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ultra_runner

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Blog Entries posted by ultra_runner

  1. ultra_runner

    Feb 25, 2006

    By ultra_runner,

    Today's update... Once again I got nine solid hours in today. "Miller Time"

    Ok - First thing I moved on was to finish laying all the Sound Deadening material so I can get the interior somewhat back in order. Took me about 2 1/2 hours to knock this part out correctly. Have a looksy!





    Here I have worked in the floor padding over the SD material, reinstalled the floor vents and the shifter assembly. Note custom stereo cable assembly provided by BING on both the driver and passenger side.



    I found some brand new wire tubing left over from my last car project so if you notice up in the dash I've cleanly put most of the wiring in tubing. This makes things much easier to figure out and I should have done it long ago. ALSO notice the SD Material that I put on the Knee Bolters. I even put the ABS sticker over the top of it. The Knee Bolster is nothing but a hollow metal assembly which I'm sure acts as a drum with road noise, etc... so I covered it with SD Material.



    Here is the deal... I've been working up the bolt posts on my dash with the forementioned ABS goop. Unfortunately, my wife commandeered the Camera to here is a semi-finished set of pictures. Note - I built up using the ABS Goop and then put a final smear of ABS cement over the entire thing. That ABS cement contains both MEK and ABS so I wonder what the real difference is between the Goop I made and the ABS cement??? Anyway - I am going to let this cure over night to ensure that it is ready ready ready when I try to get that dash back in tomorrow!!!





    Finally - got the drivers side carpet, etc. etc. all intact. Looks pretty good and clean. I still need to install the clutch master cylinder so it's not over just yet. Hopefully get that dash back on tomorrow. Then it might start looking like a real car again!!!!



    Later - Scott C.
  2. ultra_runner

    Feb 25, 2006

    By ultra_runner,

    Thor - I took you advise on this one. I mixed a batch of ABS pudding using ABS shavings and MEK. YOU ARE RIGHT - that MEK is some seriously nasty stuff, but it gets the job done!

    Here are a couple of pictures of me just trying to setup what pieces I could salvage. Once I have once complete, I can try to replicate the position, height, etc. for the others. Again - I'm just setting these up and plan to reinforce the whole area better than stock.





    The consistency of this stuff if perfect for repairs. The MEK evaporates rather rapidly and it sets pretty quickly. Here is another post but the lighting is not so good:





    I will continue pics and posts throughout the weekend. Goal is to get the dash back in this weekend! (Yeah - Right )

    So I tried to knock out some more of the SD Material in the interior. Hopefully can finish this out tomorrow and get the floor padding and carpet back in. Then its ready for the dash. This stuff if more work that it appears!!! I don't envy anyone who does this for a living!!!





    And one final thought. Don't hold me to this but... I'm thinking of trying to create a custom Throttle Body for the 850 using an S60 Throttle Body. The S60 TB is on the left and has an outside diameter of 3". The TB on the right is actually an SPG9 overbored TB for the 850. I know, I know about the bolt holes and the throttle position sensor differences, etc. etc. But time to get creative!!! This would be perfect to run 3" IC piping into a 3" IC into a 3" TB and flow into a 3" DP to a 3" full exhaust... talk about flow!!!



    Will post more tomorrow as things progress!!

    Scott C.
  3. ultra_runner

    Feb 20, 2006

    By ultra_runner,

    Today was another 9 hours at it!!!! 9 am to 6 pm with a small break to jam half of a cold chicken quesadia and a coke!!

    Let's get right to it. I finished putting SD material around the roof area first.



    Then I got the sun roof assembly mounted back up again. For those of you who have never tried this alone - I suggest that you don't try. It is very painful on your head (holding the assembly in place) and your shoulders (trying to bolt in the corners while this thing is resting on your head). I should have called it a day right here!!!!!



    At least the headliner was much LIGHTER!!!!



    Well - I took a break from all this padding this and padding that. I wrestled in the clutch assembly Unfortunately, you have to pull the steering column to do it. I don't know HOW anyone can do this with the dash still on the car!!!



