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smoothys 242 Turbo Build

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
. What do you think about sealing it with RTV?

IMO I only use RTV if the sealing surface is badly pitted or not properly cleaned (with alcohol to remove all oil). We use it to seal transfer cases at my work and it works very well. The problem is that most people put to much of the stuff on and when the sealing surface sandwiches together it squeezes the excess into the the t-case which can create problems down the road. It really a matter of preference. I did use it to seal the oil pan, front/rear crank seal housing and the thermostat. On my M46 I was able to get the bell housing gasket surface very clean as so I didn't use it + I didn't want to run the risk that some small particulate breaks loose and clogs up the OD hydraulics.

You really need to slow down, you are making a lot of us (me) look really bad!

Car is going to be better than new when you finish it!

Slow down? I have been working on this since September 2013. Most of that time was spent battling rust. Wait until I get the car back from paint and you will see how fast I really work. But little by little the car will come back together.

looks good (I crushed cars with a lot LESS rust)
btw instead of grease use wet bread next time in the pilot bearing - less messy

Next time send them up here!
 
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smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
Body Work Update

I went to the body shop to check in on the progress made on the car. It looks like significant progress has been made and they body shop says the car will be ready to paint Thursday. With that being said it looks like I will be busy this weekend.

Here are few photos of the progress made thus far.





 

Sharingan 19

Member
Joined
Sep 5, 2013
Location
Jacksonville/ Tampa
IMO I only use RTV if the sealing surface is badly pitted or not properly cleaned (with alcohol to remove all oil). We use it to seal transfer cases at my work and it works very well. The problem is that most people put to much of the stuff on and when the sealing surface sandwiches together it squeezes the excess into the the t-case which can create problems down the road. It really a matter of preference. I did use it to seal the oil pan, front/rear crank seal housing and the thermostat. On my M46 I was able to get the bell housing gasket surface very clean as so I didn't use it + I didn't want to run the risk that some small particulate breaks loose and clogs up the OD hydraulics.

Yea, the sealing surface was fine, but not fine enough to get by w/o a gasket, and since I wasn't going to pay for one and wait for it to arrive....I used a thin layer of RTV.
 

4-cyl

In too deep
Joined
Aug 23, 2008
Location
Seattle, WA
Your progress is looking great. The braided k-jet fuel lines are high on my list of purchases to be made. It's nice seeing someone else interested in keeping the original fuel system alive.
 

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
Your progress is looking great. The braided k-jet fuel lines are high on my list of purchases to be made. It's nice seeing someone else interested in keeping the original fuel system alive.

Thanks. I am hoping to have the car back this weekend but I have relatives coming in from out of town so I doubt I will get much done.

Unfortunately the steel braided lines will have to wait. I have other non Volvo related projects that also tap into my resources. With warmer weather approaching I will be stretched to have this project road worthy in 7 weeks!
 

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
Paint Update!

I received the car back from the paint shop. . . . well at least most of it. The painter still owes me the rad support, bumpers, sunroof and front air dam plus he will need to perform some touch ups. I would say I am fairly pleased with his work. He wasn't the cheapest nor the most expensive but his work turned out decent. The attached photos make the color look grey but I the car is in fact silver.







Tomorrow will be a busy day :cool: Followed by several weeks of busy days :-(

My plan is to have this think back together in 7 weeks. Keep in mind I do have a day job, a wife and an 8 month old! We shall see how it goes. wish me luck.
 

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
Progress Update

Its been a few days and I have had the time to begin to reassemble the engine bay. I had to repair a bunch of wires which had crumbling insulation but for the most part things have moved along fairly well.



I have attached a couple of photos from my project.






I have found I needed a couple piece of side molding (Pass Door, Drivers Fender) as well as a couple of Rain gutter trim junctions. In addition I am not sure how the wires for the engine bay lamp (mounted to the hood) and the after market intercooler harness was routed through the fire wall. I have highligted what I know goes where which doesn't leave any open access ports that I am aware of. Perhaps one of you can chyme in?




I should be on track to install the engine this weekend.
 

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
"Intercooler harness" ?

Probably bad wording.

When the aftermarket intercooler was installed from volvo it came with a wiring harness which connected to the ignition coil to a relay which switches on a solenoid value which bleeds some pressure to the waste gate at a specific RPM.

This "harness" needs to be routed through the firewall to pin fuse 12. I cant seem to remember how it was routed. The installation instructions are fairly vague.

 

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
Doors Reassembled

The project has progressed well the past few days. I was able to finish assembling the doors which included the; window regulator, latch, striker, door handles, key cylinder, weather strip seal, glass, window scrapers, mirrors, and black surrounding trim as well as the always fun task of aligning the latch and striker.

The interior trim panel will have to wait until I get a couple of 4" speakers.

The window scrapers where a major pita to separate the rubber from the steel but after a light sanding and wash the came out looking really good. Installing the new window scrapers (courtesy of Mr. Redwood Chair) may have given me a little carpel tunnel but once they were in they looked great.

here a photo of the drivers side door.





I still need to sand and paint the "b" pillar as well as finish painting the mirrors I bought from PunKKnuckle24.

This weekend the motor will be going back into the engine bay! :clap:

In addition, the door and fender molding I was able to get for free :omg: which is always a treat when get rare free stuff.
 

smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
Cam has been broken in

Well I finally got all the vacuum connects, wiring, and coolant and oil lines connected.

I had to repair a few broken wires, bypass a faulty boost overpressure switch (I may be looking for a new one) and find out the ins to the distributor have pulled out of the connector, to get this.

Broke in the new cam and found out the reman power steering pump leaks.
 
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smoothdurban

I do my own stunts
Joined
Jan 4, 2013
Location
Kemble Ontario
On the road and running strong

After 9 months of work my 242 is back on the road . . . . more or less.

Saturday was a final garage day for my car. Between Friday night and Saturday afternoon I was able to complete some finishing touches.

  • wired in media player
  • connected power antenna
  • evacuated and charged AC system. (burr burr blows cold now!)
  • installed engine splash guard
  • balanced and installed new tires
  • had an alignment done
  • adjusted brake booster rod to lessen travel of brake pedal
  • replaced a stuck frequency vlave relay - buzz buzz

I still need to
  • replace all u joints and drive shaft carrier
  • repair seat lumbar
  • replace seat belts (They don't retract well)
  • replace dash speaker grille (looking for a blue one)


Here she is at home


and the engine bay


ANd this is what I started with





Not bad for nine months. She is fast but working with the spec clutch will take some getting used to as it grabs all or nothing.

I may need to get some stiffer engine mounts.
 
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