https://lh6.googleusercontent.com/-e...hoto%25204.JPG The car was dusted off and loaded up. https://lh3.googleusercontent.com/-V...0/IMG_0108.JPG Raised up on the table at ride height. https://lh5.googleusercontent.com/-P...0/IMG_0111.JPG The old wheel wells were made with smaller wheels in mind so we had to hack the rear frame rails out completely. Got one of the rear wheels jammed up in there to get an idea of how the car will sit. It was a real motivation booster to see the wheel in there, and it finally dawned on me how dumped the car is really going to be, but still with usable suspension travel. https://lh4.googleusercontent.com/-q...255B1%255D.JPG Hacked the trans tunnel out and got the driveline temporarily mocked up to see where it should go. Because of the V8 having some extra crap hanging off the back the firewall will need to be moved back just a smidge more than it already is. The parts have all been measured and positioned in CAD. https://lh4.googleusercontent.com/-C...0/IMG_0132.JPG Pulled the intake manifold off the engine. The intake ports look pretty good, but the tight packaging of the engine leaves a little to be desired on the exhaust side. https://lh3.googleusercontent.com/-W...hoto%25202.JPG Scored some good stuff on ebay too. Got a Nascar reverse mount starter, a ring gear for that, and a hydraulic release bearing. The ring gear is known as reverse mount style and bolts to the top of the Tilton 7.25" clutch cover. Since the clutch and starter package is so small the bellhousing can be brought down in diameter quite a bit. The bellhousing and other driveline parts are nearing finished design in CAD. https://lh3.googleusercontent.com/-p...255B1%255D.JPG https://lh4.googleusercontent.com/-m...255B1%255D.JPG https://lh3.googleusercontent.com/-w...0/IMG_0148.JPG |
Put in some time on the clutch/flywheel assembly as well:
https://lh4.googleusercontent.com/-s...screenshot.PNG Unfortunately I wasn't around to snap any pics of the turning operations, but the basic procedure was the following: Rough cut a circle out of 20mm plate with the oxy/acetylene torch, weld a scrap slug to the center of the plate for the chuck jaws to grab, then turn the front and the back profiles. After the turning and drilling the bolt patterns, he milled recess slots for the clutch cover bolts: https://lh3.googleusercontent.com/-G...0/IMG_0182.JPG Adding some chamfers: https://lh5.googleusercontent.com/-0...0/IMG_0183.JPG Final weight: https://lh5.googleusercontent.com/-7...0/IMG_0184.JPG The reverse mount ring gear we're using is intended for a newer 7.25" cover than what we have, so the cover needed a small amount of material removed from the OD. Alex started by mounting the cover on the flywheel and clamping the flywheel in the soft jaws: https://lh3.googleusercontent.com/-W...0/IMG_0234.JPG Checking for runout: https://lh5.googleusercontent.com/-4...0/IMG_0235.JPG Turning down the OD: https://lh3.googleusercontent.com/-s...0/IMG_0239.JPG Fits like a glove now. You can just barely glimpse them, but there are small alignment tabs on the bottom of the ring gear that keep it concentric with the clutch cover. https://lh6.googleusercontent.com/-u...0/IMG_0242.JPG Next up: trigger wheel. It's going to be a 60-2 mounted on the starter ring gear Found a perfect steel pipe on the material rack. Unfortunately it was pushing the limits of what fit in the horizontal band saw, so we had to get a little creative. https://lh4.googleusercontent.com/-F...0/IMG_0245.JPG Almost through. We didn't trust the clamp completely, so we kept the feed low. I think it took about 15 minutes to make this one cut. https://lh4.googleusercontent.com/-c...0/IMG_0246.JPG This is the part after the first setup: https://lh3.googleusercontent.com/-K...0/IMG_0250.JPG Re-setting the soft jaws: https://lh5.googleusercontent.com/-F...0/IMG_0252.JPG https://lh6.googleusercontent.com/-1...0/IMG_0253.JPG This is as far as Alex got last night. The clock struck midnight and the lathe turned back in to a pumpkin. The trigger teeth are getting cut out of that standing ring section and the other ring with the tapered step will get reduced to a few mounting ears that will bolt to the starter ring gear. Projected weight of the trigger wheel is about 150 grams. https://lh4.googleusercontent.com/-U...0/IMG_0255.JPG https://lh6.googleusercontent.com/-e...0/IMG_0256.JPG |
nice job on the shop guys!! bet that sawdust smelled ripe! good to see its moving along again:thumbsup:
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New shop looks great!
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Pretty funny looking back at your first post with you saying this isn't a pro-build. The scope and tech of this car eclipses many if not most pro-builds and you guys are an inspiration to everyone who has ever turned a wrench at home in the name of performance. My new favorite Project thread.
