40 replies to this topic

[Darth R]

We decided to undertake a new build for the Ipd show which will hopefully get rid of all the smoke too.

The previous motor setup was,
A 100k mile short block
Rebuilt turbo head
N/A cams
16T with straight flange turbine housing
3" down pipe 2.5" axle back
Rip Kit with RFL Bov
M56L manual swap
R clutch
R manifold
T5 manual ecu from Europe with an Ipd Flash
Stock air box with K&N filter, and 2.75" aluminum J pipe for the turbo intake.
Ipd plug wires and a MSD coil
We dyno'd it back on January 2011, for 214 whp and 288 whtq on a Mustang dyno at 18 psi.

Some shots before we dug in







And now to dig in:

New parts started coming in and old parts started coming off:



Easy stuff:


Turbo is off and new one has arrived:

[Darth R]

So the first bit of work was to tear everything down to the short block. Even though the head was professionally rebuilt < 20K miles ago it had 4 exhaust valve stem seals that were leaking and carboning up on the stems. I sent the head in for a cleaning and a new batch of stem seals.



The first few days, consisted of pulling everything off, and doing some heavy cleaning. The oil pan came off, along with pulling the pistons out of their bores. We were fortunate that the motor had very little wear in the cylinders and I didn't have to use a ridge reamer to pull the pistons out. Soaked the pistons in a cocktail of carb cleaner and gasoline, to loosen up the carbon and gunk. Popped out the wrist pins, swapped in the big fat rods, squished the rings down, and pushed them back into their holes. Wiped down the journals, installed the bearings, and torqued down the arp rod bolts.

Before:


Piston 1 is in:


Something is missing here:


Some underneath shots:



Once the bottom end was back together, we cleaned up the oil pan, and pick up screen, and threw that back on along with some new rubber O rings. Tech tip, a few dabs of crazy glue will hold the O rings up in the bottom of the block while you wedge in the oil pan, it a tight fit but do able.

While we were waiting for the head to get back from the shop, we decided to get the intake and cam cover polished up for the Ipd show. I picked up a 97 n/a intake and t-body about a month ago, to go on this build. I spent probably a good 6 hours grinding out the casting lines and all the roughness before taking it to a local polish shop. The difference is quite stunning, you can do alot of the grunt work yourself and cut the cost down considerably.

Chris working on the intake:


Our work:



Back from the shop:


Michelle worked in the engine to get it spiffy, plus the old downpipe:




I picked up the head just this last Friday the 29th, the cost for a cleaning, and r&r the stem seals ran a $113 with the tax. So if your head is burning oil, go get it fixed its not that expensive. I torqued down the head with new bolts and gaskets on Friday, and tossed the R mani on.

Next on the list was to bolt up the new turbo, so this turbo is a Taiwan knock-off of the Mitsu 19t. I picked it up on E-bay from Nickel Sport the cost shipped was $438, there is nothing that throws up a red flag to me, it appears to be well made and the price was right, cheaper than getting my 16T professionally rebuilt by a local shop. The 19t didn't come with a turbine housing, but I had a oem angle flange one from a previous turbo.

[Darth R]

Before I put the turbine housing on the turbo, I spent about an hour porting out the waste gate opening, I feel this will help to calm down the instant spool up that causes so much grief. I'm not so worried about the motor handling the abuse as I am worried about the car having a hard time getting traction, its running an open front diff.

So this is where it gets fun, well at least for me. I picked up a mild steel angle flange from C.J. to start my down pipe build. Along with that I grabbed a 3" mandrel U bend from Summit racing, and flexy joint and an Evo test pipe from E-bay.



Once the turbo was mounted Saturday morning I spent the rest of the afternoon fabbing up the downpipe. Essentially it takes 3 joints to make, a roughly 130 bend, a 15 degree kicker, a straight section with about 30 degrees to level it back out.






Now your probably wondering why I have a Evo test pipe in the mix, well one of our other cars is an Evo 9 that we autocross. It happens to have a nice 3" HKS hi-flow cat, that cat is now on the Volvo. In return the Evo is getting a Mil-Spec 100 cell race cat. The Evo test pipe was cannibilized for its flanges during the down pipe build for the Volvo. The Volvo exhaust is now setup like an Evo exhaust, in that I can use any Evo 8/9 cat or test pipe in the Volvo. Since we already had a nice Perrin test pipe and HKS cat it just made good sense.





To finish up the downpipe I wrapped it in a black header wrap from Summit and adding a O2 bung in the stock location.



The previous downpipe is getting handed down to local V.S. member and autocross buddy, ttown s70


Thats the update to this point.

Things left to do, install na cams, na intake, and t body, rip kit, new ipd wires, new fuel filter, new timing belt, new lower radiator hose, blue injectors, ipd phenolic spacer, ipd skid plate, new radiator over flow tank, a couple things the wife is working on (Ipd surprise) and cross fingers. Dyno, then go to IPD

[boxpin]

Crazy beautiful

http://i1113.photobu...11/IMG_4704.jpg

[Swag Swag]

Nice progress, things are lookin good. now im for sure not going to open my hood at IPD, haha


what IPD tune are you running currently?