    FINALLY - THREE PEDALS!!!



    Well - after that wrestling match, I figured I would go back to installing SD material again. Still got alot to finish here!! Look carefully and you will see the silver material along the top of the firewall, etc. This should quiet things done a bit!!!



    I need to pick up a few small dash parts tomorrow, so I focussed on the rear of the car again. Here is the car with most of the rear padded.



    Let me remind you that EVERY piece got a solid scrubbing with Simple Green (plastic) and Lexol PH Leather cleaner before going back into the car. Almost there!



    Voila!!! An immaculate interior. Every piece you see in there has been cleaned including the headliner and carpets!!!



    Now I just have to focus on the Clutch master cylinder install, the dash and wiring, and then completing the DF material for the front. I didn't get to any of the doors today, so I still have those to do, but they are probably easier while sitting on a nice clean leather seat!!!

    I'm thinking of relocating the battery to the trunk as well while I have the chance to wire everything. SUGGESTIONS???

    Well... my back will never be the same but a couple beers might cure me!!!

    Later!

    Scott C.
  4. ultra_runner

    Feb 19, 2006

    By ultra_runner,

    Sound Deadening of the Interior.

    Well, this morning I woke up nice and early, drove to Krispy Kreme and scored a half dozen assorted and a large coffee. The Breakfast of Tuners!

    So at 9 am sharp I embarked on applying the Damplifer Pro from Second Skin Audio. I figured I would cut me teeth on one of the rear doors first. Ok -the panel was already off. But hey - you know me... I want the job done right and sound dampen the INSIDE of the doors. It too me a while to figure out how to remove the power window motor assembly - namely how to unclip the window from the assembly.

    Did everyone know that you're 850 door has this like "Honeycomb" plastic in it??? I was looking for some bees to come out or something. Ahhh... Swedish Engineering once again.



    OK - so I laid up some S.D. material on the inside of the door.



    I then laid a sheet of material between the two Honeycomb assemblies. This should stop them from passing noise from the door skin to the inside panel.



    Took me a while to figure out how I took these things out and how the went back in together. I finally figured it out though. With one layer on the door and one layer between the honeycomb assemblies, the unit fit pretty snuggly back into the door.



    I then laid up sheet on the door itself. One thought was that it would be easier to lay it up on the inside of the door skin itself, but I probably would not stick for long. SD Material is better against clean metal.



    Now complete with door assembly back in place. Gee... that only took two hours to complete!!!



    Well, I continued onward... I spent the day on the back end of the car where most of the difficult parts are (I figured I wouldn't leave those for last). Here is a picture half way through the day (maybe).



    I will try to take picture through tomorrow as well. Hoping to get an early morning and the two Coronas and one Heineken are slowing me done. Later!

    Scott C.

    Here is a bit further along.



    Well. I ended today about 6 pm~ish. 9 hours plus a few minutes to jam a sandwich and a Red Bull. So - I have the back half of the roof complete, one door, the rear deck and the rear seat area. Tomorrow's goal is to complete the other rear door , the roof and roof framing, as well asthe rear part of the floor boards. That way I can reinstall the sunroof assembly and (nice and clean) headliner assembly. I can also get the rear door panel back on as well as rear carpet and back seat. That should give me some more space in the garage (mess).

    Look for more tomorrow. I keep recalling something I read on a Sound Dampening site. "You have to want it!" This is a lot of work, but I just kept telling myself that all day today

    Scott C.
  5. ultra_runner

    Feb 17, 2006

    By ultra_runner,

    Scott - I'm not sure on the part number. Even if it is riveted on, would it be a seperate part number??? I'm headed up to VolvoSaab early tomorrow to be there when the open to get some "stuff". I'm going to ask while I am there. I'll print out pics of the dash.

    I thought I would share some pics of what I've been trying to describe to everyone. Below are the four broken points. Tomorrow (when my arms get tired of putting sound matting on my roof), I'll break out the fiberglass and try to craft something back together. I figure if I create a fiberglass tab (possibly with some metal screen in it) I can sand it down to where the original sping nut will slide over it. Then, the bolt has a self-tapping (with some help) head and I can line up the spring nut and go right through the fiberglass. That should hold well enough.

