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LH2.2 Tuning For Non-Volvo Installation / X1/9 Dallara + K24 Swap

Got sidetracked with replacing the DP flex coupler on my C30 last week - royal PITA with the AWD conversion

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After that, got the stone chip & undercoat done in the wheel wells

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Brake line retainers installed - put rivnuts in the skin & used torx machine screws

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struts & brakes back in

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Reworked the #8 hose to the condenser, required a #8 FOR 90? elbow due to the rad/cond re-alignment. I'll work on the #6 hose to the evaporator soon

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ran the hose along the rail instead of along the water pipes - since the dogleg end of the stock hose is gone

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The other end, I had to cut & splice a new section where the original was sliced in the accident

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#8 straight MIOR was needed here to attach to hose running to compressor.

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#6 line with orifice tube figured out. Then removed & crimped line fittings.

Fuse panel installed.

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made a bracket to retain the fan relay to the inner fender

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Check everything fits. I'll have to rework the carpeting for the frunk around all this

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Put the HVAC back in, finished the floor stone chip & undercoat

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Added a Volvo chime relay to use for 'lights left on' warning

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Had to repair another rust hole in the d/s cowl - probably what caused the floor rot

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Then dash back in

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Finished the brake ducts

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fan shroud & hoses back in.

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Speakers from the S40 mounted in the kick panels

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Cleaned the X1/9 ready for Carlisle Import Show tomorrow morning

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Hopefully I'll get the final touch on this year -

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The 'factory" rear spoiler used on the original Dallara

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EDIT - also swapped out the fans for 12" FFD 1600cfm versions

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Drove the car to Colombus, Ohio & back this summer. Fiat gathering out there. Car ran very well, but.... the header I made leaks at the flange, and it is a significant restriction in terms of performance.

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I found a PLM header for the K24 - so I'm in the process of making that fit

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bought 2" SS mandrel bends to fix it

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had to cut out the cross support to do this - I'll make a new section when it's all done

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runners rerouted for the Fiat chassis

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Slip joint sections cut from original header & reinstalled

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reworked 2-1 collectors to fit

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mostly welded

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Cool seeing your progress on the X1/9. Definitely one of the better-executed custom ones out there, considering how many things you've modified.

I'm using the same two-speed VW fan switch on my wagon, and may someday adapt one for my X1/9 as well. Where did you get the plug/pigtail for it? I looked for it online for ages and couldn't find it available anywhere.
 
Cool seeing your progress on the X1/9. Definitely one of the better-executed custom ones out there, considering how many things you've modified.

I'm using the same two-speed VW fan switch on my wagon, and may someday adapt one for my X1/9 as well. Where did you get the plug/pigtail for it? I looked for it online for ages and couldn't find it available anywhere.

Thank you.

I got them from the local Audi dealer - VW dealer should also work:

connector 893906231 boot 867972525B, and 6mm Faston (female spade) terminals

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Made a new access cover to clear the headers

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covering for access panel

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foam, then carpet on the trunk side

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Upper cross bracing figured out

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exhaust layout Solo Performance STL25 muffler, Vibrant 1792 resonator, Red Hat performance tip

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figuring out modified trunk floor

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SS panel to cover it all

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New rear tires mounted so I can start driving the X1/9 once more. Have an alignment scheduled for next Wednesday, so before I wear them out again

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Worked on the trunk lid and spoiler over the past couple days

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wet sanded 1-7k, compound, polish

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closed cell foam on the standoffs

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then today I put the lid and wing together, added the vinyl to the foils, and then the tape stripe across the trunk & uprights.

Steel lid required shorter offset bump stops

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template for vinyl for foils

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closed cell foam between spoiler & foils

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going to take some getting used to - I already smacked my head a couple times closing the lid due to the rear overhang

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added tape stripe to continue from sides, had to stagger the inner stripe since these uprights aren't flush with the rear edge as with the original design

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will require reworking the inset strip where it meets the standoff

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added two reinforcements for the plastic engine cover mesh, where the header heat had started to make it sag

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wing doesn't impede rearward vision, I hadn't even thought about that

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Volvo C30 car cover actually fits now

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Timing chain broke back in July. Wasn't an OEM chain, lasted 5K miles. Being used to generally equal quality with non-blue box Volvo parts for timing belts, etc., it did not occur to me that companies might actually make critical components that are ****e. Obviously I'm replacing everything with Honda-packaged items

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if you look closely you can see fractures in many links

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drivetrain coming out

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gods must have been smiling - the valves did not hit the pistons, and this was with high(er) compression pistons

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short block being reassembled

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.... adding Cruise control from an '05 RSX while I have the access with the drivetrain out

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chopped & reconfigured mount bracket to suit

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head came back, confirmed zero damage

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all Honda **** this time around

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ready to reinstall

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heater return hose is a 740 turbo rad-to-expansion tank hose cut to fit

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almost there. Hopefully up & running tomorrow or Tuesday.
 
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Is it too late to suggest 4P chain guides?

:roll: - The setup is basically stock output (around 220 max), just between a little higher rev limit & cam iVTEC cam advance. Other Honda ppl have used stock parts for much more, so they reckoned I just needed to make sure the critical parts are OEM.
 
:roll: - The setup is basically stock output (around 220 max), just between a little higher rev limit & cam iVTEC cam advance. Other Honda ppl have used stock parts for much more, so they reckoned I just needed to make sure the critical parts are OEM.


I only said that because the engine was already back in the car :rofl:
 
Got the rest of the car back together. couple hundred miles so far, no oil consumption, running well.

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EMS back in

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Federal 595RS 205/50xZR15, 245/45xZR15 on Rota TBT 15x8 4x100 67.1 bore. Going on in the Spring.
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Dallara wing
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Made Lexan covers for the lights, A feature from the original Dallara
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New wheels went on last Spring, in time for Carlisle
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Got the car back from the bodyshop (4 months!) - Had them repaint & blend the spoiler & skirt I damaged back in June. Front end needed attention - felt really squirrely after the accident. Turns out the radius rod poly bushes had compressed to about an inch so both wheels were sitting way too far forward. Also left rod was bowed - worse than it appears in the pic.
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Also the thin tape stripe has separated - have to replace all that. Not sure how they stored the car for that to happen.
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I have casually followed this thread through the years, and my mind is consistently blown by the amount of tedious work you put into this car while modifying everything. With the amount of your life you have spent on it, I hope it gives you much pleasure.
 
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