Building my 1984 245 Turbo Build |
UPDATED: January 15, 2024 CONTACT |
D O M
A I N S |
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THIS IS
(mostly) AN OLD PAGE While some of this info on this page is a bit out of date, please keep in mind I originally began posting it in 1999 and some things were added over time. |
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MODIFICATIONS: Exterior: AXIS SE7EN wheels, 18 x 7.5 inch, 20 mm offset. Tires: Bridgestone Potenza S-02 A's (225/40ZR-18). Cross-drilled and grooved ATE Power discs in front. Cross-drilled Brembos in rear. Braided stainless steel brake lines from ipd. IPD sport lowering coils have now been replaced by adjustable coil-overs from MVP. Scroll down for details. Spherical end solid sway bar end links from MVP. |
Update note: The
below multi-sway bar setup was abandoned in
2003 when coilovers were installed.
Scroll down for details.
Big Front Sway -- Dual Rears: from ipd (rare) 28 mm front sway bar along with trick end links from MVP. The big front sway bar was developed by IPD for the 260 and has been used for 240 V8 conversions. It is no longer available. I
also installed dual 25 mm IPD REAR sway bars. I
initally played with this setup back in the early 90's
on my old 244 DL as a way of increasing rear stiffness
without parting with the sway bar cash. Then on
my 245 Turbo I played with it there also since there
was no single rear bar big enough to compensate for
the huge 28 mm front bar. I had been
previously running smaller rear sways, but found a
little too much understeer at track speeds with the 28
mm bar in place. It turned
out that the car handled pretty well with the 28 mm
front and dual 25 mm rears. This is a very simple
installation. The plate that held the sway bars
together was 8 gauge mild steel. It measured
about 10 inches by 3 inches. The offset for the
sway bars is about 3/4 inch with the bottom one 3/4
inch rearward, or basically just enough to give the
sway bars a tiny bit of breathing room.
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Custom re-valved Bilstein shocks and struts. Update note April 2003: The below shock/strut setup was changed to adjustable coil-overs with R-Sport shocks. Scroll down for details. Some of you may have heard my complaints that I felt the HD "Heavy Duty" Bilsteins that I had previously installed in my 245 (October 2000) were too soft, particularly at the rear. I was experiencing an unpleasant amount of rebound... most noticeable at the rear, especially when adding passengers to the back seat or a load in the cargo area. This was while using ipd Sport Springs. I think these rear shocks may be just right for a sedan (I later put them on my 242 DL with iPd springs and they were fine), but I felt they were inadequate for my heavier wagon (it weighed 3240 lbs. empty). I
contacted Krupp-Bilstein in San Diego (Ph.
800-537-1085) and talked with Tech. Manager Jack
French, who was happy to help work out a formula for a set of re-valved Bilstein HD shocks and
struts using my car weight and approximate front/rear
split. I purchased a new set and they charged $55.00 per shock or strut to
rebuild and/or re-valve. At that time they would agree to re-valve any new or used Bilstein HD set.
