Simply Volvo Posted August 2, 2020 Author Report Share Posted August 2, 2020 Built M58 : M66 Quaife, Reinforcement plate for bearings, P1 M56H 4.25 (strongest volvo gearset out there & steel synchros) and a custom mount to adapt it to the P80 FWD subframe / steering rack. 3 Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 3, 2020 Report Share Posted August 3, 2020 Nice work! I could have told you better to check the freeplay / movement in gears using either the assembled AG, an axle or even an old clutch disc- as you found, hold the input shaft you don't have enough leverage to overcome the gear ratios With the oil drain, better to avoid 90's - if you can keep a slight downhill all the way it's gonna be better - remember that you are dealing with oil foam when running high load/rpm, not just oil flow. 1 Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 3, 2020 Author Report Share Posted August 3, 2020 (edited) 48 minutes ago, lookforjoe said: Nice work! I could have told you better to check the freeplay / movement in gears using either the assembled AG, an axle or even an old clutch disc- as you found, hold the input shaft you don't have enough leverage to overcome the gear ratios With the oil drain, better to avoid 90's - if you can keep a slight downhill all the way it's gonna be better - remember that you are dealing with oil foam when running high load/rpm, not just oil flow. Thank Hussein! Yes the oil drain is something I need to continue playing around with. I found this piece which might order up and try. Its a flexible turbo oil drain. It might allow me to get a better angle off the turbo. Then I can weld on an AN fitting or something. https://www.summitracing.com/parts/bdd-1453106 On a side note... Hussein I kinda remember the mods you made to your AWD fuel pump sender to fit a DW300 but all of the links to the pictures are dead... from what I remember the pump outlet fits the sender fine, but you had to make a spacer on the pump inlet in order to hookup the strainer screen? Do you remember the ID of that spacer? Edited August 3, 2020 by Simply Volvo 1 Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 4, 2020 Report Share Posted August 4, 2020 I wouldn't use corrugated tube - I did try that for a couple versions - the corrugations are not helpful for oil foam I just found a piece of thin wall aluminum tube that was a snug fit over the inlet - I never made a note of it, sorry Add the safety ground sleeve - and + - are reversed. Cut a small opening in the underside of the case near the bottom (not shown), since the DW has no secondary pickup for fuel residing inside the pump housing 1 Quote Link to comment Share on other sites More sharing options...
andyb5 Posted August 4, 2020 Report Share Posted August 4, 2020 Matt, for the dw300 install - Ben McNally (@B Mac) sells custom-machined sleeves to fit the pump into the stock pickup. He has them ready to ship if you shoot him a message. I bought one for my car that I hope to install soon Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 4, 2020 Author Report Share Posted August 4, 2020 1 hour ago, lookforjoe said: I wouldn't use corrugated tube - I did try that for a couple versions - the corrugations are not helpful for oil foam I just found a piece of thin wall aluminum tube that was a snug fit over the inlet - I never made a note of it, sorry Add the safety ground sleeve - and + - are reversed. Cut a small opening in the underside of the case near the bottom (not shown), since the DW has no secondary pickup for fuel residing inside the pump housing Thanks for always taking the time to write up such details posts. I appreciate the insight & help greatly. I made some progress on the oil drain tonight. Ill post up a few pictures when I get things tacked up. I was able to use some 1" OD aluminum tubing to basically shoot the drain directly towards the firewall and then 180 around and switch to 12AN braided hose. It mains a downhill the entire time including when its going towards the fire wall and bending around the 180. The FWD 12AN drain to the oil pan was so much easier & worked so freaking well! Oh well though, there is a lot going on back there with the turbo and angle gear so its going to take some extra work. 1 hour ago, andyb5 said: Matt, for the dw300 install - Ben McNally (@B Mac) sells custom-machined sleeves to fit the pump into the stock pickup. He has them ready to ship if you shoot him a message. I bought one for my car that I hope to install soon Thanks! I set him a message on Facebook. 2 Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 6, 2020 Author Report Share Posted August 6, 2020 New clutch. Its lighter than a feather and I got it setup perfect! 1 Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 14, 2020 Author Report Share Posted August 14, 2020 Got me a rear subframe almost fully installed... 1 Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 18, 2020 Report Share Posted August 18, 2020 Why not just make a short feed line from the surge tank to the line you already made? Then you wouldn't need to run a new line all the way to the FPR/rail.... Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 18, 2020 Author Report Share Posted August 18, 2020 (edited) 3 hours ago, lookforjoe said: Why not just make a short feed line from the surge tank to the line you already made? Then you wouldn't need to run a new line all the way to the FPR/rail.... Thats what I ended up doing. My OCD was getting in the way of just extending the existing lines that run up to the bay. What a pain running the lines to the surge tank with the AWD subframe and tank. Such little room between the top of the subframe and body. Took quite some time to make sure nothing was pinched / kinked. Edited August 18, 2020 by Simply Volvo Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 21, 2020 Author Report Share Posted August 21, 2020 Finished up the fuel lines. Had to do some clerancing in body to make those bastards fit. 😄 Quote Link to comment Share on other sites More sharing options...
ryan850-t5 Posted August 21, 2020 Report Share Posted August 21, 2020 More powah! Nice work Matt 👍👍 1 Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 22, 2020 Report Share Posted August 22, 2020 Coming along nicely. So much crap to organize w/AWD. To save yourself some grief - DON'T use copper/alloy line for the exhaust back pressure setup - it will fail. Use stainless brake line & stainless fittings Also make sure to add a water trap, or the condensate will kill whatever sensor/gauge you use overtime 1 Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 24, 2020 Author Report Share Posted August 24, 2020 On 8/22/2020 at 8:10 AM, lookforjoe said: Coming along nicely. So much crap to organize w/AWD. To save yourself some grief - DON'T use copper/alloy line for the exhaust back pressure setup - it will fail. Use stainless brake line & stainless fittings Also make sure to add a water trap, or the condensate will kill whatever sensor/gauge you use overtime Yes there is sooo much crap to organize with the AWD, especially when the car never had it in the first place! I will order up some SS fittings & lines from McMaster. Thanks for the advice. 1 Quote Link to comment Share on other sites More sharing options...
Simply Volvo Posted August 27, 2020 Author Report Share Posted August 27, 2020 (edited) Finished final assembly on the last big hurdle that was holding me back from putting the engine back in and starting the car. Edited August 27, 2020 by Simply Volvo 2 Quote Link to comment Share on other sites More sharing options...
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