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Double Dutch

Chilm

Double Dutch
Joined
Apr 28, 2009
Location
The Netherlands
Hello TB enthousiasts,

I'd like to make my own thread about my Dutch Volvo 945, to get comments and advice and for people who want to be inspired modding a steel brick :cool:
It will be wth bits and pieces because i did a lot an can not post everything in one evening duhuh.

Dunno if this is the right place or it has to be in "Showroom" mod's, do what you have to do ;-)

I am very precise in sorting my "stuff", it saved me many many times.

531_gesorteerd.jpg


I bought this air tools and carbid burs for the ruff stuff, i can tell with this tools it's going a bit too fast, Aluminium is soft as you know. I will do the fine work and finishing with my good old Dremel, the best tool I ever bought. A friend of me milled a nice long shaft for it to get deep and smooth :-P

kamer4.jpg


531_setje.jpg


531_burs.jpg


And then i bought the so much sought after 531 head, very common here in Holland har har :nod:
I marked the holes with a Widia pen and used the gaskets as a guide:

531_531.jpg


The bowls from the 531, much is said about it, i'm gonna unshroud the outlet side and take some other material from the bowl and spark plug surroundings, mark the angle of the spark plug thread.

531_bowl.jpg


Some more marking, take it to the limit ;-)

531_inlaat.jpg


531_uitlaat_voor.jpg


And now for the first time the ruff grinding, don't hesitate just do it:

531_uitlaat_na.jpg


531_short.jpg


531_inlaat_voor.jpg


531_inlaat_na.jpg


531_inlaat_klaar.jpg


The outlet side:

531_uitlaat_na2.jpg


uitlaat.jpg


Bowls:

531_bowl_voor.jpg


531_bowl_na.jpg


The inlet side, also a huge mismatch with the gaskets:

inlaat.jpg


531_ridge4.jpg


531_ridge3.jpg


531_ridge2.jpg


531_ridge.jpg


bougiegat_1.jpg


bougiegat_22.jpg


bougiegat_2.jpg


Now it can be shaved, i also like to go tight squish but haven't the numbers yet (deck and amount of shaving).

kamer1.jpg


kamer2.jpg


Also going to drill the extra holes 3,4 and 5 mm. for more equal cooling of the head and to avoid hot spots. Next picture is from Stoni's website just to show you where to drill.

Nr.1 has a 3mm hole, Nr.2 has a 4mm hole, Nr.3 has a 5mm hole, Nr.4 has two 5mm holes at the rear end.

DSCF2477.jpg


DSCF2469s.jpg


DSCF2471s.JPG


Again above 3 pictures thanks to Stoni's World website: click

Well... that's it for now. i will make updates asp ;-)

The brandnew 3inch stainless steel exhaust with racecat handmade by Jelmar from www.crossroadmotorsport.nl a real peace of art if you'll ask me, a craftsman "pur sang".

jelmar_1.jpg


jelmar_2.jpg


I am reeeeeally going to sleep now :omg:
 
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MDVLN

Kapitän Klugscheißer
Joined
Mar 25, 2013
Location
Varies
Great wagon colour :drool:

Great head work as well!!! I just hope njal doesn't see this, I love the guy but he might have a few words for you... haha :-P
 

Chilm

Double Dutch
Joined
Apr 28, 2009
Location
The Netherlands
Nice work. What's the story on "Limited Edition" badges?

Well the story is i saw an ad on "Marktplaats" (the dutch E-Bay) and thought YES, he had two of them, brand new and original Volvo. I have never seen them before and now also got one spare. I could have sold them several times but i won't as you will understand :oogle:

P.S. the car is an original LE with the full options of an LE, meaning everything possible exept the sunroof which is a sad thing lol.
 

MDVLN

Kapitän Klugscheißer
Joined
Mar 25, 2013
Location
Varies
Omg, keep him away, kill it with fire lol.

:rofl:

I didn't mean to offend any parties, that had just crossed my mind - should have been one of those thoughts that I kept to myself.

If your statement means you have a lack of a sunroof, I'd consider that a good thing. :-P I'm not a big fan of sunroofs or convertibles and the like though so there's that, haha.

Looking forward to seeing anything else you may do - Your undercar shot gave me a few ideas on what to do for my exhaust; If I do it "proper" and don't do a short exit. Ha.
 

Chilm

Double Dutch
Joined
Apr 28, 2009
Location
The Netherlands
Installing my wasted spark

After I followed the wasted spark initiatives from Karl Buchka and Blabla (Martijn) I could not wait to install this because imho it would be a huge improvement in fuel consumption and "burn" efficiency.

I bought the Buchka board but used the Blabla board that i bought too, and only because it was easyer communicating for me living in Holland (so does Blabla as you probably know).

The only thing I hated from the start was the mounting of the bracket most people did, it looked so DIY and "not original". So i decided to fab my own bracket from scratch and put it elsewhere (see pictures below).

