Continuation of the 242 16VTi build

[GTJordan]

Amazingly, I have been working on the 242 every day for the last month. I wanted to update my thread, but so many of the pictures were lost on photo bucket.

Old thread here.

A basic overview of the project.

Bought mostly clean 242 shell in 2014 (I think). It mainly sat around without nothing going on since then. I have been collecting parts since before that (I have had a couple other 242's and a 7 series project in the past.

The car currently looks like




Specs

Engine Bottom End

Note- I lost my book with all of my specs.
B230F block
2.5L penta crank
John V rods and pistons (CP)
fully rebuilt, decked, bored, torque plate honed
Melling oil pump
ARP main studs and head studs

Head
16V penta cylinder head (ported)
new springs and lifters
KL racing cams
STS cam gears
Cometic head gasket
850 timing belt, Subaru tensioner and some mitsubishi idler

Engine attachments
NIW intake manifold modified for DBW throttle body from a P2 turbo car
NIW twin scroll exhaust manifold modified to have EGT ports in each cylinder
3" MVP (Yes the OG) exhaust
3" down pipe
Griffith radiator
ASS mounts
Yoshi catch can/PCV system


Turbo stuff
Garrett GT3076 w/ .84 AR twin scroll Mamba exhaust housing
Twin tial MVS wastegates
DO88 Group-A replica

Transmission
T5 transmission that I rebuilt with the Ford motorsport 2.95 gearset and all new internals.
.80 5th gear
Yoshifab Clutch and flywheel
I attempted using a summit racing speedo electronic sensor for a speed signal - The one they list for a Ford does NOT fit the T5. They suggest you use the Ford sensor but it is a few hundred bucks. I will weld a tone ring onto my diff for a speed signal.
STS hydro clutch pedal
Tilton internal slave cylinder

Rear End
Rebuilt by Matt Dupuis (UglyDuck) with 588 trutrack, solid pinion spacer and 4.10 gears.

Brakes
Front - 6 piston Porsche with Kaplenkhe braided brake lines - Homer mounting kit on Zimmerman S60/V70 Rotors
Rear - 4 piston Porsche. Homer kit on Zimmerman rotors. The park brake has been modified to work by combining 240 inards to the shoe of a P2. I got these through Ermit72 a few years back and I forget who did the work (Davos?). It allows use of all factory hardware and no need for the extra drum inside the drum of the P2 rotor.
Mustang master cylinder on 8" booster

Supsension

Front
Gaz Gold adjustable front struts (short version) on ABS knuckles
- don't remember spring rate
BNE camber plates
BNE quick steer spacers
Reenforced A arms with STS delrin bushings
BNE upper strut brace
IPD 25MM sway bar

Rear
Gaz Gold adjustable shocks
BNE torque rods and panhard rod
BNE adjustable spring perches
BNE rear axle spherical bearings with rubber bushings at front of arm
No rear sway bar - but I do have a few different sizes to play with


EMS/Wiring
MaxxECU Race w/ 4 EGT ports in use, twin mac valves for turbo control, Drive by wire throttle (pedal from a Saab, with a mounting plate from Gilberg Engineering. I don't recommend this, I had a hard time getting the pedal in NA). Eventually want traction control and all the other goodies this ECU is capable of.
VW coils
Walbro 450
I need to run a fuel system from tank to engine
ID1000s
Volvo fan module to run a brushless cooling fan

The body harness was pulled from the car, and I layed it out on a piece of plywood. I pulled all the circuits I knew I wasn't going to need/want. I installed a Wagon Meister ACT fuse panel.

For the engine/MaxxECU I've added two bulk head connectors (deutsch connector) from Maven motorsports on their plate. I will replace most of the connectors in the car with deutsch connectors.