    Thoughts anyone???









    Scott C.


    I figured I would drop this picture in here. I got the roof liner out and the sunroof assembly. I am going to use a gentle pressure wash to clean up the head liner and the sliding cover of the sunroof. No sense doing all of this to the interior and leaving dirty headliners right!!! Every interioro part is going to be brush scrubbed with Simple Green before going back into the car. Net result will be one imaculate interior and super quiet cabin. I'm getting goosebumps already!!!

    So - here is a piece of engineering mastery. "Swedish Tar Paper". Literally this stuff is tar paper and it even had huge air bubbles under it. You can see where I pulled a bit of it off. Don't know what true purpose this serves so.... OUT IT COMES!!! You can see where I pulled a bit of it off, but it took me an hour to get it completely off with a razor and then using Goof Off to get the rest off. Tomorrow, that Second Skin matting with go down (up??) real nice. Once again, I plan to start on the top and work my way down. I'll take pictures along the way.



    Scott C.
  6. ultra_runner

    Feb 15, 2006

    By ultra_runner,

    OK - so here is a slight update... I finally got my Black Jeweled headlights in today from the SAM Sweden GB. It took 3 months... but hey, I got no dash... I'm not going anywhere!!!

    So - take a look guys. What do you think I should do with that Bi-Xenon projector sitting next to it???



    Scott C.
  7. ultra_runner

    Feb 12, 2006

    By ultra_runner,

    Project has just entered the "OH CRAP" phase. You know... the phase of a project where you are heading into areas you just know you shouldn't be headed!!!

    Well - definitely this dash has been removed at least once in its lifetime. Found that all the spring-nut points where the bolts from the firewall side (4) attached, were broken off. Thus, not much holding the dash in place. SO, out it came.

    Here are pictures of the chaos that ensued.





    Sans dash... talk about lightening up!!!





    If anyone knows where I can get a new/used black trim piece (the volvo parts program 9158192/9165373 ???) that is uncracked and looking good - drop me a line!



    OK - I also got the rear desk out. Standing by for FatMat to arrive.



    In the process of taking out the headliner. So - I will start FatMat on the roof then up under dash, then the rear deck, doors and finally the floor - top/down. I will wash and scrub all the interior parts prior to re-install to get everything purty and smelling baby-fresh.

    QUESTION: If anyone has any suggestions on maintanance or other while I have the dash / interior out, give me a shout out. AC Evap? Blower Motor? Thanks.

    It's Miller Time!

    Scott C.
  8. ultra_runner

    Feb 11, 2006

    By ultra_runner,

    I figured that I would post and update.

    I'm about 1 week away from receiving in the Venolia pistons. Once that is in, I think I have most everything needed to send out for port/polish. Then the fun will start

    So - I haven't been idly sitting around drinking beer. Well, at least not sitting. I have the interior of the car removed and 100 sq ft of FatMat should have been here by today - it's not. I figured I would post picutres of the sound matting process in case anyone else is interested in what is involved, etc.

    BING was over my place this morning helping me plan the sound system, etc. We cut out lengths of speaker and power wires so I can pre-wire everything while the interior is out. Bing also hooked me up with an Alpine R12 sub for a deal. We'll look into making a custom enclosure for it in the trunk. For those of you who don't know yet - Bing is an awesome guy that does awesome installs!!!



    Here is the interior waiting for FatMat to arrive:







    OK - I thought I'd kill some time the other night - yes, I polished the water return line. Am I a geek or what???



    I will post FatMat install progress for everyone to see.

    Scott C.
  9. ultra_runner

    Dec 31, 2005

    By ultra_runner,

    OK - most everything external has been removed. Now for the fun fun stuff!



    Ladies and Gents - boy and girls of all ages... this is what my pistons look like after 105K miles of service. The cylinder walls are actually in really good shape probably due to all that good ole Alaskan Mobil 1.



