33 replies to this topic

[T5shortblock]

A bit of progess over the weekend, PS tank completly installed, well almost, just need to remove about another half inch of length from the pump hose and get 2 other clamps and I'm good to go.

I actually made 2 brackets, first one out of a flat sheet of 1/16th thick aluminium, but the bending did not go to well because with the surface of metal I had, it wasent a big enough piece for me to bend it in the same direction of the metals grain, so it made for a great template, but I had to redo it out of a pre bent piece of galvanized steel, would of loved some pre bent Aluminium but I could not find any, and with the size of the bracket, weight was not really an issue... lol







Than I made a reducer for the pump hose because the Morosso tank has a 3/4 inch stub while the stock tank had a (aprox, real dimension is metric) 5/8th stub



final piece



ready for some rivets



In the car.



plenty of clearence



All I need now is a new ECU box




Now for the next project

I bought this awesome Stealth Oil Catch Can from 42 Draft Designs, SS piece and sleak as hell.



reason for this sexy piece of metal is obvious, see next pic, considerable oil accumulation from the PCV system. Thanks to this can there will be less junk going through my turbo and that will result in more consistant combustion and A/F ratios.







First step was to remove the foam covering the area where I will splice the PCV hard line to reroute to the can.



More on the installation in a few days.

[gilber33]

Looking good. Take some pics of the catch can installation, I'm gonna be doing that to my wagon next spring.

[T5shortblock]

A bit of progress again this weekend, made the bracket for the catch can after I decided the final mounting spot. Bracket uses the same bolt as the rad bracket. I had to bend the rad bracket a bit to make the can bracket squeeze in.

Used this piece of left over hardwood for the dining room as a jig for piercing the hole to bolt the bracket up to the can, since I bent the metal before making the holes, thats because the bracket is not really precise so if I made the holes before bending it, it might not align exactly like I wanted.













Installed in the car, I think it looks pretty cool, If I want to hide it later for fear of getting reprimanded buy emissions police, I can easily put a clean up plate over it or something...







Then came the time to splice the PCV hard line.



Once I started cutting, it was difficult to get through the entire thing, my tool was jerking... eventually a went throug 3/4 of the line on 1 side, I then bent the thing until it split and removed the section I wanted out of there on the bench.



I grinded the part that was still attached to the block so it was a clean cut, and removed all the chrapnell from the line after that with a q-tip.



Next step is to source 2 reducers for the can, since the tips of the can are 3/4 inch and the hard line, while not being perfectly round, should form a tight inner seal with some 1/2 inch rubber hydraulic line, more on that later.



Next step will be to finish up with the lines from the hard line to the can, and to chop the ECU box to fit around the PS tank... stay tuned!

[T5shortblock]

A few updates for today, I finally decided to add a PS steering cooler after discussion in this thread:

http://volvospeed.co...cooler-install/









I also plumbed the catch can with some adapters and some hydraulic hose



The flow for the ram air is kind of interupted by the position of the can wich is probably insignificant, but not very engineeringly esthetic o to speak. So I'm going to route the flow with some 2.5inch intercooler piping more directly to the intake and I'm also going to make a heat shield/air box for the intake so the cold air from the ram will be more directly sucked up instead of going everywhere in the engine bay...

I also closed up the ECU box with some sheet metal and a few pop rivets.

[S8ET6]

T5shortblock, on 14 December 2009 - 03:16 AM, said:

The flow for the ram air is kind of interupted by the position of the can wich is probably insignificant ...

Got any pictures of the ram air setup? I'm using the same intercooler as you are, and I needed to reroute mine, so I'm looking for some ideas

Quote

I also closed up the ECU box with some sheet metal and a few pop rivets.

Looks good, but I don't know about putting sheet metal so close to the ECU...

[T5shortblock]

one thing I dont know much about is electronics... lolll


You think I could get some shorting or something? How about if I put some electric tape on the inner surface? There is no contact between the metal and the ECU...

I just continued the ram air tonight, I'll be making the heat shield next week, will post more pics as soon as possible!

[shanehutton]

T5 - I am going to be back in Ottawa for Xmas. I would love to come see this beast if you are going to be working on it while I am in town. I fly in on the 24th but I am not sure when I am leaving yet.

[Mesoam]

the ecu is inside its own case inside the box, really shouldn't be a big deal but if you're concerned hit the sheet metal with a few coats of rubberized coating

progress looks good!

[C70drvr]

Looking good buddy!

[T5shortblock]

shanehutton, on 15 December 2009 - 10:49 AM, said:

T5 - I am going to be back in Ottawa for Xmas. I would love to come see this beast if you are going to be working on it while I am in town. I fly in on the 24th but I am not sure when I am leaving yet.

Hey dude! I would love to meet another fella from VS, i'll pm you my cell number right now, the beast is at my home so even if I'm not working on it, it'S not a problem...

I'll be in Montreal from the 23rd to the 27th, I hope you will still be in town by the time I'm back, comming back early in the morning on the 27th.

Thanks for the comments fellas,

I'll probably use some tape on the inside, I'll also be aplying some gold reflective tape on the outside of the sheet metal to reflect heat since the sheet metal absorbs alot more than the stock plastic, not to mention it's colser from the ECU than the plastic all that I removed...

[T5shortblock]

Got some stuff done today, finished the ram air/heat shield today... I didn`t really make it to actually reflect heat but more to contain the cold air from the ram air around the filter instead of having it blow everywhere around the engine bay...

I actually got inspiration from this DIY air box for a Ford Lightning, the guy made it with a 10$ rubbermaid garbage can

http://www.f150onlin...air-intake.html

only diffrence is I used an OEM volvo part as a startig point instead of a garbage can... it's the trunk battery cover found on P2 V70s... So my shield has a volvo part number





after some choping and a few holes



a few anodised brakets and some pop rivets



voila



made this more as a template to make a nicer one with aluminium sheet metal eventually...







Bolted every thing nice and tight, put the diverter back on and a few odds and ends





next step is to instal the new XC90 Spring seats and I'm all set for the summer

oh ya I also shaved the slash mounting points from the grill, sanded down the hole thing and re-painted





That's it for now folks...

Next week I will be ordering my new wheels, I'm pretty sure they will be one of if not the first set made for a Volvo, pretty excited about them... will post pics when I get them... keeping the make and model under raps until I get them

[bpray9223]

i love your car. period

[project_850]

The money shot. Great work, I love the heat shield.

[SAFEBOX]

man i wish i could do this kinda stuff