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ultra_runner

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Blog Entries posted by ultra_runner

  1. ultra_runner

    Mar 16, 2007

    By ultra_runner,

    Sorry to keep you guys hanging. Just I have some things at work that are creating 16-18 hour days for the past couple months. I have been working it piece meal when I can.

    So as you know, I took that damn dashboard out again. I hate that damn dashboard. I almost gave up on that damn dashboard. The tabs broke again and the upper trim near the windshield is cracked and breaking (on that damn dashboard). I actually have a good dashboard from a '98 S70. Much better construction and material than my damn '97 850 dashboard. Unfortunately, it would need to be heavily modified to fit the good S70 dash in place of my damn 850 dash. There will be a time and place when I replace the entire damn dashboard. 'nuff said.

    Last night I wrestled that damn dashboard back in. As mentioned, there were a few things I modified in the wires and cables inside that damn dash. I also mounted my Alpine Ipod interface box in a perfect location.



    Second, I installed the ashtray gauge pod custom made by Owned. Quality product there and sets right under my other three gauges.



    I got the "A" gauge pod all sorted out. Hey - my oil pressure is already 44 pounds!!!



    Here is where we stand. Everything is 95% wired up. Interior is pretty much done (again). Sorry to bore you guys will lame stuff like this. I promise there will be some exciting pics coming shortly.



    Scott C.
  2. ultra_runner

    Feb 7, 2007

    By ultra_runner,

    Wednesday night and its 1 am. I just got finished with a few hours under my dash installing the clutch master cylinder. I've been procrastinating on this for weeks if not months so I have I've made a personal breakthrough here. Had to get under the dash unbolt the brake master... then wedge the clutch master into position, then bolt the clutch master from under the dash and finally rebolt the brake master. Simple huh? I don't wish this task on anyone. My hands are torn and my back is killing me! No pictures as it would have only been me with my head up under the dash.

    Next step, finalize the wiring, etc. in the dash area and then getting the dash installed again (once and for all).

    Scott C.
  3. ultra_runner

    Feb 3, 2007

    By ultra_runner,

    Ok - last weekend I pulled the dash again. As I said, I wanted to re-do some of the wiring and run more power into the cabin so never have to think about getting through the firewall again. Now I can run a fuse block inside the cabin and power things.

    First I ran three strands of 10 gauge through the harness assy and into the cabin. Conveniently a bit of the fuse block was already broken down in the corner and allowed me perfect space to drop down into the cabin.



    I then mounted a distribution block in a good location. The large 4 gauge runs to the trunk to power a future amp.



    The finished product. Don't worry - there is a plastic cover that goes over that distribution block. Also notice that I have a new battery try to turn the battery sideways. I will go with an Optima Red Top. More to come tomorrow.





    Scott C.


  4. ultra_runner

    Jan 27, 2007

    By ultra_runner,

    I changed plans on the gauges locations, stereo, etc. So, I want to re-wire everything correctly. Plus I need to loosen the master brake cylinder to get the clutch master installed. Much easier without the dash, etc. So - I should have everything back in a couple of days or so.



    Scott C.
  7. ultra_runner

    Nov 24, 2006

    By ultra_runner,

    Major updates all. After much waiting and anticipation, the bottom end of the engine got built today. Doug K hosted and facilitated the event - I made coffee runs and defrosted the refridgerator

    Anyhoo... here is how the day went. Venti Egg-nog Latte, extra hot.



    Tediously cleaning out all the bolt threads



    My what a clean crank you have!



    Crank set into the block



    Bottom end put together:





    Torquing down the block to gap the piston rings.



    Installing piston and rod assembly



    We sacrificed a goat over the block to ward off any evil rod spirits



    Alas - a nice clean bottom end.



    Stay tuned!

    Scott C.
  8. ultra_runner

    Nov 10, 2006

    By ultra_runner,

    Update - So, the imfamous Doug K just stopped by my house to pick up most of my engine parts (bolts, piping, oil pan, etc.). He also grabbed my Turbo which by way looks great all put together!

    So - Head should be complete next week. Doug is going to start the bottom end and should be ready for the head at that time. He say he may have the engine complete by Dec 1st. I will cart the M66 up to his place and we will assemble the clutch/trans/engine all together, wrestle it into the back of the wifes SUV and get it back to the shop. If I make it that far, its all about taking some of that PTO time and getting the thing into the car and all hooked up again. May be on the road by Christmas?