Body
Shell is an 82 with sunroof. The car originally came out of California circa 2008. Paint is faded and crappy, but car itself is solid.
Flat hood swap
86+ front fenders
86+ e-codes
euro grille
86+ front bumper
81-85 small rear bumper
I have a Group-A spoiler when the body gets painted one day.
Removing terrible shape turbo trim for thin trim from a 242GT
Keeping the power mirrors

Interior

Corbeau seats with sliders
242GT door panels and rear side panels
Dash modified
- Cluster replaced by PowerTune digital dash fed info via CAN network from ECM
- VDO 52mm fuel level sensor
- Cheap Atoyo double DIN head unit - this to provide me with android auto, but at the same time the ability to connect via bluetooth to the ECM for data.
- Dash is a late dash that I repaired the cracks in and flocked

Heating system was removed. I've installed a Summit Racing small heater core/fan assembly. I installed it with a new coolant valve that I can still control via the factory temperature control slider. STS machining firewall pass through.
Yes I need a heater - it will be 30c in the afternoon, but 5c in the mornings through the summer here.

Somethings to do still - or to figure out

- Cooling fan. I'm actually having a hard time finding a BRUSHLESS cooling fan that will fit my radiator. Spal makes a couple that I can't seem to actually locate

- I have a CWA400 coolant pump from a SPA 2.0Vep engine. I need to figure out how/where to mount it and connect hoses to it- then figure out water pump by passing (either cutting fins of pump or some sort of junction block to the block, head and heater?)

- I have a buddy that is going to come over and fab up the downpipe, wastegate tie-ins, intercooler piping and weld in the tone ring on the trutrack. (I really want to learn to weld/Tig specifically).

-Have a P1 power steering pump I plan to connect via CAN to the ecu. I haven't found a clean place to mount it yet, and I'm unsure I really want to mount it in the trunk and run hoses to the front like I see quite a few people do. At the same time, I have seen a bunch of these fail when left out in the weather in the wheel well. So I'd like to get it underhood. I'm unsure this will actually work. Mock up is in progress.

-Alternator? I will have quite a load with the PS pump and the water pump. I won't have space on RH side of the engine. And I can't put it UP on the left. So it needs to go lower left under the throttle body. Mechman shows me 6-8weeks out for an alternator, but they won't deal directly with me because I'm Canadian- they tell me to order through Summit. Annoying. Maybe I can use something else?

-I need a front T5 drive shaft. Gary is firing me a big balancer. Either get one local or hope someone has one kicking around they aren't going to use?

-Fuel system- 6AN is likely good enough for the 500HP crank max I'm looking for?

My plan is to have it MOVE, turn and stop under its own power this summer.

So next steps are
Finish mocking up EVERYTHING. wiring- engine- fuel system
Then have buddy build my exhaust and IC routing
Then finish the wiring completely.
THEN remove the wiring and wrap it, terminate it and final installation

A couple more shots of how it sits currently.

 

[brendon_ak]

If the Oilers can mount a comeback (fuckin win at least 1 game) you have to post regular progress on this fantastic build.

Nice work man, keep it up!!

 

[GTJordan]

If the Oilers can mount a comeback (fuckin win at least 1 game) you have to post regular progress on this fantastic build.

Nice work man, keep it up!!

Deal. It will keep me motivated also!

I'm about to go to a hockey wrap up BBQ for a kid, then watch the oilers (probably) lose. I hope they can at least win ONE game.

 

[GTJordan]

Spent the morning in the garage putting things where they belong!


I swapped turbine housings on the turbo.
Clocked the turbine and center section - roughly. Man I really have no room for a return line. Out of the bottom of the turbo one of the wastegate ports is right there. Gonna be fun.

I put the front center section back onto the car.

I put the radiatior in place and stuck the water pump on some studs to check clearance.

I put the DO88 intercooler in. Man it is HUGE. You'll see in the pictures that where my throttle body lines up, is going to make a strange/awkward connection (I still need room to fit a blow off valve in there also).
The intercooler intake on the turbo side sits essentially where my turbo intake is.

Do I move the IC forward a couple inches? Do I lop the side of the tank off and weld something else on there? Sort of defeats the purpose of having the replica IC. Unsure 100% at this moment.


EDIT- I tried both the Ron Davis radiator as well as the DO88 aluminum radiator. Might have to get the Ron Davis pressure tested - been sitting a long time!

Here are some pictures!

 

[brendon_ak]

One fuckin game boys, jesus! Florida is pretty impressive though.

See, look at that! Of course a little hockey motivation will get ya goin! Fingers crossed this evening...

That IC is biiiiig, no kidding! For the motor did you get an AQ171 or piece the bits together?

