Project 254

Posts

Post 793518 by oblark on 2015-12-20 19:37:29

As 240 turbo's using the 940 lpt red block engines are get as common as muck I think it's time to take the 240 to the next level ........ T5 it :) With the help from Steve we went and picked up a OBD1 850 T5 engine with 118k miles. The first thing I found was the turbo is well passed it's best, but the rest of the engine is Ok it looks like it's had the PCV changed and a service not many miles ago. The first thing to do is to remove all the bits that are not needed. Image Image Then bolt on all the bits that are needed. Image Image Image

Post 793520 by Nealevo on 2015-12-20 19:42:51

Looking good Rob, don't suppose you got the gearbox with that engine??

Post 793522 by oblark on 2015-12-20 20:07:12

[QUOTE=Nealevo;793520]Looking good Rob, don't suppose you got the gearbox with that engine??[/QUOTE] When we turned up the engine and gearbox was still on the sub frame, As it would fit in the back of Steve's car we had to break it down to just the engine. I'll pm you his phone number but he won't post anything.

Post 793524 by Dangerous Dave on 2015-12-20 21:10:12

Nice :D You going to run a custom sump or fit a modified 960 one?

Post 793527 by oblark on 2015-12-20 21:17:25

[QUOTE=Dangerous Dave;793524]Nice :D You going to run a custom sump or fit a modified 960 one?[/QUOTE] A modified 960 sump :)

Post 793529 by Dangerous Dave on 2015-12-20 21:33:29

Sweeeeet! Looking forward to future updates :)

Post 793674 by oblark on 2015-12-23 19:22:47

Picked this up from the profilers this afternoon before they closed for Christmas. Image

Post 793710 by Dangerous Dave on 2015-12-24 16:08:42

[QUOTE=oblark;793674]Picked this up from the profilers this afternoon before they closed for Christmas. Image[/QUOTE] Gearbox adapter? What you going to be running?

Post 793762 by oblark on 2015-12-25 10:59:42

[QUOTE=Dangerous Dave;793710]Gearbox adapter? What you going to be running?[/QUOTE] It's a gearbox adaptor so I can use the red block M90 gearbox.

Post 793764 by Dangerous Dave on 2015-12-25 12:02:55

Ah yes, I do like the smoothness of the M90 (well compared to the M47)

Post 793790 by oblark on 2015-12-26 16:52:47

Started to countersink the holes in the adaptor plate so it can be bolted to the engine, Did all but 4 as my countersinking bit has now passed it's best so I'll order a new one in the new year. Did a trail fit of the red block bell housing and all looks ok. Image Image

Post 793791 by craigoodwood on 2015-12-26 17:05:18

i dont suppose you got the profile drawing with it too?? :B_thumb:

Post 793838 by oblark on 2015-12-27 17:37:03

[QUOTE=craigoodwood;793791]i dont suppose you got the profile drawing with it too?? :B_thumb:[/QUOTE] I gave the profilers the bell housing and they used that to cut the adaptor plate. The gearbox adaptor plate is finished. Image Image Image

Post 794326 by oblark on 2016-01-03 19:23:44

Made a new turbo oil return pipe as the turbo has been "clocked" and the 850 wont fit anymore. The new pipe was made from a 940 lpt and a 850 oil pipe. Image Image Image Image The down pipe looks like it could be fun. Image

Post 794360 by t5steve on 2016-01-03 21:40:01

looking good rob

Post 794517 by oblark on 2016-01-06 18:58:10

This little beauty arrived in the post today :) Image

Post 794860 by Basil on 2016-01-11 14:01:00

The intercooler you posted a photo of, may I ask if the tubes have internal turbulators, (internal finning)? Or are the tubes "empty"? Thanks.

Post 795177 by oblark on 2016-01-16 19:14:22

Some major parts arrived from classic swede during the week so today I was out in the man cave cutting down the sump from a 6 cylinder to a 5 cylinder. Also the oil pick up tube modified to fit. Image Image Image Image Image Already to be welded. Image On the engine mount front, the inlet side only has 3 out of 4 bolt holes that line up. But the exhaust side only has 2 out of 4 bolt holes that line up so I'll be fabricating so new engine mounts out some steel plate. Image Image

Post 795862 by oblark on 2016-01-30 19:18:21

I purchased the CAD file of lower engine mounts from Homer and had them manufactured from 5mm steel. I wasn't happy with how the upper engine mounts sat so I manufactured them from also 5mm steel. I used a CAD (card aided design) to make the mounts. Image Image Image Picked the sump and the oil filter bracket from the machine shop this morning. The sump had to be skimmed as it bent when it was welded. With the aid of some Volvo chemical gasket the sump was fitted and the oil filter bracket was screwed into the sump. Image Image Image Image Image Image

Post 795906 by kmb on 2016-01-31 14:47:14

Lol at the card aided design - Thanks for the updates Rob!

