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голубой вагон (Blue Wagon) 1986 245GL
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OKflyboy Offline
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Post: #26
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-01-2012 08:54 PM)thebornotaku Wrote:  you did your exhaust a lot like mine, except i cut off the last bend and put a 18" bit of straight pipe there so it still exits out the back.

looks good though man. keep it up.

(01-02-2012 11:08 AM)Coupe' de Tat Wrote:  
(12-29-2011 06:49 PM)blu92in99 Wrote:  Damn, from zero to hero in short order. Well done! Can't wait to see the +T results.

this! some quality work there, nice save

Thanks guys!

Got a little more work done tonight. I wired up the e-fan a couple of days ago, but it was a quick down-and-dirty job just to make sure everything was going to work right. So tonight I redid the wiring to make it look more professional.

Volvo 850 2-speed relay. Originally had the relay just clipped to the shroud itself, mainly because the wires from the fan were too short to put the relay anywhere else. So the solution was to extend the fan wires. Here's the relay's new home:

   
   

This is an Autozone SW533 temp switch. Its got a cooler temp trigger then the 740 "overheat" fan switch, though I can't find the numbers right now (will update when I can find them) Its connected to the low speed portion of the relay.
   

I have a switch inside the cab that will trigger high speed if needed but so far its running so cool that even low speed hardly needs to come on (I'm certain that will change with the weather, however):
   

The e-fan in all its glory:
   
(This post was last modified: 01-09-2012 02:34 PM by OKflyboy.)
01-06-2012 01:14 AM
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Redwoodchair Offline
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Post: #27
RE: голубой вагон (Blue Wagon) 1986 245GL
Nice work.
Looks like you are missing the belly pan, and likely the air pickup panel out front.
Those will do a lot to keep the engine clean and direct the airflow, as much or more than the fan which really only works at low speed.

All Hat No Cattle.

[Image: volvo_10.jpg]

01-06-2012 01:44 AM
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thebornotaku Offline
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Post: #28
RE: голубой вагон (Blue Wagon) 1986 245GL
Speaking of which, Ken, How hard do you think it would be to fabricate a pick-up, out of sheetmetal or something? If it really as helpful as you say it is (which I would assume is true), it would serve me well to have one...

1985 Volvo 245DL "The Battlewagon"
1974 Volkswagen Super Beetle "Diego"
01-06-2012 02:13 AM
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Redwoodchair Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 02:13 AM)thebornotaku Wrote:  Speaking of which, Ken, How hard do you think it would be to fabricate a pick-up, out of sheetmetal or something? If it really as helpful as you say it is (which I would assume is true), it would serve me well to have one...
Ever notice the newer rounded cars have small grills and mostly use air pickups to catch the air being compressed under the car?
The rounded nose it throwing the air up and over the car anyway so there's not much point in a big grill per se.

Not too hard at all.
Part of my 5 dollar & an hour per modification program on the 86 245 Blacknose.

It took me just about 2 hours for the pan, pickup and screen.
An old stainless BBQ hood, and the sawsall, although the jig saw with a metal blade would have been more controllable.

[Image: Blacknosestainlessairpickupandbelly.jpg]

Stays are fashioned from stainless bicycle rack straps.

[Image: AirPickupStay.jpg]

And an hour for the braces.

[Image: Blacknosebraces-2.jpg]

Throttle spool clearance was @1/4".

[Image: BlacknoseBracesThrottleSpoolClea-2.jpg]

All Hat No Cattle.

[Image: volvo_10.jpg]

(This post was last modified: 01-06-2012 02:54 AM by Redwoodchair.)
01-06-2012 02:51 AM
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OKflyboy Offline
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Post: #30
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 01:44 AM)Redwoodchair Wrote:  Nice work.
Looks like you are missing the belly pan, and likely the air pickup panel out front.
Those will do a lot to keep the engine clean and direct the airflow, as much or more than the fan which really only works at low speed.

Yep, Gabe mentioned the exact same thing at work yesterday. I think I'm going to pick up a belly pan from IPD very soon.

(01-06-2012 02:51 AM)Redwoodchair Wrote:  Ever notice the newer rounded cars have small grills and mostly use air pickups to catch the air being compressed under the car?
The rounded nose it throwing the air up and over the car anyway so there's not much point in a big grill per se.

