960 Rally Car

Spac · 2020-01-27T22:34:50+00:00

Some of the bits were already accumulated, some have been purchased specifically for this project. The BMW gearboxes are $1200 from Aussie wreckers ?, or abo...

Philia_Bear

Have you already removed the 3 vibration dampening weights from the engine bay?

ramrod

@Philia_Bear

There is only one isn't there? The square in the middle of the firewall

carnut222

ramrod
@Philia_Bear
There is only one isn't there? The square in the middle of the firewall

There’s one inside each chassis rail behind the front bumper mountings...

Philia_Bear

carnut222
https://ozvolvo.org/discussion/comment/171111#Comment_171111
There’s one inside each chassis rail behind the front bumper mountings...

This

carnut222

I did a weight reduction project on my 740T before taking it to a fun day at Winton raceway in Benalla...ages ago...did a write-up for the club mag IIRC. Here's a couple pics of the tuned absorbers (ie rubber mounted weights) that sit inside the front chassis rails. They're held in by 4x nuts from the engine bay side of the chassis rails, then pull them out through the front after removing the bumper shock absorbers.

carnut222

Found the article...not a whole lot of detail on what things actually weighed unfortunately. I thought I had weighed everything I removed, but that was when we were doing the EV conversion on the 240...

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Spac

Today’s progress. Nothing particularly big or interesting, but I am trying hard to make some progress every day.

The lack of crap in the engine bay is making me happy. Hope to leave as much of it out as possible when it is time for reassembly. This is part of the motivation for a floor mount pedal box, which I think I have talked myself into buying.

Spac

Bonnet pins.

Still flinch when drilling into a nice straight bonnet, but less and less each time.

Because the inner bonnet frame is so far away from the skin at this point, I needed a hole larger than the pin diameter in the frame.

Getting the alignment right is always a hassle but this was worse than usual because the pins actually point forward slightly.

But got there in the end.

Other news from today is that the rollcage man wants the car on Monday.

So I’ll try to get the motor and auto out over the weekend, to make it easier to push around.

Ex850R

Never a dull moment!

Spac

Got the motor and box out, in between real life (The Girl having a friend over, picking up The Boy’s new XR80, etc).

Had to take the headlight out because my long-suffering engine hoist ran out of oil before the engine was above the height of the radiator support...

Removed the Greg Weights ( ? ) too.

And the towbar that I didn’t even know it had until I started messing with it...

Spac

Very rough trial fit of the driver’s seat.

I was happy that the Mirage’s seat was about 120mm from the door. This is more like 200mm! But it will have to move back outward by at least 50mm to get the pedal position right.

As it is right now. Green tape on windows is a guide to where the seats will be, to help the rollcage design.

Spac

Rear bumper rattled when I removed it.

Pulled the skin off the support and shook out 1.2kg of rocks and dirt!

I haven’t been too concerned about weighing stuff on this build. Partly because it will end up weighing whatever it weighs, partly because manufacturers lie about weights, and partly because the weight comes out of a Volvo so easily.

That said, there’s a few times where curiosity has gotten the better of me... headlights are 3.5kg each; rear bumper skin is just under 4kg, rear bumper support is somewhere over 10kg (too lazy to weigh it properly).

Heater/AC stuff is insane - I reckon the 940 under dash stuff alone, weighs more than the entire E36 climate control system!

I already have plans to ditch the stock headlights (as per 99% of Swedish rally Volvos), but now looking at what I can do with bumper supports within the rules.

nugget_940

Spac
Rear bumper rattled when I removed it.
Pulled the skin off the support and shook out 1.2kg of rocks and dirt!
https://cdn.ozvolvo.org/uploads/711/V8N5822AEU22.jpeg
https://cdn.ozvolvo.org/uploads/235/U5BET60FISHU.jpeg
I haven’t been too concerned about weighing stuff on this build. Partly because it will end up weighing whatever it weighs, partly because manufacturers lie about weights, and partly because the weight comes out of a Volvo so easily.
That said, there’s a few times where curiosity has gotten the better of me... headlights are 3.5kg each; rear bumper skin is just under 4kg, rear bumper support is somewhere over 10kg (too lazy to weigh it properly).
Heater/AC stuff is insane - I reckon the 940 under dash stuff alone, weighs more than the entire E36 climate control system!
I already have plans to ditch the stock headlights (as per 99% of Swedish rally Volvos), but now looking at what I can do with bumper supports within the rules.

Off topic but how tf did you get the rear bumper off!!! Are there hidden bolt somewhere that I dont know about??

Spac

Rain stuffed my original plans for today.

Rally car (to be) on the trailer meant empty garage...

I have two 960s that I have no affection for. I chose this one as the donor motor supplier because it has way less kays, and ... ah, no, that’s the only reason.

Motor is now ready to come out. Sort of surprised me - I was just fiddling away and realised that I had run out of things to do!