    Scott C.
  9. ultra_runner

    Nov 9, 2006

    By ultra_runner,

    Ok ok already....

    Bottom end is finished. Crank is just getting a bit more polished up. Top end will be ready end-of-next-week~ish.

    Anyone recognize that bench???





    Time to get busy!

    Scott C.
  10. ultra_runner

    Sep 24, 2006

    By ultra_runner,

    I drove two hours to the machine shop to check the progress on the head work. Things are moving... albiet slowly, but moving. On this project, it is Quality over Quantity. It's kind of hard getting good pictures of head ports with a crappy little camera but here it goes:

    So I guess you can figure out what angle this is from... at least it if from the intake side. Notice how the port has contoured all the way into the valve guides. We're opening that puppy up!



    Here is a closer view of one the contours.



    Now - the above two pictures are on the ports that have been ported and contoured. On cylinder 5 we have continued to port all the way around the backside of the valve stems. This will be more compressed air onto the back side of the valve when under boost. It looks a bit rough as it is still work in progress, but once smoothed out and polished... it will look pristine.



    This is a shot up the mock cylinder on the air flow machine of cylinder 5. Not all to sexy, but this is the view your piston gets all day... just a bit darker.



    Well, I have some other goodies to post but that will be for tomorrow. Calling it a day.

    Scott C.
  11. ultra_runner

    Sep 21, 2006

    By ultra_runner,

    This thread not be dead!!!

    The Project is still alive. I just needed to devote some time to other priorities that popped up, etc. However, I think it's time to start bringing thing together and get this sucka running.

    So, an update. I've got all the guages installed and wired up into the dash. I fixed a jeweled headlight assy after breaking it trying to figure out a projector project that went sour. Anyway, got those back in.

    But for the meaty stuff. I got some of my polished parts back today. WOW is all I can say. Here are some teaser pics.







    Headed to the machine shop tomorrow AM (2 hours away... one way) to check the status. Schedule said everything was to be finished today and going to inspect the work. May still be waiting for the custom grind cams to come back from So. Cal. If everything is ready to go, then I just need to figure how to get it out of hawk (...hope he takes food stamps). Then Doug K. is going to start bolting it together and that is when the fun really begins. Hope to pick up the new Civinco unit from Doug tomorrow and get that at least wired in while the dash is still "open".

    Anyway, hope to get this thread back alive and get this thing runnin'!

    Scott C.
  12. ultra_runner

    May 28, 2006

    By ultra_runner,

    Just an update for today.

    I got the S60R shifter cable assy installed and routed up to the trans. I had to modify the mounting on the floor panel and went through about 20 of them flimsy Dremel cutting wheels. CJ is going to help me make some custom length connectors back on the shifter assy... then this part is done!



    Bing will soon be filling that empty spot below the gauge panel



    I've also been figuring out the wiring, cables, etc. and getting the front of the car back on. Here are the pics from today.

    It's starting to look like a real car again!!! Psychologically I had to put the front end back on the car and put the drivers seat in. This get's me thinking that I'm almost at the end!!!





    Later!

    Scott C.
  13. ultra_runner

    May 28, 2006

    By ultra_runner,

    Just an update for today.

    I got the S60R shifter cable assy installed and routed up to the trans. I had to modify the mounting on the floor panel and went through about 20 of them flimsy Dremel cutting wheels. CJ is going to help me make some custom length connectors back on the shifter assy... then this part is done!



    Bing will soon be filling that empty spot below the gauge panel



    I've also been figuring out the wiring, cables, etc. and getting the front of the car back on. Here are the pics from today.

    It's starting to look like a real car again!!! Psychologically I had to put the front end back on the car and put the drivers seat in. This get's me thinking that I'm almost at the end!!!





    Later!

    Scott C.
  14. ultra_runner

    May 27, 2006

    By ultra_runner,

    Got some work done today but I messed up with the camera. Forgot to put the memory card in so the pics are in internal memory and I need to download on my wife's PC. Will post later.

    Ok - today I embarked on the wire harness conversion as written up by Hank_Scorpio. Pretty straight forward but I still get the jitters cutting into a perfectly good wire harness assy. A couple of items.
    That harness is an oil and dirt trap right behind the fan. So I had to clean out the whole assy as I hate even knowing there is dirt and crud in there. Check all your connectors and wires carefully. I found some that were darn near close to breaking so I pulled them apart, re-soldered the connectors and put new loom on everything. I replaced the red 4gauge wires that go to the alternator and starter. Rather replace them now than later.
    Did I mention dirt???