If used ones were to be re-valved, they would be
rebuilt as well. Mr. French worked out a formula
based on the weight of my car, the front to rear bias
(they had charts on this for different vehicles), and
the spring rates, if known. SPRING RATES The result of the new re-valved shocks was a big improvement in control and only a slightly stiffer ride. Ride was actually quite pleasant on the highway. Below is the actual resistance measurements (before and after) for the Bilstein HD struts/shocks I had re-valved. |
For comparison, measurements are in NEWTONS and at a peak velocity of 500 mm/second (19.7 in./second) on Bilstein's computerized dynamometer. | |||
BILSTEIN HD SPECS |
Rebound/Compression | Part Number |
NOTES |
Original Bilstein HD Front STRUT: | 129/75 | 34-181539 |
Front
Bilstein HD strut supplied by iPd |
Original Bilstein HD Rear SHOCK: | 225/107 | 24-002967 | Rear Bilstein HD stock supplied by iPd |
Re-valved HD Front STRUT: | 220/100 | P36-0081 |
Front
Bilstein HD strut custom re-valved 34-181539 by Krupp-Bilstein San
Diego recommendation for 245 front with 152 lb. spring rate. |
Re-valved HD Rear SHOCK: | 300/120 | B46-0296 |
Rear
Bilstein HD shock custom re-valved 24-002967 by Krupp-Bilstein San
Diego recommendation for 245 rear with 129 lb. spring rate. |
OTHER
BILSTEIN SPECS |
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Bilstein HD (B6)
Front STRUT: |
350/150 |
34-030837 | Front
Bilstein HD (B6) strut designated for rallye |
Bilstein HD (B6) Rear SHOCK: |
275/200 |
24-022118 | Rear Bilstein HD (B6) shock designated for rallye |
Bilstein HD (B6) Front STRUT: |
305/206 |
34-030806 | Front Bilstein HD (B6) strut designated for cup/clubsport. These are a bit shorter. |
Bilstein HD (B6) Rear SHOCK: |
225/150 |
33-067230 | Rear Bilstein HD (B6) shock designated for cup/clubsport. These are a bit shorter. |
Bilstein HD (B6) Front STRUT: | 300/175 |
34-031520 | Front Bilstein HD (B6) strut designated for ambulance |
MEASUREMENT NOTES: Bilstein measures
its damping force in Newtons at a velocity of 500 mm/second (which
is approximately 20 inches/second). One Newton is the amount of force
required to accelerate 1 kilogram of mass to a rate of 1 meter per
second squared. Bilstein damping ratings involve two numbers, which represent the Rebound Force and the Compression Force — written as XXX/XXX. These numbers are an abbreviation representing 1/10 of the Newton value result. For example, a rating of 300/120
means 3000 Newtons rebound and 1200 Newtons compression at the specified velocity. Higher numbers
have firmer damping forces than lower numbers, so a shock rated at
300/120 will be stiffer than one rated at 130/75.
Some shock companies like to use Pounds-Force (lbs.F) for measuring damping. this is commonly used used by Koni and Gaz. These figures may be converted: 1 pound (lb) = 4.45 Newtons (N). |
Update 2016: Most of
the above B6 part numbers still seemed to be available through Summit
Racing.
Bilstein USA B6 listings: http://cart.bilsteinus.com/search/mmid=49239/drivetype=RWD ---Thank you to Knox Motorsports for Bilstein B6 racing designations listed above--- |
Other
Volvo
Owners'
Re-Valved Bilstein Experiences: Gary Harris owned an ’84 244 with a Corvette LT1 / 4lL60E drivetrain. He wrote: "Jack (French) recommended I go with 240/100 front and 300/120 rear since I am primarily (ie: 100%) street use. I have installed the new springs (which are progressive, 175# at ride height, 250# at full compression) and I am so far very pleased with the results. We definitely did not go too stiff on the front struts for my taste, and the vehicle has a very nice “taut” ride and no longer feels like a pogo stick! I think your 300/125 suggestion at the front would have been just fine."
Spring Works, 50 |
And the below specs
from KGTrimning.com illustrate the different specs
used
for some special-valved Bilsteins for 240 racers.
Bilstein stötdämpare 200-serien (Rally/Racing)
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WHAT ABOUT KONI YELLOW SHOCKS?