Post 796593 by oblark on 2016-02-14 19:43:44

The old red block engine and M90 gearbox came out without much grief. The gearbox was removed ready to be fitted to the T5 lump. The adaptor plate was drilled and tapped to the hole pattern of the gearbox. The m90 pivot ball was measured and was 24mm long (RHD side)but the pivot ball from the m47 gearbox was 30mm (LHD side) long so with the aid of 2 8mm washes the pivot ball was the required length of 34mm. Had to grind the corner off the drivers side lower mount so the steering column would miss. Image Image Image Image Image So today the T5 lump and m90 gearbox was fitted into the car. What a PITA, had to drop the cross member by 40 so the sump could fit over the top. Once passed the cross member it dropped in perfectly and lined up with all the mounts. Image Image

Post 796603 by Dangerous Dave on 2016-02-14 20:11:00

Coming along nicely :) Thats some gap in front of the engine, the 5 pot can't be much longer than the redblock by the look of it.

Post 800345 by oblark on 2016-04-30 20:27:53

Up date time as the car is up and running now :) Time for a bit of wiring. Image ECU fitted and wired in. Image Oil and water lines were made from 10mm hydraulic pipe. Image 3" induction pipes. Image Image Fuse board relocated to the glove box. Image 2.5" downpipe with lambda and wideband semsors. Image 3" maf and heat shield. Image

Post 800346 by oblark on 2016-04-30 20:38:46

Two secondhand struts to be turned into coilovers. Image Coilovers with brembo calipers and custom 290mm discs. Image Nice ride height. Image Later type brake reservoir. Image The old panhard converted to a adjustable one. Image Bumper removed to add some more air flow. Image Image Custom power steering fitting. Image New strut brace and catch tank fitted. Image Image Strut brace all painted up. Image Image Image

Post 800347 by Doingitsideways on 2016-04-30 20:49:46

So is it running now? :D

Post 800350 by oblark on 2016-04-30 21:23:15

Yep it's up and running. [video=youtube_share;FaB6Fu8upl0]https://youtu.be/FaB6Fu8upl0[/video]

Post 800352 by kmb on 2016-05-01 08:12:53

This is looking great Rob, lots of hard work and attention to detail - Particularly like the glove box relocation of the fuse board. What's left on the list of things to do?

Post 800421 by Bigsi15 on 2016-05-02 21:03:52

Fair play rob this is great work. I felt pleased with myself for removing rebuilding and refitting a t5 engine but that came from the same car and is nothing like the complexity of this! A t5 lump in a 244 body shell is the perfect combo, it's going to be great fun! I wish I had your skills mate

Post 801564 by oblark on 2016-05-29 21:52:25

Had to fit the 16T that I was going to convert to a 19T as the 15G decided to eat its self, So with the 16T fitted and once I'd fixed the rough running it was time to do some data logging, For a 16T and white it produces some good boost :) [ATTACH=CONFIG]30741[/ATTACH]

Post 801577 by MoleT-5R on 2016-05-30 00:30:36

Another awesome thread Rob, great to see the fruits of your efforts

Post 801582 by petrolh34d on 2016-05-30 01:03:17

Some tidy work there. The strut brace is a work of art though. :B_thumb:

Post 801642 by oblark on 2016-05-31 21:04:46

Finally got around to having some adaptor rings made so I could fit the chrome centre caps. Image Image Image Took the 240 t5 to the Winchester classic car & bike breakfast meet on bank holiday monday. Image Image

Post 810317 by oblark on 2017-03-07 19:31:11

The 240 has started a bad habit of eating cluthes, the reason for this is the frition plate is hanging off the end of the gearbox imput shaft. To overcome this problem a construction grade disc was bolted to the face of the flywheel then drilled to loose the additional weight of the disc. So the flywheel went from 7 kgs to 10kgs then down to 9 kgs. Just need to get it balanced then I can get it fitted. [ATTACH=CONFIG]31412[/ATTACH] [ATTACH=CONFIG]31413[/ATTACH] [ATTACH=CONFIG]31414[/ATTACH] I also built a plenum chamber inlet manifold as the throttle was a PITA to get at on the old ME7 manifold. [ATTACH=CONFIG]31415[/ATTACH]

Post 812862 by oblark on 2017-07-09 18:53:30

Well the 240 got converted back to the B230FK engine then she was sold. [ATTACH=CONFIG]31658[/ATTACH] [ATTACH=CONFIG]31659[/ATTACH]

Post 812896 by MoleT-5R on 2017-07-11 05:07:05

Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??

Post 812897 by martin_r_smith on 2017-07-11 07:35:21

[QUOTE=MoleT-5R;812896]Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??[/QUOTE] Don't worry moley, the work hasn't stopped ;) I'll start a new project thread soon.

Post 812908 by MoleT-5R on 2017-07-11 19:53:06

Nice one Martin, nice to see that the car is still in the forum, you kept that quiet. ...:mischievo

Post 812910 by oblark on 2017-07-11 20:01:14

[QUOTE=MoleT-5R;812896]Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??[/QUOTE] It's full steam ahead on the awd conversion which all starts in just over a weeks time :)