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1980 242 GT T5 swap. An unreasonable pursuit.

The Full Banana

The Full Banana

Drive, Revive, Tinker
Joined
Apr 15, 2007
Location
Lake Mills, WI, USA
Check it out on YouTube:
www.youtube.com

Volvo 242 with T5 engine swap

Videos showcasing my 1980 Volvo 242 GT with a b5234t T5 engine swap, Getrag transmission, Porsche brakes, and more.
www.youtube.com www.youtube.com

50027853741_3e729bb9d7_b.jpg


A brief history, linked to posts in thread:

Building your own 240 T5? This might help:

Current 5 Cyl Setup (2016+)
  • Engine
    • '99 S70 T5 (B5234T) block with crankcase windows & liners shimmed
    • Wiseco 81.5mm pistons & rings
    • Maxspeeding 139.5mm H-beam rods
    • '98 850 T5 (B5234T) head lightly ported
    • NA cams (timing: intake 7 deg ret. & exhaust 5 deg adv.)
    • 960 oil pan & transfer tube shortened & rewelded in middle; 10an & 1/8NPT ports welded on for turbo drain & oil temp
    • '07 S60R intake manifold w/ plenum shortened to clear PS pump
    • '07 S60R ethrottle valve
    • Saab ethrottle pedal (Hella 6PV 010 946-141)
    • Modified S70 fuel rail (machined for factory FPR, bungs welded on for 6AN inlet & 1/8NPT pressure sender)
    • '98 850 T5 (B5234T) 3 bar FPR
    • ATP C30 cast exhaust manifold ceramic coated with Cerakote Air Cure
    • Turbosmart 38mm external wastegate
    • Garrett GTX3067R with ceramic coated .82 A/R turbine housing
    • CX Racing Evo VIII intercooler (32"x12.5"x3.5" with 2.5" inlet/outlet)
    • Gates Racing kevlar timing belt
    • Volvo 260 Diesel passenger side engine mounts on one-off brackets
    • S60 PWM cooling fan
    • Full 3" TIG welded 304SS exhaust with a cat and 2 Vibrant mufflers
    • 92+ 940 NA radiator
    • Mann Provent oil separator (returns to pre-turbo intake pipe; drains to oil pan with check valve)
    • Bosch FR7DPP+ spark plugs
  • Engine Management
    • MaxxECU Race with lambda, knock, and EGT monitoring built in. Custom wiring harness.
    • Previously: MS3x w/ knock module, 4 bar MAP, dual VR conditioner added in
  • Driveline
    • Getrag 265 5 speed manual transmission w/ removable bellhousing
    • Volvo 960 bellhousing from auto trans
    • One-off adapter plate connecting trans & bellhousing
    • e46 M3 rubber transmission mounts
    • Sachs 240mm full-faced clutch disc from BMW e34 M5
    • e36 M3 / e34 M5 giubo
    • lengthened m47 front driveshaft
    • 940 driveshaft support bushing with j9fab bracket
    • modified getrag 265 shifter bracket mounted with e46 m3 trans mount
    • garagistic DIY shift selector, shift selector joint & tall shift lever
    • Tilton 60-1100 hydraulic release bearing
  • Suspension
    • Front
      • GAZ Gold coilovers + 336lb x 8" main springs & 6" helper springs
      • Homerbuchka camber plates
      • Control arms boxed with Yoshifab plates fitted with STS Machining delrin bushings
      • Kaplhenke V2 QSRC spacers with adjustable Ackerman
      • GT firewall braces
      • cravingboost big strut brace
      • iPd lower chassis braces
      • STS Machining 28mm drop swaybar
    • Rear
      • Shortened trailing arms (20mm shorter)
      • Speedway 5" adjustable spring perches
      • 200lb x 5" x 9.5" main springs
      • Gaz adjustable shocks, 40mm shorter
      • factory rear swaybar
      • Kaplhenke hybrid torque rods with Volvo bushings
      • iPd adjustable panhard bar
      • Genuine Volvo front trailing arm bushings
      • Kaplhenke spherical rear trailing arm bushings
  • Brakes
    • S60R front & rear rotors (330mm)
    • '05 Porsche Cayenne V8 front calipers (6 piston)
    • '05 Porsche Cayenne V8 front calipers (6 piston)
    • Homer's caliper & brake line adapter kit
    • iPd braided stainless 240 brake lines
    • Bosch Quietcast pads
    • '94 Ford Mustang Master Cylinder w/ 240 reservoir
  • Wheel/Tires
    • BBS RC305 17x9 et32 w/ motorsporttech adapters (38mm front, 32mm rear) w/ 245/40R17 Pirelli P Zero Nero GT
  • Interior
    • Recaro LS-B seats from mkII VW reupholstered in black leather with new bolster foam
    • GT door cards
    • Flocked 1987 240 dash
    • Momo 360mm leather steering wheel & horn pad a la Volvo R-Sport on Momo hub with 2.5” spacer
    • Rattletrap (sound deadener) below 1/8" closed-cell foam (decoupler) below 1lb/sq ft mass-loaded vinyl (sound barrier) below factory black carpet
  • Exterior
    • 7" round H4 ecodes with 12 gauge harness powered by high & low relays in sealed relay box
    • GT fogs with 12 gauge harness and 100w bulbs powered by relay in sealed relay box
Click to expand...
 
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I'm excited to see Brian's 242 live on, but I reeeeally love your wagon.... That color/wheels/ overall fitment, it's just right.

Good luck with this beastie, ill keep an eye out for this
 
Yeah the rattle can job sucked. I just touched it up as I scratched it.
That car is a engine slut. Is this your basic goal? It was a fun setup.
<a href=http://s265.photobucket.com/albums/ii234/2fast242gt/?action=view&current=PICT0002-1.jpg target=_blank><img src=http://i265.photobucket.com/albums/ii234/2fast242gt/PICT0002-1.jpg border=0 alt=></a>
 
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Great angle in the pics. Keep that hood up and fender off, haha.