    What the heck is this all about???



    I hope these are the wires I was truly supposed to cut



    Here is a fuzzy - unsexy pic of the results. I got the harness all reinstalled to the engine bay.



    I also installed Slater's upport torque mount and the AutoMeter temp gauges in the single-DIN panel. There is a great firewall pass-thru on the passenger side and the time sensors cleared with no problems.



    Ciao - Scott C.
  15. ultra_runner

    May 26, 2006

    By ultra_runner,

    Ok - took half a day off from work... ate some Indian food... took a nap and then worked on the car.

    So, I got all the M66 slave cylinder assy, piping, etc. ordered today. Also picked up a new accel cable assy to replace the one I broke . Gave a ring to the machine shop and greased the skids ($$$) to get them moving on my parts. I must have called 8 numbers trying to get someone who can get me a custom Sachs setup. Anyone out there have any connections, PM me please!

    I tied up some items in the engine bay and figured where I was going to run all the gauge wires through the firewall, etc. I've decided to put the front of the car back on for now. I wanted to keep it off while we got the engine, trans, IC mounted, etc. but I figure I can work around most of it if I am careful.

    I got all my ATP parts figured out... almost. Word to the wise to anyone who gets a new turbo exhaust housing. Always check inside. I found some left over burrs from when the drilled and tapped the housing. That sucker would fall off and go right down the throat. I wish ATP would check things like this more carefully.



    This is what the GT35R looks like with the .82 A/R housing and ATP's Ultimate Internal Wastegate setup. Notice how much wider the entire unit is compared to stock... thus I will need a custom 3" downpipe to be fabbed.



    Here it is looking into that ATP UIWG assy.



    I wish I still had that 16T laying around to do a side by side comparison



    Got lots of work to do over a three day weekend. Stay tuned.

    Scott C.
  16. ultra_runner

    May 13, 2006

    By ultra_runner,

    OK - a day under the car and a few skinned knuckles. What a way to spend a Saturday.

    Well, let's get at it... got the QBM lower torque mount, front IPD sway and QBM end links installed today. First - out with the old:



    Now - let's do some comparisons here. First, take a look at the IPD Sway compared to the stock sway. A noticable difference!



    Note the thickness. And YES the urethane matches my paint job



    Now let's do a compare of the endlinks. This is probably going to kill me when I try to sell these VMS links later but.... for the betterment of the VS community. Below we have....

    the stock endlink
    the VMS endlink
    and the QBM endlink

    No slander here but... SLATER for the WIN!



    While I had the front of the car jacked up (...plus me after a large coffee, a Krispy Kreme donut and 4 Red Bulls ), I pulled the control arms do that I could get the axles set into the M66. Seems to fit like a Latex Glove!!! Here is a pic of the front sway and endlinks installed:



    I also hacked out the old exhaust which will soon be up for sale to some new proud owner (teaser). Stock downpipe into a 2.5" pipe and into a Magnaflow CAT.



    Here is a pick of the whole exhaust including Stainless Magnaflow muffler. People have commented on the nice exhaust note from this setup. The buyer would just need a muffler shop to do two welds and you are GOLDEN



    Here are the components for the new exhaust. Starting from the right hand side:

    - the beginnings of a custom 3" downpipe
    - Magnaflow Stainless high-flow CAT
    - Magnaflow Stainless Resonator
    - HKS Stainless 120mm muffler

    All sections with have V-band flanges so that I can drop out components occasionally.



    And finally... I was going to keep this under my hat for the Davis meet. But since it is not running yet - I figured I would post what is soon to come!!! I figure it will take about a week for every COP in the south bay to remember that plate!



    EDIT: Now I have to make this project work, because I can't go back and change the plate to "Project 5"

    Tomorrow is another day.

    Scott C.
  17. ultra_runner

    Apr 25, 2006

    By ultra_runner,

    Dang guys.... I should have know Volvo guys are hockey fans too! Anyway, back on topic.

    Interior is 95% finished. I have not installed the drivers seat or center console because I am still working on cables. This weekend I applied sound deadening material to the entire trunk.







    I also applied a layer of OverKill foam matting to the rear deck to kill yet more sound. See that ball of black material in the background? I later used that up on top of the SD material in the trunk. Trunk is all assembled now, but my wife stole the camera while I was working on this stuff.



