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242 Build

DavoS40

Member
Joined
Nov 12, 2002
Location
Fort Collins, CO
The project originally started out as a 245 then in 2003 I decided to switch to a 242. I've been working on it off and on when I'm home from school the past couple years. I'm just going to start off with the work that's taken place since springbreak 2005.

Engine:
B21FT
-align honed mains, decked for .030 squish
-2nd oversize stock pistons, balanced
-stock rods resized, cyrotreated, new hardware, balanced
-reground crank, balanced
-bmw oil piston squirters
-meling oil pump

Cylinder Head:
-398 SCP
-port & polished, unshrouded exhaust valves
-40mm exhaust valves, stock intake valves
-K cam

Turbo Setup:
-Holset HY35
-Powerstroke intercooler
-SS header from Jonathan(Stereophile33)
-XS RFL blow off valve
-3 inch exhaust (half of it from Doug's old car!)

Suspension/Brakes:
-front coilovers 315 lb springs
-rear coilovers 250lb springs
-revalved/shortened Bilsteins (towery's specs)
-Kaphlenke camber plates
-IPD adjustable torque rods
-adjustable panhard rod (homemade)
-poly bushings from Dale (245gti)
-new rotors, calipers, pads, ss lines, master cylinder, junction block

Driveline:
-93 Cobra T5 tranny
-Pro5.0 short shifter
-custom Spec stage 2+ clutch/pp (Volvo pp and clutch with the T5 spline)
-3 inch aluminum driveshaft

Fuel/Ignition:
-MS'nS
-EDIS with Ford coil pack
-Ford CFI injector's
-walbro pump

B21 block fresh from the machine shop
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Notice the spots machined for the squirters
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Sprayed the garage down with a hose to keep the dust down
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Test fitting the squirters
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rods, pistons, oil pump installed
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finished short block
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the light! (40mm exhaust valve)
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seam welding
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painted bay
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preparing to drop in the motor
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ready to go in
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motor in, test fitting header with junk head
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body still needs a lot of work
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engine bay
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The new motor has been run through 3 sessions of stealth's run in procedure. When I was almost finished with the 3rd session I blew a freeze plug. I wasn't sure if this was due to the coolant system getting pressurized from a slight leak in the headgasket or if the machine shop installed the freeze plugs incorrectly. The blown freeze plug was replaced with one of the rubber expandable plugs and the head gasket replaced. If another one blows the motor is coming out and all of the plugs are going to be replaced(JB will be involved). The motor did sound great and sounded really smooth after the 2nd session.
I'm heading back to Colorado tomorrow, so I won't see the car for a few months. The plan is to get a bunch of little parts needed while I'm away. Hopefully get the car painted over springbreak or the beginning of summer. Once the body is painted the 93 block cloth interior(that's sitting in the basement) is going in the car. Then a few test drives (I smell Missouri) and if all goes well it'll get registered.
 

Delfosse

New member
Joined
May 4, 2006
OMG I wet myself!.. that is killer! good lighting on the engine bay pic's!
 
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Tom Wiley

New member
Joined
May 23, 2006
DOnt do anything to the outside!

SLEEPA POWA!

EDIT: I spy Eikers! What rubber are you gonna put on them?
 

DavoS40

Member
Joined
Nov 12, 2002
Location
Fort Collins, CO
Thanks for all the complements guys!

DOnt do anything to the outside!

SLEEPA POWA!

Originally that's the attitude the project took on, screw all the looks and just make it fast. Now I'm going for just a great all around car: handles great, plenty of power, nice interior, clean factory looks on the outside but nothing that says look at me.
 

edicius

Super Moose!
Joined
Apr 15, 2005
Location
Calgary, Alberta, Canada
Just a thought, some after-market water pumps if not shaped like the oem blade can cause freeze plugs to pop. Not sure what it has on it but just in case you didn't know
 

DavoS40

Member
Joined
Nov 12, 2002
Location
Fort Collins, CO
Just a thought, some after-market water pumps if not shaped like the oem blade can cause freeze plugs to pop. Not sure what it has on it but just in case you didn't know

I read the stories about the stamped impellers and made sure to get the one with cast impeller.
 

Homer

OEMplus++
300+ Club
Joined
Aug 7, 2003
Location
San Francisco
Very nice Dave. I've seen the car in person and "helped" a bit. I like where it is going and can't wait to ride around in it. This project is being done like it should, on a budget nonetheless.
The lighting is very high tech too! ;-)
 
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DavoS40

Member
Joined
Nov 12, 2002
Location
Fort Collins, CO
Very nice Dave. I've seen the car in person and "helped" a bit. I like where it is going and can't wait to ride around in it. This project is being done like it should, on a budget nonetheless.
The lighting is very high tech too! ;-)

Without the parts hook up and the motivation to do it clean it wouldn't be where it is now man!

this project has been in the dark, this the first time you've posted anything on it?

I've made a few threads about it in the past, but not since last summer when I totally tore it down.

What did you do for a WG?

Two summers ago I ran the stock wastegate and it held a consistent 19psi(which it was I think the original actuator opens up at). Now I ported the hell out of the wastegate, and I'm planning on fabricating something similiar to atp's ultimate wastegate over springbreak with an internal wastegate I can get different springs for. Eventually I'll get a the header setup for twin wastegates with a nice twin scroll turbo.
 
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