Let me know when you need a hand with the engine and stuff!

Also, what happened to 50 shades of grey as the thread title?
 
New car, new thread.

This will be the continuation of my wagon project which you can see here --> http://forums.turbobricks.com/showthread.php?t=257147. Pretty much everything from that car will be swapped into this shell. The primary difference is that now I incorporate the goals of having a nice interior and body.

My goal:
The car needs to do everything as I personally expect it should to make for an enjoyable driving experience. If something stands out as being subpar, I will attempt to fix it to make it good. This is my all-inclusive, wholly subjective metric.

-It needs enough power to get out of it's own way and justify the suspension. ~230-250rwhp should be plenty, but that yet remains to be seen.
-It must handle well, but also be street-able enough for me to happily drive to work in the summer, around town casually, and on a long trip to iPd.
-It has to look 'good', but in doing so also give minimal concessions to drivability (no scraping, no rubbing, etc).
-The interior needs to be a nice place to be (quiet-ish, comfortable, and pleasing to look at).


Anyways, this was Brian's (2fast242gt) old shell that was graciously donated to me. A huge thanks to him for this, and for saving me from wallowing in my rusty-shelled misery.

Here is my starting point, after rolling off the trailer and a quick wash.

IMG_3604_web_zps92712d87.jpg





With that, the work begins.

Pulled the front apart to begin prepping the engine bay for paint. It was rattlecanned black, and was in really poor shape.
IMG_3648.jpg


IMG_3655.jpg


Spent a good portion of the day removing the paint. Not fun.
IMG_3668.jpg


IMG_3669.jpg


I pulled the dash the other night. I will be swapping in the dash from the 87 after I fix it up.
IMG_3650.jpg


And now it's time to replace the destroyed window scrapers. Thanks Ken for shipping so quickly.
IMG_3677.jpg


------

Old Iron said:
This will be a cool project! What's wrong with the wagon.
Click to expand...

Rust and just a generally haggard shell.

smith_t240 said:
Great angle in the pics. Keep that hood up and fender off, haha.

Let me know when you need a hand with the engine and stuff!

Also, what happened to 50 shades of grey as the thread title?
Click to expand...

Yeah, that just reminded me to order paint. Thanks for your help with the initial work in getting the car. I'll let you know when I'm thinking it's time for the engine to go in--probably a couple weekends from now. 50 shades of grey was swept under the rug after I decided to make paint a higher priority.


Anyways, cleaned up and painted the valve cover. This was in this car the last time it had a 8v redblock in it. Brian modified it to work with a 530 head years ago.
IMG_3692.jpg


I took Redwood Chair's advice and ordered SprayMax 2k primer and clear coat. I used the POR Prep & Ready to take care of some flash rust that showed up in the past couple days. I'll reapply it to prep before priming.
IMG_3682.jpg


I used the clear coat on the GT grille and headlight surrounds after repainting them black just now. That stuff is pretty great.

Tomorrow I'll finish prepping the engine bay, and then lay down the SprayMax 2K epoxy primer.
 
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I'm thinking about it.

I like the letters sanded on the newer style valve covers with the larger lettering, but on these old covers with small lettering I think it might be best as-is.
 
where did the car get flash rust? engine bay? i have some ooolldd pictures of this car and I when i was like 17, so I may photobomb this thread sometime. if you need help anytime or just want to hang out let me know! id love to help.
 
Old Iron said:
Dang, whats the address, I am shipping you a valve cover for you do do for me! Look forward to more from this thread!
Click to expand...

Maybe if I get bored I'll use the extra paint on a spare 530 valve cover. If I do, I'll shoot you a PM.

2fast242gt said:
where did the car get flash rust? engine bay? i have some ooolldd pictures of this car and I when i was like 17, so I may photobomb this thread sometime. if you need help anytime or just want to hang out let me know! id love to help.
Click to expand...

Yeah, just a tiny bit in the engine bay which was to be expected. I will be finishing up the rest of the engine bay prep and priming tomorrow. I would definitely appreciate some help when it gets to be time to drop the engine in the car, but that will be a little while yet. I'll probably be working on it pretty much every weekend, with a little tinkering on weeknights. Stop on over!

I've been ordering so much stuff for this lately. Lots of little stuff, but quite a steady stream. Excited to get everything in!
 
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Really nice job!:)Keep on going!

The rust/crash fix on the driver side doesnt look so nice, planning on changing that while your at it?
 
2fast242gt said:
Awsome! Did you score a new grill? Or did you paint my old one? Looks very nice I like the progress.
Click to expand...

Same old grille, just cleaned up and painted

smith_t240 said:
The foundation to greatness.

Great progress on stripping the bay and getting some stuff painted. Should we do a double header engine swap weekend? I am finally getting what I need for the new longblock.
Click to expand...

Thanks. Double header sounds rough... but yeah, let's get cranking. The whole non-running car thing is lame.

volvobrage said:
Really nice job!:)Keep on going!

The rust/crash fix on the driver side doesnt look so nice, planning on changing that while your at it?
Click to expand...

Thanks! I would like to change it, just trying to figure out the best way to go about it. Some day I will have to buy a welder and learn to use it.
 
The Full Banana said:
Thanks! I would like to change it, just trying to figure out the best way to go about it. Some day I will have to buy a welder and learn to use it.
Click to expand...

Look how I did it in my project thread:)If you take good time dismounting and have a donor car its actually a quite easy job!
But ofcourse you need a welding machine first:-P

Keep on going!
 
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