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On to the evening's update! Ran the (soon to be) trigger wheel through the CNC to carve out the mounting feet: https://lh3.googleusercontent.com/-F...2000.21.55.jpg Hopefully the final result is becoming clearer. The trigger teeth will get cut out of the remaining solid ring. The step on the feet centers on the ID of the starter ring gear. Weight so far (300 grams, ~10.5oz): https://lh5.googleusercontent.com/-Z...2000.21.42.jpg |
Love it! awesome workshop and intense machine work! :thumbsup:
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Got some more work on the trigger wheel today. Hoisted the dividing head off the shelf and set to cutting the trigger pattern in the manual mill. https://lh3.googleusercontent.com/-f...0/IMG_0264.JPG https://lh3.googleusercontent.com/-Z...0/IMG_0263.JPG Unfortunately, the above picture is about as far as we got before things went pear shaped. We fought a few different issues for a while, and when we finally made it to the last slot, it became apparent that the teeth were not evenly divided. I think the trigger wheel had been slipping imperceptibly, so by the time we got to the end, it was too late. Definitely a drag, but such is life. Gentlemen, we can rebuild it. We have the technology. Better than it was before. Better...stronger...faster. |
wow that sucks after all that machining! i think you underestimate yourselves in what you are acheiving here, this build goes way beyond what most guys are capable of including some "pro" shops,! all credit to you and keep up the good work , you are a great inspiration to us all when we are having a downer over whatever issue we have in our builds!:thumbsup:
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Wow Dude im a fan of hard work and that you have been at for sure,
Best of luck amazing work keep us posted! |
Hello Karl.
I send you a private message. best regards :thumbsup: |
Would it help to cut the teeth before dancing the feet?
Nice work btw |
Anytime I see a post from this I am always hoping for a huge update. Love this build
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great design and great details.
I love the perfection that is used in the pieces. Here in Portugal there are only few people who do that well. respects :thumbsup: |
update please, we need our fix!!
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What's better than a B8444S?
Two B8444S's. https://lh3.googleusercontent.com/-9...s800/photo.JPG Block, crank, rods, and pistons look pretty good. Other than that, it's fairly wasted. The failure mode was fairly obvious once we got the balance shaft out. Rear balance shaft bearing seized up and fell apart, leading to failure of the front balance shaft bearing. Once the shaft was unable to spin, the sprocket sheared off and the timing chain suffered... shall we say "spontaneous catastrophic disassembly". The chain cracked the oil pump housing and broke one of the tensioners. Also found some bent valves. https://lh4.googleusercontent.com/-V...hoto%25201.JPG https://lh6.googleusercontent.com/-q...hoto%25203.JPG https://lh4.googleusercontent.com/-V...hoto%25201.JPG https://lh6.googleusercontent.com/-F...hoto%25202.JPG https://lh5.googleusercontent.com/-m...hoto%25203.JPG Haven't looked too closely at anything yet, but first impressions of the design are good. The castings look to be very high quality and the designers have clearly gone to some lengths in order to make a compact and light weight engine. |
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My brother is out slogging with the pressure washer as we speak. Should have a nice assembled mock-up engine by the end of the day. |
Decided to go Megasquirt on this build. My brother and I have done MS installs on previous projects and for a few friends, so we're pretty familiar with it. The one thing I've always hated about MS has been the ****ty connectors, the need for a lot of extra hardware, jumper wires, and board mods.
Decided to do something about it, and here's the result. https://lh4.googleusercontent.com/-g...s1024/ems1.PNG Designed a replacement main board. Takes an MS3 processor. Has hardware for 8 spark outputs, 8 injector outputs, four cam VVT, dual map sensors, six wheel speed inputs, real time clock, knock sensor interface, spots for two SLC DIY wideband drivers, on board CAN I/O expander with 16 analog inputs and 8 digital inputs, and waterproof automotive grade connectors. There's a bunch of other stuff in there as well. It's a long list. |
^^^^^^^^^^^^^^^^^^^^^^
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: |
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:
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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 |
Talk about engine set back! This is going to be cool as hell.
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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 |
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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 |
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 |
Had to go back quite a bit - nice unique Volvo motor you have there!
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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. |
More tubes:
https://lh3.googleusercontent.com/-h...2023.00.48.jpg https://lh4.googleusercontent.com/-v...2022.51.58.jpg https://lh6.googleusercontent.com/-O...2022.51.43.jpg The tube that goes across the front of the windshield is bent and notched, just needs a little more trimming to fit in. The first 60' of DOM tube is now all used on the car. Probably going to need an extra 60'-80' to finish up the entire cage structure. |
Mocked up one of the front wheels:
https://lh4.googleusercontent.com/-r...2023.34.23.jpg Alex measured the cams. Since it's a single point measurement on the lobe itself, the values are really only useful for a rough estimate of duration and lift. More conventional values for duration and things like acceleration profiles would require a better setup. https://lh5.googleusercontent.com/-p...2015.35.55.jpg https://lh6.googleusercontent.com/-4...%2520chart.PNG |
The cage fit up is lookin good.Love the body style and build.
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Are you going to raise the wheel wells or are you just gonna run it like that?
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LOL! Yes. The wheel arches. I put a lot of new wheel wells in cars. Gets stuck in the brain.
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Haha, no problem.
The wheel arches are staying that way, at least that's the plan now. I think the tuck looks good. |
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My brother started digging in to the steering rack. A rebuild kit is on order and he turned new stainless gland nuts that hold the central steel tube onto the aluminum ends. The old ones were pretty trashed. He also cut the old rack mounts off and turned the aluminum parts down to a uniform diameter in order to accept a new, more stable mounting solution: https://lh4.googleusercontent.com/-n...2023.35.34.jpg He also made a spanner wrench to aid in assembly: https://lh5.googleusercontent.com/-v...2023.38.44.jpg |
this build is off the hook!! so much creativity and engineering knowledge, this is truly a one off build:thumbsup:
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