Not too hard at all.
Part of my 5 dollar & an hour per modification program on the 86 245 Blacknose.

It took me just about 2 hours for the pan, pickup and screen.
An old stainless BBQ hood, and the sawsall, although the jig saw with a metal blade would have been more controllable.

[Image: Blacknosestainlessairpickupandbelly.jpg]

Stays are fashioned from stainless bicycle rack straps.

[Image: AirPickupStay.jpg]

Very cool! I think I see a DIY air pickup mod in store for the Blue Wagon!
(This post was last modified: 01-06-2012 08:45 AM by OKflyboy.)
01-06-2012 08:44 AM
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OKflyboy Offline
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Post: #31
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 01:14 AM)OKflyboy Wrote:  This is an Autozone SW533 temp switch. Its got a cooler temp trigger then the 740 "overheat" fan switch, though I can't find the numbers right now (will update when I can find them) Its connected to the low speed portion of the relay.

Found it! Its a direct cross of a NAPA FS150: on 87, off 82 C (198/188F)
(This post was last modified: 01-09-2012 02:35 PM by OKflyboy.)
01-06-2012 08:53 AM
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arnoroth661 Offline
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Post: #32
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 08:44 AM)OKflyboy Wrote:  I think I'm going to pick up a belly pan from IPD very soon.

Hurry up and wait! I ordered in the middle of December and am still waiting on my card to be charged for the belly pan.. Violin
01-06-2012 09:59 AM
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OKflyboy Offline
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Post: #33
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 09:59 AM)arnoroth661 Wrote:  
(01-06-2012 08:44 AM)OKflyboy Wrote:  I think I'm going to pick up a belly pan from IPD very soon.

Hurry up and wait! I ordered in the middle of December and am still waiting on my card to be charged for the belly pan.. Violin

Lame...

I'm currently having the same problem with Jegs. I ordered a Grant wheel install kit on 12/8 (I think) and its still not here yet. After two delivery promises had come and gone they finally stopped promising anything, they are now estimating a ship date of 1/19 but I'm not holding my breath. rant
01-07-2012 11:47 PM
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thebornotaku Offline
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Post: #34
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 08:53 AM)OKflyboy Wrote:  
(01-06-2012 01:14 AM)OKflyboy Wrote:  This is an Autozone FS533 temp switch. Its got a cooler temp trigger then the 740 "overheat" fan switch, though I can't find the numbers right now (will update when I can find them) Its connected to the low speed portion of the relay.

Found it! Its a direct cross of a NAPA FS150: on 87, off 82 C (198/188F)

Any idea if this will fit in the Saab T-fitting? I would love to drop my switching temp...

edit\\

also I can attest to the usefulness of the air pickup, my fan doesn't come on at all now when the car is in motion, vs. occasionally, and the temps stay nice and cool.

1985 Volvo 245DL "The Battlewagon"
1974 Volkswagen Super Beetle "Diego"
(This post was last modified: 01-08-2012 01:36 AM by thebornotaku.)
01-08-2012 01:35 AM
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OKflyboy Offline
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Post: #35
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-08-2012 01:35 AM)thebornotaku Wrote:  
(01-06-2012 08:53 AM)OKflyboy Wrote:  Found it! Its a direct cross of a NAPA FS150: on 87, off 82 C (198/188F)

Any idea if this will fit in the Saab T-fitting? I would love to drop my switching temp...

I don't know much about the Saab T-fitting, to be honest. Though if the Saab fitting is also 22mm then I don't see why not...

(01-08-2012 01:35 AM)thebornotaku Wrote:  edit\\

also I can attest to the usefulness of the air pickup, my fan doesn't come on at all now when the car is in motion, vs. occasionally, and the temps stay nice and cool.

Cool. I will definitely add one whether it be a new one from IPD or a DIY version like Redwood's.
01-08-2012 02:08 AM
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thebornotaku Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
(01-08-2012 02:08 AM)OKflyboy Wrote:  
(01-08-2012 01:35 AM)thebornotaku Wrote:  Any idea if this will fit in the Saab T-fitting? I would love to drop my switching temp...

I don't know much about the Saab T-fitting, to be honest. Though if the Saab fitting is also 22mm then I don't see why not...