 

[GTJordan]

One fuckin game boys, jesus! Florida is pretty impressive though.

See, look at that! Of course a little hockey motivation will get ya goin! Fingers crossed this evening...

That IC is biiiiig, no kidding! For the motor did you get an AQ171 or piece the bits together?

My oldest is a goalie, so I spend a lot of time watching the goalies now. Bobroski (sp) is on FIRE.

I put a TV in the garage so I can watch games and putter.

The engine I actually bought from (of all the names) Hockey930 a bunch of years ago. But when I pulled it apart to inspect it, I found a pocket in a cylinder wall. Machine shop thought it would be OK to run. But I ended up swapping all of the internals over to a spare B230 block I had. So The AQ crank just swapped into the B230 block. They are JohnV 160mm rods with CP pistons. I had to get CP to make up some new rings for me. The pistons are extremely short - like a modern engine.

 

[brendon_ak]

goalie=psycho (kidding), I think you mentioned elsewhere, he's in the no contact league or not old enough yet to go full Patrick Roy?

Atta boy with the TV's, SN and TSN at all times

Pretty cool story with the motor! Been thinking about a AQ151 for a fun little NA driver.

Can't wait to see progress man, thanks for sharing!!

 

[DET17]

Funny how small the TB world is (regarding parts sales). I've got the Gil Racing wheel spacers that came off the HockeyXXX car when it was parted out maybe 10 years ago. He was a Charlotte guy, fairly close to me. I'm sure I read that he ran a 2.5L stroked 16V, maybe with a Getrag behind it? Propav8tor parted that car, but I didn't know the engine flew all the way out NW! On the flip side, the original Captain Bondo engine and trans were sold to a guy in Southern central Ohio.... I saw the engine last December!

Jordan, what color is your 82 242? My 84 is "Richileu Red" which supposedly is red wine colored. Yours looks close, but might be a slightly different shade.

Getting that nice FMIC to play well with that Garrett compressor and your intake/throttle is going to be challenging!

 

[GTJordan]

goalie=psycho (kidding), I think you mentioned elsewhere, he's in the no contact league or not old enough yet to go full Patrick Roy?

Atta boy with the TV's, SN and TSN at all times

Pretty cool story with the motor! Been thinking about a AQ151 for a fun little NA driver.

Can't wait to see progress man, thanks for sharing!!

He is definitely a different kid, but I've noticed all goalies are "off" a bit. The first time he went to his goalie coach he had said that goalies are weird and to not be offended by that. He said it is unnatural to stand infront of a flying object and to drop down into a butterfly is not natural. Takes a special kind of idiot to do that. This year he decides between hitting and non hitting teams. I think he will try out for hitting, but will be happier if there is no hitting. It doesn't *really* affect him though (as a goalie). I have two others that play also - Daughter is a left winger and a son gets to pick position this year.

Funny how small the TB world is (regarding parts sales). I've got the Gil Racing wheel spacers that came off the HockeyXXX car when it was parted out maybe 10 years ago. He was a Charlotte guy, fairly close to me. I'm sure I read that he ran a 2.5L stroked 16V, maybe with a Getrag behind it? Propav8tor parted that car, but I didn't know the engine flew all the way out NW! On the flip side, the original Captain Bondo engine and trans were sold to a guy in Southern central Ohio.... I saw the engine last December!

Jordan, what color is your 82 242? My 84 is "Richileu Red" which supposedly is red wine colored. Yours looks close, but might be a slightly different shade.

Getting that nice FMIC to play well with that Garrett compressor and your intake/throttle is going to be challenging!

The parts world is small in Volvo land for sure. Propav8ter did crate and send the engine to me. At the time I thought it would be a quicker route to get the engine and slap it in. Didn't quite work out like that in the end.

I'll try to remember to get a snap of the build plate for you. I would have no doubt it is the same. But, this car is from Cali and EXTREMELY faded. That might be the shade difference? The paint is near non-existant.

 

[244tiCanuck]

Bobroski (sp) is on FIRE.

This aged well.


EDIT: Also, good to see the progress. Let me know if you need a hand with anything.

 

[doucheNozzle]

Make it happen!

 

[t8fanning]

Looking good!

-6 AN is plenty for 500 crank. I made 580 wheel on a mix of -6 AN and stock hard line. Just make sure you have enough pump.