    Ok - I received in my IPD sways (nice!) yesterday. I need to install them this weekend along with VMS endlinks unless Slater can come through with his newer version soon.

    Scott C.
  18. ultra_runner

    Apr 21, 2006

    By ultra_runner,

    Ok - I'm back on this thing 'cause I'm tired of hearin' Pras' razzin' me!!!

    Well - this morning started early with a bit of jetlag. First thing I did was pull the rear bumper and the interior of the trunk. I completed the Walbro 255 retrofit with no problems thanks to a sweet deal from the UNDERLORD. I also got the trunk lid and part of the trunk lined with sound deadening material



    Ok - next was to finished painting black the last piece of trim which was the rear bumper. Unfortunately it is one big piece so it requires masking off very carefully. Great day for painting!!! Here are progress pics:





    And the finished product:



    Some other things I got done but was not worth taking pictures was getting the S60R rear mount installed and the bracket onto the M66. Next step is to rebolt that M66 up to the loaner block and drop it in the engine bay again. This SHOULD solve the rear mount problem. Once in there, I can work the shifter cable assembly appropriately. There is going to be some cut and weld action for that. Basically use the 850 shifter and cables but weld to the ends of the cables at the correctly adjusted length the S60R/M66 clips. Yes - Volvo used different sized clips!!! This should solve the shifter cable challenge.

    Tomorrow is another day.

    Scott C.

    PS - GO SHARKS!!!
  19. ultra_runner

    Mar 26, 2006

    By ultra_runner,

    Checking in... no I haven't been goofin' off.

    I've gotten the interior about 90% buttoned up... except for the pieces that I broke here and there.

    I did get CJ's ventilated block bolted up to the M66 and dropped into the bay so that I could figure out the cables, etc. WOW! - This sure is a shiney motor mount!!!



    Yesterday I was a bit under the weather thanks to Mr. Merlot. But I did get most of the interior back in play. Just need to tie up a few things here and there.

    Today - I went to work on the engine bay. Time to get clean in prep for the engine.... hopefully

    So boys and girls.... if you are going to clean your engine bay, this is the only right way to go!!!!







    OK - after a good degreasing and scrubbing... I carefully applied paint code 601 in all the right spots.





    When you paint... masking is the most important thing. Look at that!!!!



    Somewhat put together again at the end of the day.



    Now I need to modify the wire harness assembly for the Manual trans. So many things... so little time!!!

    Ciao

    Scott C.
  20. ultra_runner

    Mar 19, 2006

    By ultra_runner,

    Ok - Folks. A good friend of mine told me to take a look at the upper torque rod bushing... the one at the firewall. It's kind of funny how everyone looks that the front and they spend money on a poly bushing, etc. etc.

    Take a look at mine. There is nothing left of the bushing. You can see right through it!!! I guess the nice looking front poly bushing is meaningless if there is NO bushing left on the rear!!!



    WOW!!!

    Scott C.
  21. ultra_runner

    Mar 14, 2006

    By ultra_runner,

    Pistons and Rods - arrived today!!!

    The elusive Venolia .020 over forged pistons and SPM con rods arrived on my doorstep today as promised. Not much time to take a look at them. I'll sleep with them under my pillow tonight and they are being shipped off to the machine shop first thing in the morning. Can't wait to see all of this together!!!

    I also ordered my IPD sways today. If you don't know already - they are currently on sale!!!





    Scott C.

    Late Edit: I spent the evening pulling the headliner completely out of the car again so that I could get to the sunroof and fix the sliding cover. That mistake was costly in frustration and time. I got everything back in there. While I had the headliner out, I added a layer of Overkill sound deadening foam mat on the headliner. So many things - so little time.
  22. ultra_runner

    Mar 12, 2006

    By ultra_runner,

    I took Pras' advice and started pulling all the external molding and using Black Duplicolor bumper coating. I actually disassembled the side mirror so that I could get to the grey plastic parts only. I will post pics of the finished product. But I want to show everyone who keeps their ride nice and clean, what is look like under that side molding. For those clean freaks out there... it only takes about 2 minutes to take them off to clean underneath.



    Last week I got the passenger side door lined with a double layer of FatMat. Door is back together and I will apply one layer of the panel and one layer of SecondSkin's Overkill matting on the inside of the door cover. That should quiet things down quite a bit.