[magicaljake]

looks awesome!

makes me wish my project was still kickin :/

[Oreo931]

Great work!! The manifold turned out awesome. You really make it looks easy dropping in a set of rods like that


Ugh, I really need to get my angled flange exhaust outlet and downpipe on

[Matt_]

Subscribed! Like Oreo said, you two are making this look way to easy. Lol. Every thing you're doing look awesome!
What are the power goals you two have in mind with the build?

Very cool that you guys are kicking down the old downpipe to Marshall.

questjah, on 03 May 2011 - 04:58 AM, said:

Nice progress, things are lookin good. now im for sure not going to open my hood at IPD, haha


what IPD tune are you running currently?

That makes 2 of us. Lol.

Edited by Mad Matt, 03 May 2011 - 05:33 AM.

[herz3mc]

boxpin, on 03 May 2011 - 04:54 AM, said:

Crazy beautifulhttp://i1113.photobucket.com/albums/k509/watchoutcones/Volvo%20Upgrade%20Spring%202011/IMG_4704.jpg

Thanks - see Chris, i'm not the only who likes shiny bits. I was staring at it all night saying it's so pretty!

questjah, on 03 May 2011 - 04:58 AM, said:

Nice progress, things are lookin good. now im for sure not going to open my hood at IPD, hahawhat IPD tune are you running currently?

I'm not sure (Chris knows), but we might need a new one.

Mad Matt, on 03 May 2011 - 05:30 AM, said:

Subscribed! Like Oreo said, you two are making this look way to easy. What are the power goals you two have in mind with the build?

Not that easy - we've had a few hiccups but worked through them.

As for power - i'm hoping for a unicorn sticker

[Darth R]

Gunning for the magical 300hp mark

[lookforjoe]

Nice Work!

I was wondering about the hand with nail polish .... great that you both get to work on it. The most assistance I can get from my wife is the occasional laptop session with TurboTuner

The bores measured out OK to not even need a hone? That's very impressive!

The bay looks very good - and the intake manifolds look so much better with all the casting lines removed.

[TRACStar]

lookforjoe, on 04 May 2011 - 12:29 PM, said:

The bores measured out OK to not even need a hone? That's very impressive!

+1

Hmmm, I should yank my head and check it out, maybe I can get away with just bearings. My shortblock has about 90K.

Good progress so far

[RZT5]

Nice engine build! You do make it look easy

If a 19t is stage iv, does that make my car a stage v or vi?

[herz3mc]

UPDATE: Chris has been making great progress after work this week getting things back together. Shooting for Friday to have it all wrapped up.

Here's a little photo detail of where things are at:
Valve cover on:


Timing Belt Done:


Downpipe installed:


Easy stuff like the airbox and battery!


Lower radiator hose and lots of electrical components:


Will finally get the skid plate on once we are done with the leak check:


More coming soon...Stage Infinity and beyond

[Darth R]

My current tune is a Stage I ipd flash on the euro t5 manual ecu. I have a set of flow tested blues to throw in. I plan on talking to Lucky or his replacement at the show and get their input if that tune is adequate, hopefully it is good to go. That is one thing about Volvo's and Ipd in general that is over priced in my opinion. I recently got my Evo tuned for $200 plus $100 for the dyno, retunes start at $100. My flash from Ipd came in way under their listed crank horse power, but no one seems disappointed about that.

The cylinder bores I did not mic out, but they had no wear ridges and still had the cross hatching pattern., not 100% sure of the history of this short block, I bought it from Lucky back in August 2010, compression came out an even 165#'s. I'm going to assume its got some life left and run it till it lets lose. The vacuum is a solid 20-21 inches and it seems pretty sound. Motors are pretty cheap for Volvo's especially is the n.w., plus George has one he's swapping out right now.

The painted finger nails belong to Michelle my wife, I forget sometimes how fortunate I am to have such a great spouse who enjoys working on, and driving cars as much as I do. I sometimes take it for granted because she is always there pitching in and helping out, but your the best M

[dmelviØØ7]

Sweet skid plate!!

[DARKSIDE]

damn, you sure did get a lot done in a few days...good work...

[herz3mc]

The final moments are upon us and things are coming together quite well.

Chris spaced out the intake a bit


Got the injectors in. If you have a turbo motor make sure to get the baby blues (395 cc) and not the black and blue (200cc from an NA). if anyone needs a set of cleaned and ready to go NA blues, let us know

BAD for turbos


GOOD for turbos


After getting the intake on Chris realized that he couldn't get his hands in to attached the dipstick, so small hands to the rescue. No the car is not eating me:)



WINNING


Extra Go with NA Throttle body!


Had to get a new overflow tank - it's clean!


RIP kit on, oil cap on, plugs in, ready to go!


First Start:


Couple plastic pieces to put on and Chris is heading to Top Gun to get the rest of the exhaust welded up!
Next post: Marshall gets a downpipe

[sconeman]

sweeet you two make a good team

[Matchbox22]

some serious work getting done by you two ftw!