This is the Blabla board that must be soldered in to the EZK

ws_board.jpg


And I bought some soldering equipment because I had nothing, soldering was not part of my system lol.

solderen.jpg


And some other well known goodies.

ws10.jpg


Making the cable from yunkyard stuff i collected.

ws13.jpg


ws14.jpg


ws15.jpg


And the finished tiny board ready to be married to the EZK

ws16.jpg


And allmost done now.

ws17.jpg


Sexy looks

ws18.jpg


ws19.jpg


After this was done I was going to make a brace from a piece of scrap Aluminium from an Alumnium illuminated sign, in the Netherlands we say "he, who is not strong. must be smart" ahum. This was done from a paper mold that i made first to have the correct measurements.

ws0.jpg


ws1.jpg


ws2.jpg


ws3.jpg


ws4.jpg


ws5.jpg


ws6.jpg


ws7.jpg


ws8.jpg


ws9.jpg


ws11.jpg


And finally test fitting, looks good i think.

ws12.jpg


The final fitting.. I did make an other cable, this one was a bit too long and had a strange angle towards the bobine or DIS. The DIS was from a Alfa Romeo and the powerstage from a Volvo 960. I will make a picture tomorrow with an overview of the engine bay and how it sits.

deze.jpg


The latest "overview" picture.

ws_final.jpg


The WS is working very well and without any malfunction or other oddities. As stated before a much stronger spark, better throttle response and last but not least better fuel economy. So a win/win situation in my case,
I can really recommend it to you.
 
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Chilm

Double Dutch
Joined
Apr 28, 2009
Location
The Netherlands
PCV tubing renewal

After I had (for the third time) bought the PCV breather thingy because it was broken again I decided to make the whole thing myself from Aluminium tubing. Easy to bend with my tube bender (for plumbing tubing) and easy to polish ;-)

ontluchting_1.JPG


Above the original but ugly PCV pipe with broken "thingy".

ontluchting_2.JPG


Above the broken "thingy" that started this little project

ontluchting_3.JPG


Aluminium tubing from the DIY: 20, 16 en 6 mm. tubing is 2 mm. thick so i have enough material to tap threads for the little vacuum hose.

ontluchting_4.JPG


Bending measuring, bending measuring, it wend well after all, patience is a good habit lol. Bend it with a piece of fabric in the bender just to prevent scouring and scratching.

ontluchting_5.JPG


Tubing cut (6 mm. section) tapped thread (m6) for the vacuum hose to the inlet. I will position this higher up just for convenience.

ontluchting_6.JPG


Drilled a hole for the little tubing and tapped it.

ontluchting_7.JPG


Mounted it with Loctite just to be sure.

ontluchting_8.JPG


"cuff" 20 mm. for mounting on the inlet. Sandpaper 600 did the first polish job.

ontluchting_9.JPG


Just cold fitted (tapped with hammer) with Loctite, it's a snug fit. the inner and outer sizes match allmost exactly, outer 16 mm. to inner 16 mm. and: chrome polish ha ha.

ontluchting_10.JPG


The TUBE lol.

ontluchting_11.JPG


Mounted and much more attractive imho.

ontluchting_12.JPG


Detail to inlet.

ontluchting_13.JPG


Detail to pre turbo and pre heater.

After reading THE PCV thread i decided to go for the real thing and buy the Mann ProVent as CC so I'll have something to do when that comes in. Don't know yet if I am going the tube- or the hose way..
 
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Dirty Rooster

New member
Joined
Mar 3, 2008
Location
Northumbria
The big ugly foam-covered PCV hose always bothers me ... yours is excellent but do I want to spend such time on it?
Maybe a brass/copper one ... Hmmmm
 

Chilm

Double Dutch
Joined
Apr 28, 2009
Location
The Netherlands
The big ugly foam-covered PCV hose always bothers me ... yours is excellent but do I want to spend such time on it?
Maybe a brass/copper one ... Hmmmm

Only for the bling bling no "oemphhh", I agree it's a bit gay-ish, lol.
Brass/copper will be the same amount of work imo and does not match the overall looks.
 
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Chilm

Double Dutch
Joined
Apr 28, 2009
Location
The Netherlands
That tiny under estimated 13C scavenger

Some 13c porting just to have a look what the gains are... Well after some heavy test driving I'm now in doubt if I will swap it for my also ported 15G because it spools so fast (got a full length 3 inch exhaust too) that I'm beating a whole lot of cars in the first hundreds of meters gna gna. The faces of Audi, VW Golf etc. yes even Porsche drivers are hilarious to look at when they finally are passing me ha ha.

I've never heard a loud whistle in a 13C but mine does. Not stating this to show off but to express what fun it can be with a little port work on that tiny 13C, it will spool like hell.

I'm on 1 bar (14,5 psi), tuning on LPG (liquid gas), no gasoline, cool (but slightly slower) burn and high Octane (105) so less knock. Chipped (Blabla) ECU and EZK and an Erland Cox regrind (lash caps) as a camshaft.

turbo2.jpg


Wastegate ported and polished to let it react quick when foot off the paddle. Rounded everything up for the flow...

turbo3.jpg


Other site of the "dome".

turbo4.jpg


Nice smooth me like.

spruitstuk1.jpg


Opened the inlet and got rid of some material, this one was cracked too, I had it welded just to be sure.

spruitstuk2.jpg


Close up with little cracks, don't worry they will close if everything is heated up (and it will).

spruitstuk3.jpg


Go with the flow, after 2 years it's still working, no setbacks whatsoever.
 
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blkaplan

50 shades of beige
300+ Club
Joined
Jul 30, 2002
Location
Rockville, MD
The WS is working very well and without any malfunction or other oddities. As stated before a much stronger spark, better throttle response and last but not least better fuel economy. So a win/win situation in my case,
I can really recommend it to you.

What kind of change in economy did you see?
 
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