    Here is an interesting part. I confirmed today that yes indeed, I was running NA cams unbeknownst to me. Anyway, when I removed the head I found that #5 cylinder exhaust valves were hitting the piston. Check the picture above real closely (#5 is all the way to the right) and you will see two shiney marks on the upper portion of the piston head. I also confirmed this on the valves as shown below:



    I also found that the intake valves on #2 were hitting the piston as well.



    Well, tomorrow it another day. I need to get a 12 point socket to get the con rods off and everything should be broken down by then. Plus I ran outta beer and it was too late to crack a bottle of Cab. Take a look at my garage and you wonder why my wife is on my a$$ all the time



    Scott C.
  10. ultra_runner

    Dec 31, 2005

    By ultra_runner,

    Today's Progress; Learned a couple new things today... like how to strip cheap sockets on Swedish head bolts. But there was some good too! The FEDEX man kindly dropped off my brand new "R" bumper - many thanks for George for making this available.


    I might even be tempted to paint it black




  11. ultra_runner

    Dec 29, 2005

    By ultra_runner,

    Someone has been in my CAMS?

    How does on visually determine an NA cam from a Turbo cam? No real part numbers on them. Here is the reason I ask. The cam gears have written on them (painted) AND inscribed with both "E" and "I" which tells me someone was doing something.





    Then I'm looking at the grind and it looks pretty aggressive and I have painted bands on the cams. Any ideas?





    Also - just for giggles, I slapped the S60R Ex. manifold on to see what is looks like. This is much better than the stock one, but wait until it gets all ported and polished!



    Scott C.
  12. ultra_runner

    Dec 29, 2005

    By ultra_runner,

    S60R Exhaust Manifold finally arrived!!!

    I just love when FEDEX leaves gifts on my doorstep! These are a much better design that the 850 stock manifold. Now. Where is my Dremel???





    Another score - $118 brand new - SHIPPED!

    Scott C.
  13. ultra_runner

    Dec 29, 2005

    By ultra_runner,

    Ok guys - you're keeping my honest. I said I'd do it... albiet I'm an hour late. But I scored some free 2nd row hockey tickets so my priority changed. I did get up the gumf to get in the garage at 11 pm after the hockey game and give this a whirl.

    So - GOOD NEWS!!! IT FITS!!! Tight, but no problemo! Here are some pics.

    I always thought the original color of my subframe was BLACK???




    IN!!! Notice I have the front engine mount bolted up.



    Sorry - need more light in there. About the same clearance as the previous auto tranny.



    Ok - note that I had to keep the chain on the engine as the rear tranny mount will need to be modified slightly. There was nothing holding the engine on the back, but the motor mounts were connected. I will have to cross this bridge during final assembly on the subframe prior to install.



    Yet again about 1/2" of clearance like the previous tranny.



    Time to call it a night. Will start the engine teardown tomorrow. I'll probably slow down on the posts and pics as I don't want to bore everyone with engine pics and oily hands.

    HOWEVER - IF ANYONE HAS A PDF OF AN EXPLODED VIEW OF THE M66, THAT WOULD COME IN VERY HANDY FOR ME!!!!! Thanks.

    Scott C.
  14. ultra_runner

    Dec 27, 2005

    By ultra_runner,

    OK - so today I got the engine block cleaned up a bit so I'm not spreading grease around the garage, etc. The wife is not really speaking to me lately... but that means I can spend more time in the garage - right?

    So - I got the M66 bolted up to the block today. IT FIT LIKE A GLOVE!!! Here are some pictures of it. Tonight I will try to clean up the engine bay a bit as I've not touched it since the engine came out. I still need to get a few things outta there. Tomorrow I will try to pressure spray the engine bay and THEN - try to drop in the motor with the tranny. I am doing this to see the "fit" onto the motor mounts, etc. I want to figure out what modifications I will have to make BEFORE I start working on the engine. That way, when parts are out, I can work on some of those items, etc. and minimize the down time. If I can get all of this done tomorrow without catchin hell from my wife, I'll hopefully be able to post pics of the engine in along with the tranny so you can all see what it looks like.