Koni Yellow or "Sport" shocks are known as single adjustable dampers. They have a fixed compression stiffness setting, but the rebound has three stiffness settings. While
I have not yet used Koni yellow shocks on a Volvo 240, I will add
the following info for comparison. This comes from
240 owner Michael Yount:
"I've spent a lot of time talking with the tech folks at Koni about their Sport shocks for the Volvo. They are MUCH stouter than the Bilstein HD's. The front struts offer 213/157 lbs damping force rebound/compression. The rebound damping has three settings - and the 213 lbs is the minimum. They will adjust to 427 lbs of rebound damping. The rears are more stout because of the motion ratio - the rear spring being 27" from the pivot point, while the rear shock is only 22" away. The Koni rear shocks offer 494/259 lbs of damping force in rebound/compression, and the rear rebound will adjust up to 990 lbs of damping force." For comparison purposes to Bilstein settings, the above rebound/compression measured in Lbs. Force have been converted to NEWTONS. KONI FRONT: 95/70 Rebound/Compression. Rebound adjustable to max of 190. KONI REAR: 220/115 Rebound/Compression. Rebound adjustable to max of 440 KG. MEASUREMENT NOTES: Bilstein measures its damping force in Newtons at a velocity of 500 mm/second (which is approximately 20 inches/second). One Newton is the amount of force required to accelerate 1 kilogram of mass to a rate of 1 meter per second squared. Bilstein damping ratings involve two numbers, which represent the Rebound Force and the Compression Force — written as XXX/XXX. These numbers are an abbreviation representing 1/10 of the Newton value result. For example, a rating of 300/120 means 3000 Newtons rebound and 1200 Newtons compression at the specified velocity. Higher numbers have firmer damping forces than lower numbers, so a shock rated at 300/120 will be stiffer than one rated at 130/75. Some shock companies like to use Pounds-Force (lbs.F) for measuring damping. this is commonly used used by Koni and Gaz. These figures may be converted: 1 pound (lb) = 4.45 Newtons (N). |
Updated 2003: Adjustable
Coil-Over Suspension Kit
The
below
pics show MVP's Coil-Over kit for the 240.
MVP no longer offers these kits, so you'll need
to look elsewhere. I opted for 200 lb.
front springs and 175 lb. rear springs. The
result, combined with the competition R-Sport
shocks,is a pretty firm ride, but certainly not too firm for a street driver. If you decide to go with springs this stiff I recommend some very firm shocks to overcome the rebound for these springs. I don't think unmodified HD Bilsteins will do at all. The front strut housings in
the pics didn't normally come with MVP's kit.
Your housings can be modified by a
machinist (they included instructions for that).
I paid extra for MVP to send a set of
modified housings on an exchange basis. Installation took me about 8 hours at a leisurely pace. That was including changing my previous monster sway bars to a more tame setup, flushing my brakes with ATE Super Blue fluid, and overcoming a few unplanned problems (related to Murphy's law). Current sway bar is now a stock 23 mm front bar and one 25 mm rear IPD bar. My feeling is that the stiffer springs and shocks pretty much eliminates the need for really large sway bars. |
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BIG
BRAKES Project completed March 2004. The front caliper/rotor on the left is stock (except for the custom drilling) and those on the right are from the 2004 and later S60 R. The R caliper is aluminum 4-piston Brembo. CLICK HERE FOR 240 BIG BRAKE PAGE FOR MORE |
Diagonal upper strut tower braces and lower A-arm to crossmember frame ties from a late seventies 242 GT. Tower to tower aluminum strut brace from Steve
Bucina in
Florida. Under Hood:
As of April 2001, my new motor and tranny are in. You can get more details on the motor from my Engine Project Page. Here are some older under hood pics: |
Transmission: Awesome
links for T5 transmission conversion info:
https://forums.turbobricks.com/showthread.php?t=3620 https://forums.turbobricks.com/showthread.php?t=23541 https://forums.turbobricks.com/showthread.php?t=23646 https://forums.turbobricks.com/showthread.php?t=23284 https://forums.turbobricks.com/showthread.php?t=18952 https://forums.turbobricks.com/showthread.php?t=17614 https://forums.turbobricks.com/showthread.php?t=17283 https://forums.turbobricks.com/showthread.php?t=16921 https://forums.turbobricks.com/showthread.php?t=15408 https://forums.turbobricks.com/showthread.php?t=16019 https://forums.turbobricks.com/showthread.php?t=11183 https://forums.turbobricks.com/showthread.php?t=37552 And Aaron Baker's page: http://www.aaronreedbaker.com/t5swap.html |
Custom
aluminum
intercooler
from Spearco in Torrance, California. This intercooler is 22 inches wide (at the bottom of the tanks), 28 inches wide overall, 17 inches tall, and 3 1/2 inches thick! While the surface area on the front of this intercooler is approximately the same as a stock one, the displacement has increased from 375 cubic inches to 952 cubic inches. Some of you have asked if I think this intercooler produces more lag.... absolutely not! Also I recall modifying the brackets for the oil cooler, but I eventually got smarter and began placing the oil cooler in my 240s UNDER the bottom radiator crossmember, about 8 inches behind the front spoiler opening. That is a much better place. The stock oil cooler lines can be moved and tweaked to allow the oil cooler to be place down there without needing any new lines.
