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This is a build thread for my s60 Started out in life as a 2002 2.4t lpt, i upped the boost without a tune which resulted in a spun bearing after detonation. I then bought a b5204t5 engine stripped it down and it looked almost new inside, clearly very well looked after i then started buying parts d5 93.2mm crankshaft Zrp conrods Weisco 81.5mm pistons (8.5:1 compression) To make a 2430cc engine Cat cams single valve springs Block mod (apparently block mods will see 600hp on an 83mm bore in a focus rs which is also 8.5:1 compression so hoping a 81.5mm bore with block mod will see out 650hp) 1.3mm mls head gasket 850 NA cams without vvt and set to no overlap and maximum advance on inlet for the lumpy noise VVT delete AC delete Arp head and main bolts 5 to 1 collector/banana manifold Pulsar Gtx3576r 0.82ar turbine housing Turbosmart 45mm waistgate with 18psi base pressure, i plan on welding this directly to the exhaust housing (space permitting) for maximum control 707 clutch with cinter clutch plate Snabb ultimate intercooler kit M56 with LSD I've port and polished my cylinder head and stock inlet manifold myself Inlet manifold spacer with much lower heat condition AEM 340lph fuel pump located when the old fuel tank was and rising rate fuel pressure regulator (60psi base pressure) with 8an hosing and 6an return to a 60 litre fuel cell in the boot Then closing off the boot completely from the cabin to protect in the case of a fuel leak 1200cc bosch injectors and speeding performance fuel rail Ill be deleting the pcv system and just installing a catch can to the turbo intake for crank case ventilation ECU master black control unit and 7 inch ECU display The engine will be running on volumetric efficiency rather than maf flow Bosch pressure and temp sensors for oil and coolant (coolant pressure to keep an eye on the liners 2x knock sensors 1x bosch 4.9lsu wide band o2 sensor Im a qualified auto electrician so will be doing all the wiring myself Im unsure if i want to run a water meth system yet or not as the intercooler is massive anyway and dont think intake temperatures will be an issue E85 isnt really very available in the uk so wont be using flex fuel (a 200l barrel of e85 fuel is about £600 so dont think its worth it) My plan is to run a 3.5 inch exhaust from the turbo to the back box then step up to a 4 inch for the tip, and a 48mm screamer pipe out of the bonnet for the waistgate I wont be running a blow off valve because i love the sound of turbo surge and i know it doesnt actually affect the life of the turbo but does slightly increase spool time when changing gear (this is meant to be a fun road car not a time attack car so i dont mind loosing a bit of spool for my favourite noise) Ill be sticking with the fwd rather than upgrading to awd Im going to build my own roll cage bolted to chassis points to strengthen the body for flex My goal is eventually 650hp but 500hp to start with when the build is complete to test it for 6 months and then check the compression and general health of the engine as ive never built one before but am teaching myself with the Internet how to do it properly then ill turn the boost up if all is well with the engine ive been a mechanic/vehicle technician for 9 years 8 of which were with volvo Cambridge so i know pretty much everything about these engines and the platform I already have the lsd, coil overs, 9j bola csr wheels with 245/40 r18 tyres. Im using s60r brembo brakes fron and rear with yellow stuff pads and slotted discs. 40mm wheel spacers all round with extended arches. The interior is completely stripped out aside from the dash and radio as it is still a road car and i love my music so i might upgrade all the speakers while im at it Im still currently using the stock leather front seats as im not sure which seats i want and would like to try them before purchasing. Does anyone know of seat rail adapters for p2 volvos to suit sparco or omp seats?? If anyone has any suggestions for doing the build a bit better it would be very appreciated Do you need to apply sealent to a mls head gasket?