Project '82 Volvo 242

[coolwelder62]

Totally Awesome Machine work.

[Karl Buchka]

Originally Posted by coolwelder62

Totally Awesome Machine work.

Thanks!

Here's the latest on the trigger wheel. The fixture and programming for machining the mounting tabs was re-used since last time so the entire thing went pretty quickly. Also drilled and tapped the ring gear to check the fit. The trigger wheel has six countersunk M4x0.8 cap screws that will get loctited and staked to hold them in securely.

[Karl Buchka]

Alex machined a 60-0 trigger pattern in the wheel earlier tonight.





Anyone have a thermal deburring machine handy?

[FETorino]

That is some impressive work

[Karl Buchka]

Originally Posted by FETorino

That is some impressive work

Thanks!

Alex came back to the states last week, so he's started putting in some work on the car. Here's his update, along with some photos he snapped:

Together with the steering rack rebuild kit I ordered back in January and the new gland nuts and spanner wrench I made up the rack was ready to go back together. Assembly was relatively straightforward and the ~$180 savings over buying a re-man rack was money well saved.



I just taped over all the oil and breather holes since the updated steering rack mounts I've designed will need new hydraulic lines. That's a project for later though.

Here is one of the new gland nuts in action. Really made assembly a breeze, much more convenient than the old castellated nuts:




Test fitted the bellhousing on the torque tube. Looks like the hole pattern was absolutely spot on, it snapped right onto the dowel pins:





Time to transfer the bolt pattern on the engine to the bellhousing. I started by removing the hollow dowels on the mockup engine block and replacing them with some brass bushings I turned earlier:



The reamed hole in the bushing accepts a length of drill rod that I turned to a point. That way I could center the bellhousing on the crank and tap the punch from behind to get the proper hole positions:



Centering the bellhousing was really easy with this plate I made up. The ID fits snugly over the crank snout and the OD goes inside the bellhousing



I snapped the bellhousing onto the centering plate and rotated it to the correct orientation using a protractor and a spirit level, then I transfer punched the dowel positions:



That's as far as I got today. I don't have a 16mm reamer, a matching drill bit, or a drill chuck big enough to use either so I decided to drop the bellhousing off with a local guy named Keith Fenner, the owner and operator of Turn Wright Machine Works, to have the drilling and reaming done.

If anyone is at all interested in any kind of machining, welding, brazing, or general shop practices I can highly recommend Keith's youtube channel:

https://www.youtube.com/user/KEF791

He is truly a talented machinist and his videos are some of the best out there.

[shok]

Pretty instructional post
I also subscribed to that youtube channel.

[Bowtieracing]

Any F1 team would hire you in a second for R&D ! Awsome work!!

[sonu]

Any update?

[Karl Buchka]

Originally Posted by sonu

Any update?

There has definitely been some progress, but we would like to get it to a certain point before making an update.

We’ve also been working on some other projects that have been taking time away from this car.

A good friend of ours asked us to help him do a set of individual throttle bodies for his ‘73 Volvo 142. It’s powered by a 2 liter pushrod inline 4 called the B20 (no, not that B20 ).

Here's one of the initial mock up photos. The throttle bodies have been stripped down and moved apart to check the stack-up and alignment.


When we had figured out what spacing we needed on the throttle bodies, Alex turned new spacers and extended the long bolt on the top side. I fabricated a new brace for the bottom of the throttles.


Alex fixtured the cast manifold in the mill and machined the mounting surfaces flat and parallel. They turned out to be anything but because he needed to take over 5mm off the head side to get a surface that was even close to being parallel.


Welding the throttle barrels to the Weber flange. In this photo you can also glimpse the step that was turned in to the mouth of the throttle body. The custom made velocity stacks slip in there and get locked down with a small grub screw. Changing to either a plenum, filters, or different length velocity stacks only takes a few minutes.


A small part of the weld bead had to be milled off to make clearance for the bolt heads. It's a pretty tight fit.




Turned the fuel rail ends between centers to prepare for welding.




Boring out the injector holes.


Progress shot.


The fuel rail needed to have a small notch milled out to clear the bolt head.


We extended the linkage brackets by simply welding on longer tabs to fill the gaps we created earlier.


At this point the manifold was nearing completion, so we decided to add some "flair" to the fuel rail.


Here's a quick shot I took of the fully assembled and completed manifold. The casting got another round in the mill to clean up a few mounting surfaces and to get rid of whatever ****ty company name was cast in to the thing.


This is getting shipped out shortly, where he'll be able the finish work like re-plating the linkage brackets, port matching, and general prettying up.

[lilcraigford]

You guys are just too much!