It's gonna be annoying but it's probably worth cutting the throttle body flange off and we welding it so it points more toward the intercooler outlet.

You could always put a BOV flange directly on one of the intercooler end tanks if you don't have room on the piping.

 

[Harlard]

Sweet. We need more 16v weirdness around these here parts.

 

[nibroc]

^^^^^^^^^^^^^AGREE^^^^^^^^^^^

 

[GTJordan]

Looking good!

-6 AN is plenty for 500 crank. I made 580 wheel on a mix of -6 AN and stock hard line. Just make sure you have enough pump.

It's gonna be annoying but it's probably worth cutting the throttle body flange off and we welding it so it points more toward the intercooler outlet.

You could always put a BOV flange directly on one of the intercooler end tanks if you don't have room on the piping.

-6 AN it is.
I agree that modding the manifold (again) will be a good option. I had already started planning on mounting the BOV to the end tank on the outlet side was likely to be the best fit. BOV showed up today- knock off Tial.

So. Today's progress was frustrating.

I got some nice new studs for the exhaust manifold, but it required rethreading. According to Full Race. I could just run a thread chaser through the 3/8-16 threads with a 10X1.5 chaser. All was going well on the first one until the last 5mm when the ARP thread chaser EXPLODED. That was fun. So now I have the chaser broken off in the manifold. Sweet. It is always these "small things before dinner" that cause me the most grief.





So I thought F this I'm going to do something easy. So I threw the front end on the car to see if I would be able to slide the intercooler/radiator forward a bit. Turns out that I could only gain about 30mm of space somewhat easily. My welder friend said not to worry about it yet. He says he has worked with worse arrangements. We will see what he can come up with this weekend. Might be a pause after that as I'm in Toronto the week after for work, and he is at Pikes Peak with a car he helped build.












Need to paint the eyebrows for the headlamps.

Things I plan on accomplishing this week
- Remove the fuel tank and the old fuel lines
- make a list and order plumbing stuff for new fuel lines

Then onto the interior
- finish plumbing the heater core
- start terminating some of the body harness
- if there is time, start terminating the ECU->bulkhead connector

That is it for tonight.

 

[t8fanning]

BOV showed up today- knock off Tial.

Everything else sounds good, but there's still time to fix this. We sell slight cosmetic blemished BOVs for a little cheaper:

***BLEM***TiALSport Q-Series Blow-Off Valve -CHOOSE OPTIONS

*BLEMISHED EXCESS INVENTORY - LIMITED QUANTITY* *Other Spring and Weld Flange Options May Be Available By Request. Please email Sales@tialsport.com to confirm other availability* The first revision of TiAL's original BV50 blow-off valve, the Q Series flows 60% more than its predecessor and...

tialsport-outlet.com

So. Today's progress was frustrating.

I got some nice new studs for the exhaust manifold, but it required rethreading. According to Full Race. I could just run a thread chaser through the 3/8-16 threads with a 10X1.5 chaser. All was going well on the first one until the last 5mm when the ARP thread chaser EXPLODED. That was fun. So now I have the chaser broken off in the manifold. Sweet. It is always these "small things before dinner" that cause me the most grief.

You could just use bolts and nuts instead. That's what I use on my manifold. It'll be a bit tight for you with the wastegate ports but I bet bolts would fit.

 

[Stiggy Pop]

My buddy had issues with a knock-off Tial on an SR20 setup and ended up ponying up for the real thing. Buy once cry once?

Needs a bigger turbo

 

[GTJordan]

What I REALLY wanted, was a Nuke blowoff valve. I really want to run at least one of thier products.

T8 I had no idea you worked for Tial. I had originally thought I'd do nuts and bolts for the manifold. But then I saw the description saying "just run the chase through your existing to change over because the patterns are so close" and I thought that doesnt sound too bad. I'll do that....

Maybe I'll just use this thing for mock up then pony up.

 

[mopar318]

If you are running E85, you will max out those injectors pretty quickly. The fuel pump is plenty big though. Lookin great!

 

[GTJordan]

If you are running E85, you will max out those injectors pretty quickly. The fuel pump is plenty big though. Lookin great!

No E85 available here unfortunately.