22mm... bolt head size? I don't know what the size of the fitting is, though I have a set of big sockets I could use to check. Maybe when I get some free time I'll swing by AutoZone and see...

(01-08-2012 02:08 AM)OKflyboy Wrote:  
(01-08-2012 01:35 AM)thebornotaku Wrote:  edit\\

also I can attest to the usefulness of the air pickup, my fan doesn't come on at all now when the car is in motion, vs. occasionally, and the temps stay nice and cool.

Cool. I will definitely add one whether it be a new one from IPD or a DIY version like Redwood's.

I got one from the JY for $4, it's held on with all of four bolts and came out in under a minute with my little cordless rattle gun. Likewise, I installed it in under a minute with said rattle gun, easily the quickest and most effective mod to my car that I've done to date.

1985 Volvo 245DL "The Battlewagon"
1974 Volkswagen Super Beetle "Diego"
(This post was last modified: 01-08-2012 03:13 PM by thebornotaku.)
01-08-2012 03:12 PM
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OKflyboy Offline
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Post: #37
RE: голубой вагон (Blue Wagon) 1986 245GL
(01-08-2012 03:12 PM)thebornotaku Wrote:  22mm... bolt head size? I don't know what the size of the fitting is, though I have a set of big sockets I could use to check. Maybe when I get some free time I'll swing by AutoZone and see...

No, I believe its the threads that are 22mm.

(Sorry, I'm kind of a Volvo noob. This 240 is my first Volvo, and I've only had it 11 months.)

(01-08-2012 03:12 PM)thebornotaku Wrote:  I got one from the JY for $4, it's held on with all of four bolts and came out in under a minute with my little cordless rattle gun. Likewise, I installed it in under a minute with said rattle gun, easily the quickest and most effective mod to my car that I've done to date.

Nice! Well there's a 92 240 in one of the local yards. Its been there a few weeks, so it might be picked clean by now, but there's only one way to find out...
01-08-2012 03:42 PM
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arnoroth661 Offline
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Post: #38
RE: голубой вагон (Blue Wagon) 1986 245GL
I would have taken the last plastic belly pan I saw at a yard, it was mostly intact, too... but it was being used as a second oil sump for the front engine seals. Tongue

Is that one of 'dem Spectre cone filters?
01-08-2012 04:13 PM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
(01-08-2012 04:13 PM)arnoroth661 Wrote:  I would have taken the last plastic belly pan I saw at a yard, it was mostly intact, too... but it was being used as a second oil sump for the front engine seals. Tongue

lol. Around here they seem to use hoods - as oil drain pans, creepers, even makeshift bridges over mud puddles.

(01-08-2012 04:13 PM)arnoroth661 Wrote:  Is that one of 'dem Spectre cone filters?

Yessir.
01-08-2012 04:28 PM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
Guess what today is? The third shipping estimate that Jegs had given me. And... the third shipping estimate that Jegs is going to blow right through apparently.

I called Jegs to get an update and they say the install kit is still on backorder, they didn't even bother with an estimated shipping date this time, now they just saying "three to four more weeks".

<sigh>

Well, not too much else to report. School started again, so between work and night school I don't have much free time however once I get my tax return and can buy the remaining pieces we will be +t-ing no matter what.

Stay tuned.
01-19-2012 06:01 PM
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scottyd Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
*cough* summit *cough*

'97 GMC K2500 Suburban 6.5TD - FailBus
'84 245GLT - FailWagon
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01-19-2012 06:11 PM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
(01-19-2012 06:11 PM)scottyd Wrote:  *cough* summit *cough*

Thought about it, but it wouldn't matter, Grant themselves are out.
01-19-2012 10:43 PM
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thebornotaku Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
(01-19-2012 10:43 PM)OKflyboy Wrote:  
(01-19-2012 06:11 PM)scottyd Wrote:  *cough* summit *cough*

Thought about it, but it wouldn't matter, Grant themselves are out.

sell the grant & get a momo, then pick up a 240 hub on sleazebay or from Ben. Plus, Momo's 6-bolt pattern is used by a lot of people

I've been meaning to do just that and fit my go-kart sized wheel

1985 Volvo 245DL "The Battlewagon"
1974 Volkswagen Super Beetle "Diego"
01-20-2012 11:37 PM
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arnoroth661 Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
(01-06-2012 09:59 AM)arnoroth661 Wrote:  
(01-06-2012 08:44 AM)OKflyboy Wrote:  I think I'm going to pick up a belly pan from IPD very soon.