Getting the aircon compressor off the block without degassing it, was an utter turd of a job. Ended up taking off the PS pump and alternator, and then this little prick of a bracket was in the way of the last bolt on the compressor. I managed to get both bolts out that held the bracket to the block, but one bolt (and the bracket) couldn’t be removed because the wiring loom was in the way. And unbolting the loom was a massive hassle.

Closest I have been to losing my shit in a while. Worst part is that I have no idea what the bracket is even supposed to do - just seems to sit up against the back of the AC compressor??

Certainly lots of motivation to simplify things when it goes into the rally car.

And now I can’t actually remove the motor because my engine hoist needs more oil and I have no idea how to fill it up...

jamesinc

Spac
Rain stuffed my original plans for today.
Rally car (to be) on the trailer meant empty garage...
https://cdn.ozvolvo.org/uploads/015/GP0ZMHL6RUFM.jpeg
I have two 960s that I have no affection for. I chose this one as the donor motor supplier because it has way less kays, and ... ah, no, that’s the only reason.
Motor is now ready to come out. Sort of surprised me - I was just fiddling away and realised that I had run out of things to do!
https://cdn.ozvolvo.org/uploads/073/OBMBCLMJ03UM.jpeg
Getting the aircon compressor off the block without degassing it, was an utter turd of a job. Ended up taking off the PS pump and alternator, and then this little prick of a bracket was in the way of the last bolt on the compressor. I managed to get both bolts out that held the bracket to the block, but one bolt (and the bracket) couldn’t be removed because the wiring loom was in the way. And unbolting the loom was a massive hassle.
Closest I have been to losing my shit in a while. Worst part is that I have no idea what the bracket is even supposed to do - just seems to sit up against the back of the AC compressor??
Certainly lots of motivation to simplify things when it goes into the rally car.
And now I can’t actually remove the motor because my engine hoist needs more oil and I have no idea how to fill it up...

Bout half way up the hydraulic ram there should be a rubber bung, pull it out, put hydraulic fluid in (I use ATF myself, works just fine).

Spac

jamesinc
https://ozvolvo.org/discussion/comment/171243#Comment_171243
Bout half way up the hydraulic ram there should be a rubber bung, pull it out, put hydraulic fluid in (I use ATF myself, works just fine).

Ah, rubber! I assumed it was some sort of steel rivet because it had been painted over (and the paint hasn't flaked off).

This sounds much simpler!

Spac

Not much to look at, but the business end of the rollcage has been bent up.

Some parts were easy (like the dead straight windscreen bar) others were more difficult, like getting the front legs down past the dash mounts.

Random tidbit is the bumper supports are about 1kg per 200mm.

And the V40 is running like a bag of poop, so will take up my spare time until I sort it.

Edit: False alarm on the V40 - just the usual coil pack connector problem.

Philia_Bear

@Spac

Just fyi

The later 940s wagons have a large fuel tank which is a drop in replacement for any earlier 7/9 with the live axle if you want more range

Also I would recommend putting a walbro 255 into the tank and running new armoured line from the tank to the engine bay and moving the filter to the engine bay, the fuel fitting on the rail is the same as used on the injectors for a BMW diesel (m57n2) so I have lots of fittings with short bits of pipe if you want to make a Volvo to an4/5/6 adapter

Also makes it easier to add in a surge tank somewhere

Spac

New aluminium 3/8" fuel line will be going inside the cabin. Hadn't worked out where the filter would go, haven't worked out if a surge tank is needed.

Spac

Well hello sailor!

Sits like a 4WD now...

Kind of a bit torn about this car - non sunroof, non-Nivomat 960 is the best spec, but do I care enough to save it? Does anyone care?

Question for the learned types... What’s the stock fuel pressure?

Tuning guru is questioning the stock injector sizing for my desired ~140kW ATW.

Philia_Bear

Spac
Well hello sailor!
https://cdn.ozvolvo.org/uploads/271/VTCE419LMTSD.jpeg
Sits like a 4WD now...
https://cdn.ozvolvo.org/uploads/994/PTLXRFBTSIFA.jpeg
Kind of a bit torn about this car - non sunroof, non-Nivomat 960 is the best spec, but do I care enough to save it? Does anyone care?
Question for the learned types... What’s the stock fuel pressure?
Tuning guru is questioning the stock injector sizing for my desired ~140kW ATW.

The injectors are fine for 140KW at the wheels, TBH.... you should be aiming closer to 180KW

If you want some T5 injectors they bolt in and then you will never run out of injector (I have 50 of the blasted things just sitting around)

Also...Did you want a set of T6 behive springs so you can safely run a 7000rpm rev limit all day long?

The T6 head is way better for flow and burn even in a NA setup, it just requires some interesting work to get the B6304 cams to fit to the T6 head, but the work required is documented

And it runs 3bar stock for fuel pressure

BTW if you don't want the auto box I'm happy to take it sans bell housing.... also would love to take some bits from the 960 as I do plan to convert the rear of the tentacle wagon to IRS.....

ramrod

43psi

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