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<<< I designed the intercooler specs and provided Spearco with this drawing. It generally follows the shape of an original intercooler. This design is fatter than a stock IC and when in my 245 next to the big radiator, I had to trim some of the sheet metal from the back edge of the top radiator support. But by reducing the height of this IC by about an inch or two, you could easily tuck it under the support and not have to make any cuts. | |||||||||||||||||||||||||||||||||||
SPEARCO INTERCOOLER TESTING
The below temperatures were recorded
as temperatures increased.
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Stock Volvo Intercooler Efficiency
The below information was provided by Niels Bengaard of Denmark. The tests were done on a standard 240 intercooler and standard Volvo 240 Turbo. Owner/tester: Henrik Mortensen of Denmark. All measurements were made at a stabilized speed and boost. Outside temperature 28C (82F).
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EFFICIENCY: Stock vs. Big Spearco
Based on the above
measurements... The above tests show that a stock Volvo intercooler is capable of approximately 81% efficiency. Not too bad, but improvement is possible. The Spearco intercooler I has shown that it is capable of approximately 97% efficiency. Keep in
mind that many other factors will affect testing
results. Every modified car will act differently,
so it is difficult to tell how your car will react under
similar testing.
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For
those of you who prefer the "proper scientific" or thermal
engineering approach, the below figures were provided
by Chris [krzysztof_98@yahoo.com].
These numbers are in 'Kelvins' which are proportional to Celcius (bigger by 273 units). Neil's
OEM
Intercooler Above Spearco
Intercooler -NOTE: T1 and T2 were reversed so the result would not be negative efficiency, which is actually what you want to see since this is a 'heat engine' that cools. This means using a thermal engineering approach, the
Spearco
unit is more efficient by about 6%, which is
thermally a very good improvement. |
Custom aluminum radiator from Ron Davis Radiators in Glendale, Arizona (Ph. 623-877-5000). This radiator is 22 inches wide, 16 inches tall, and 2 3/4 inches thick. It has 2 rows of large 1 inch tubes. |
Here is an in-progress installation photo of the new intercooler and radiator. This may not look like it, but it was a lot of work to squeeze them in. Believe me, there is no wasted space. |
The primary electric puller fan is a Spal 16" shrouded high-flow type that I installed with this radiator. CFM rating is something like 2300. I purchased it from Mattson's Radiator, Inc., in Stanton, California (a Spal dealer and another custom aluminum radiator maker). Their number is (714) 826-0357. B230 (from 740 Turbo) Intake Manifold Conversion: This made a big difference in the smooooth idle department and increased power too. I was
originally using a Porsche (Bosch) Compressor Bypass
Valve for the turbo. This is a plstic type
valve was used on twin turbo Porches at the time.
It's a little more stout that the Saab CBV's that were
common and can better handle higher boost
pressures. The Porsche part number is 993-110-337-50.
I am now using the Forge billet aluminum bypass valve from Stratmosphere.com. See it at http://www.stratmosphere.com/forge_valves.htm |
Performance: Best 0-60 mph time: 5.97 seconds using my G-Tech/Pro. Auto trans. Best 1/4 Mile Time: No time recorded. MPG highway: Was 19 MPG with the auto trans... now 27 MPG with the 5-speed. MPG light-foot/city: Was 16 or 17... Now low 20's with the 5-speed. Dyno Results: RWHP: 221 @ 4500 RPM (corrected). RWTorque: 323 @ 3200 RPM |
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