    For final install though, I will probably follow CJ's lead and bring the engine/tranny assembly in from the bottom on a nice clean subframe.

    OK - the pics!

    It is so nice of Volvo to supply a Swedish Pine transmission stand with every tranny you buy!! OK - trying to line them up.



    Almost there...



    Swedish Engineering Perfection!!!



    Solenoid will fit perfectly!!!



    More perfection!!!



    Some better angles. Should I start polishing that tranny housing guys????







    Thats all for today guys. I gotta go make some brownie points with my wife!

    Scott C.
  15. ultra_runner

    Dec 26, 2005

    By ultra_runner,

    I also traveled to Dallas earlier this year to take a look at an S60R (M66) that dyno'd 540 WHP and the trans was not the issue although he had a stage V clutch. He did put enough torque into the front wheels (was in FWD mode) that it tore the entire passenger side shock assembly out and the wheel proceeded to enter the fender and door area. So - his problem wasn't the trans!

    Yes - I even work on Christmas so here are some more pics!

    We've all lost a knuckle or two while working on our engines. Nothing that a couple Heinekens won't cure!!!



    Slowly breaking it down...



    Take a look at my Exh. Manifold gasket(s) which are probably original. This is how it was when I took the manifold off. If you look close enough, you can see that I had a tad bit of exhaust leak on one and five. Also notice that white gummy stuff along the head gasket!







    When I get a bit bored with the Engine stuff, I throw stuff on the buffer. I took the RIP that I got from Doug K. last week and threw it on the buffer for a mirror shine. Also put a bit o' spice on the Thermo housing that was originally polished by VolFan (quality work). Look for a bunch of clean polished stuff on this engine. It's theraputic! Although, seeing CJ's powder coated gear sure makes me rething things a bit!!!



    Merry Christmas Guys!!

    Scott C.
  16. ultra_runner

    Dec 24, 2005

    By ultra_runner,

    Some of you may have heard this already but I just officially kicked off this project. To put the M66 six speed into a '97 850. Top that with an engine build up that will hopefully push past 500 HP.

    So - Started the engine pull this week and I got the auto tranny off. Here are some pics, hope we can make this a running thread. I'll accept pic requests if they are within reason.



    Almost there. Also made sure there was plenty of ice cold beer within reach for this project!



    OUT!!!!



    So here they are - side by side with auto on the left and M66 on the right. Notice the bolt pattern is very similar but the M66 as a few more. I also found that both are 13.5" in depth which calms my fears a bit about getting the sucker in there... but we're not home free yet.



    Notice the depth is the same. This is the best pic I could take to show the equal depth.



    See on the M66 (right) those two circles off center to the right? That whole section creats one big "hump o' metal" that you don't see over on the automatic. If ANY where is going to be a problem , this is going to be it.



    Just getting started and the target is to have everything (engine included) by May. So no more BBQs until then - OK???

    Scott C.
  17. ultra_runner

    May 13, 2006

    By ultra_runner,

    Yes - I am still alive and kicking!

    UPDATE: Still having issues getting my engine parts through the machine shop which is holding some things up. I may have to grease skids to get things... uh... "re-prioritized".

    Well, here are a couple pics of the GT35R that I will be using. I have some choice words for ATP for their lack of organization that has created some delays and then made me waste 90 minutes in my car yesteday. 'nuf said on that... but by Monday I will have a bunch of stuff ready for pickup from ATP including their Ultimate Internal Waste Gate. I will change that ex. housing to an .82 5-bolt to support the UIWG.

    Yes - that is a large KK Coffee sitting next to it!!!







    Here we have the just arrived in (as in yesterday) Brand New IPD front and rear sways along with Slater's QBM endlinks. Damn - Slater don't mess around with this stuff. Looks like they below on a Sherman Tank . I also picked up lower and upper mounts from QBM. I hope to get all of this installed today.



    If I can get the suspension stuff done today... I have 5 brand new AutoMeter guages that I will start installing. Will require punching another hole through the FW to get all the cables, etc. though. Next thread!

    Scott C.
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