    Today I started focussing on the engine bay, etc. lying in wait for the engine. I noticed a bit of dirt behind the bumper so I had to CLEAN it! Honestly though, I needed to get the grey bumper cover off to apply black Duplicolor. I also need to install the new R bumper but needs to get painted first. Also got the radiator/intercooler assembly out as well as that front black piece. This will allow me to clean everything and make working in the engine bay a lot easier.



    CJ was gracious enough to lend me a "ventilated" block so that I can mount the M66 onto and figure out the shifter cables, rear mount, etc. Time to get started on that.

    Final pic for Pras - what makes you think I'm a VS For Sale forum slut???



    Ciao!

    Scott C.
  23. ultra_runner

    Mar 12, 2006

    By ultra_runner,

    No - haven't been goofin' off. Went to the Burger Ball yesterday and it was great to meet up with everyone again. Thanks to Pat and his folks for being such great hosts!

    Received in my new soon-to-be applied UR underdrive pulley. Everything went off last weekend to start getting machined. I should have the SPM rods and Venolia pistons in hand on Tuesday. Then - we're pretty much set for the engine build.



  24. ultra_runner

    March 4, 2006

    By ultra_runner,

    Ok - this morning I went over the hill and kicked Pat outta bed to do the Atlantis deal and pick up (finally Kevin ) my Erebuni sideskirts. Wasting no time and even bypassing a Starbucks, I rushed on home and threw them on the car to check them out. I gave everything a quick cleaning.

    I have pics with and without the side skirts, but basically once the engine is in the 18" Atlantis rims should look something like.... this PS mockup???



    Here is what is looks like today:



    The Erebuni side skirts gives an appearance of another 2" drop over the stock side skirts. Along with the new R bumper, this should look pretty hot! I'd need to get the CF lip with that too.



    Another angle of with and without the side skirts:





    Please no crap about I'm missing a window and a corner...

    Back to the project.

    Scott C.
  25. ultra_runner

    Feb 27, 2006

    By ultra_runner,

    Ok guys - I haven't been loafing off too much. I mentioned that I would try to get the dash in on the weekend and I didn't post yesterday. Well, that is because I ran into a couple more things with the dash and I took a jaunt up to CJ's place. Awesome guy and an awesome 855!!!

    SO notice this cracked up defrost vent panel. You know... if I have the sucker out and I've done all this work, I just can't put it back in there and stare at those cracks.



    So I took another day to do something about it. I sent the wife on a mission (...to find a new wife. Just kidding). I needed 6 feet of good quality black felt. I made a quick attempt of covering that plastic part and it looked really good.



    OOoopsss... but then I thought about it. Will the air really vent through that felt effectively??? If I put in on high, will the felt puff upward or come completely out??? So I sprayed some 3M heavy duty glue under it. Dummy me... I just pushed it right down and the glue seeped through and left a splotch about as appealing as a Monica Lewinski evening dress . There has to be a better way than this. So... out it came (... uhhh... no pun intended).

    So first mask off the areas you don't want the 3M heavy duty spray glue.



    Then I tuck the felt into the seem of the vent assembly and the dash. Nice and tight. I basically used my handy dandy flexible PPO insurance card but a Costco card may work similar results.



    Now I shoot a bit of that glue on there and let it setup about 2 minutes. Nice and tacky... just like Monica (man I kill myself!!!! ).



    Then I just lay up the felt and tuck it into the top seems. Felt goes down and stays down. Just trim out the edges.



    I then took a very sharp Xacto knife (cause felt doesn't like to cut in straight lines) and I cut along the seam of the vent holes. Using my insurance card, I tucked the edges down into the vent between the little vent tabs. Holds great.... I hope!!! Here is a pick of the finished product. Those small slotches actually disappeared over night



    A couple of keen reminders:

    Do not use a valid insurance card. I now have to request a replacement one!
    Do not hold a very sharp Xacto knife in your mouth... not even for a moment.
    Do not huff the glue fumes until AFTER your project is complete!

    OK, so I let all that glue setup and cure over night. I came home early today and I wrestled the dash back into the car. Not fun, but looks great. Again, everything was cleaned with Simple Green and a toothbrush before reinstalling. I shot that felt with some ScotchGuard hopefully to kill all them Gamma rays from the sun that might fade that felt. Here it is. I still gotta wire up everything, but this was enough for one night!!!



    Ciao - Scott C.
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