Hurry up and wait! I ordered in the middle of December and am still waiting on my card to be charged for the belly pan.. Violin

Just an update.. Looks like they might be receiving the pan tomorrow. runaway

So, hurry up and wait! Tongue
01-26-2012 02:37 PM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
Been a while since I've been able to work on my wagon, attempting to return to school full-time while still working a full time job takes its toll. runaway Fortunately one of my classes is only 8 weeks long, and will be over next week.

Ahhhhh...

In the meantime my garage has been filling up with parts. I now have an IPD belly pan, one of DavidSamuels heater-control valves (looks very nice BTW), I bought the Grant 773 back but still haven't received the install kit, I have all the parts I need for the turbo swap except the turbo cooling lines, and I also have an IPD turbo cam and here's a taste of things to be done (hopefully) next weekend:

   

So stay tuned!
(This post was last modified: 02-24-2012 01:40 PM by OKflyboy.)
02-24-2012 01:38 PM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
The last 36 hours have been some of the most productive in months.

Yesterday morning I decided to go boneyard hunting. I didn't have a whole lot of luck with Volvo-specific parts, but I did manage to score a set of 52mm VDO gauges out of a 90 VW Cabriolet:
   

Last night removed the radiator in preparation of the intercooler install:
   

then gave a few parts some fresh paint:
   
   
   
03-03-2012 12:29 AM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
Gabe came over to hang out and we installed the intercooler:
   

Then this morning, since the coolant was drained anyway, I went ahead and installed my DavidSamuels heater control valve:
   

Then Gabe came over again to help me install my new IPD Turbo cam with one of Dale's cam gears:
   

Removing old cam/gear:
   

Installing new cam/gear:
   
03-03-2012 12:37 AM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
And finally - All together again:
   
   

Yes, for those of you who noticed, the blue valve cover (picture a few posts above) is missing. That's because I tried to get clever and polish the raised letters and effed it up pretty bad. So I tried to respray it and effed that up too! Damn So its on its way home with Gabe to get bead blasted again, and we just reinstalled the original for now...

Anyway, took her out for a test drive now and there is a marked difference. I was hoping that advancing the cam-gear would help me pick up something low-end but I didn't get much, OTOH not knowing what to expect we only advanced it 2 degrees. The cam, however made a HUGH difference in the top end, it revs higher and practically takes off after 4200. Now this is still a NA car, mind you, so I was surprised at the power in gained in the upper end with just a cam change...
(This post was last modified: 03-03-2012 12:57 AM by OKflyboy.)
03-03-2012 12:42 AM
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dl242gt Offline
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Post: #49
RE: голубой вагон (Blue Wagon) 1986 245GL
Nice project! N/a in my 93 wagon. I run my cam advanced 4 degrees. It brought the power band down a bit and has plenty of low rpm torque to get around. The power increase starts at midrange and goes up to high rpms as you noticed. Volvo was very conservative to the point of choking off the engine with the stock US cams. I want to turbo my wagon sometime in the near future. I will leave the n/a enem V15 cam in there.

1982 242 turbo. MVP coilover front and rear suspension. Bilstein HD. IPD 25/25 bars. 3" MVP exhaust. Cosworth Sierra hot side T3 .48 with upgraded stock .42 compressor. Ported 90+.True Track diff. Flat hood, 1979 front grill, 2 screw Hella Ecode park/turn lights with H4 Hella headlights. 321k miles.

1993 Classic Edition wagon 5spd 341k miles.
03-03-2012 01:58 PM
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OKflyboy Offline
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RE: голубой вагон (Blue Wagon) 1986 245GL
Thanks man! Shouldn't be too much longer till we're ready to +t!

Today I used "Restore Black" to redo the faded lower trim. All in all I think it came out great:
   

And here's a teaser of what's next:
   
(This is just a test fit for length, there's no ends on the distributor side yet)
03-04-2012 07:05 PM
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