1983 240 6.0L GEN IV LS V8 conversion

alphax · 2016-06-25T19:53:58+00:00

Going to leave the L98 stock or mod it as well?

alphax

1uzvolvo;82323 wroteReally nice solution to the location problem. Does this also give you a short/quick shift result or is the throw already fairly tight.

Also interested in what if any work has been done to the tunnel to fit the motor/bellhousing/box in.

It does quicken up the shift in that the linkages are shorter, more taunt and now has more firm bushes. It's a very direct and firm click, click into each gear.

I'll take some pics of the tunnel, but there is a fair amount of tunnel massaging required to make this work, both at the tunnel opening and throughout the tunnel itself to clear the gearbox housing. I also needed to cut a single part of the double skin further down the tunnel and a small portion of the double skinned area just behind the shifter which is to clear the output flange/adapter/tail shaft. It's only a relatively small area, but it's tight toward the rear of the tunnel using this box. Will weld some new material in there with a slightly different shape to clear the tailshaft.

alphax

robv;82333 wroteYou continue to Impress! Love the original gear knob.

Haha yes, will be making a hybrid GM/Volvo shifter that will allow me to run the stock Volvo shift knob and shifter boot and retain the well weighted GM shifter which is steel and nice heavy vulcanised rubber. You need some weight in these shifters as they are not the lightest, easiest to shift boxes

alphax

Time for an update. A lot of progress and some set backs.
Mock-up phase and is now well and truly over and is now in prep for final assembly.

Making the Airbox: 4" Intake with 6" bellmouth.

Shifter is a Stainless replica of the original, with Tremec shift pattern etc.

Got the new fuel system installed. DeatschWerks DW300 in-tank pump, New 3/8 hardline and retaining clamps from front of rear wheel to engine bay:

Stock C5 Corvette fuel filter/regulator mounted in stripped factory cradle:

Using quick disconnect fittings everywhere possible: This filter is also the fuel pressure regulator so is used to return fuel back to the stock sender/pickup unit. Factory return line from engine bay to rear is eliminated.

alphax

Rear of the tunnel is finished. Double skinned panels remain, but have moved up slightly for more tunnel clearance. Double folded sheet steel in there TIG'd into place... it's very strong. The bulk of the tunnel stays stock with some massaging.

Rubbed back for painting in factory CLR809 Sandstone Beige :-)

Philia_Bear

Where do you get the bare plastic quick disconnect fuel fittings?
Whenever i go looking i only find the alloy ones for $$$$

alphax

I source mine from Steve Newing at EFI Hardware in Mitcham. Summit have them also, but Steve has a better range, good pricing and is a great bloke with super knowledge around EFI components.
https://www.efihardware.com/products/c404/E85-Fuel-Hose-and-Pipe

Vee_Que

Efihardware is good to deal with!

GingerNinja

I'm glad you're sticking with the factory beige. The best sleeper colour for sure.

Ex850R

Good progress and done properly.
Bloke , I admire your work.

AshDVS

EFI Hardware are fantastic to deal with. Very knowledgeable and happy to help.

alphax

Among other things, today was painting day. Ceramic painted the headers, painted the airbox, piping, shifter brackets, engine mounts, engine bay, charcoal canister bracket and various other odds and ends.

Drivers side.

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photos upload

Gearbox output flange adapter has been made, so tailshaft will be ready this week. Last minute ordered a stock GM W427 clutch from the LS7, with flywheel etc to replace the clutch I have now which is probably worn about 60%. Rear brakes are in and ready to be bled etc, just waiting on Kaplhenke front end parts so I can fit the front brakes, steering etc.

alphax

Have been doing a lot of work on the air-conditioning system. Original condenser was rubbish, so I searched high and low for a modern style parallel-flow condenser as big as I could find. Turns out VS Commodore fits nicely and the OEM units are nice quality made in Japan items. These are designed to run without a dedicated fan. Integrated receiver dryer up front is nice to have. Still leaves room for engine oil cooler up front.

Decided not to run any of the LS-style variable displacement A/C Compressors. Likely not going to work well with existing evaporator/TX valve setup, so have fitted a serpentine pulley and clutch to the Sanden compressor originally fitted to the car and made a bracket up using the LS idler and tensioner system. This compressor was recently replaced on the car before I bought it.

Assembly is well underway now.

Ex850R

Quality!

carnut1100

Nice...

pauljloz

Are you considering any lower bracing below the remodelled firewall to account for some lost rigidity at the lower control arm mounting?

I expect the importance of this location within the chassis structure is better assessed from below the car than the photo / desktop.

alphax

pauljloz;86002 wroteAre you considering any lower bracing below the remodelled firewall to account for some lost rigidity at the lower control arm mounting?

I expect the importance of this location within the chassis structure is better assessed from below the car than the photo / desktop.

Yes, I 've seen a number of vehicles braced there in similar fashion but not sure what i'll do yet. The upper bracing will be pretty substantial.

timmykroek

Can't wait to see this on the road!

sucksqueezebangblow

Can't wait to hear this on the road!

alphax

Thanks guys.. Still a lot to do, but It's getting to the pointy end now

alphax

Have been playing with front brakes and suspension, almost all together. Waiting on the power steering type ball joints to come in, the type with a 10mm offset for increased positive caster. Springs, shocks and EL Falcon sway bar up front has been test fitted with adjustable end links... It's 3.3 times more rigid than the original Volvo item. Maybe too much, but will be a very different car in the end.

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RX-7 Sumitomo calipers with 740 Vented rotors are in courtesy of the DVS adapters. Made the brake lines and fitted some EBC Reds. Will be interesting to see how much punishment this setup can take.

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LS7 (7 litre) clutch has come in. It has a shorter stack height compared to a normal LS clutch, so the slave cylinder will need to be spaced out for proper engagement. Typical project car 'bolt on' solution... that is not really bolt on at all. You can see the LS7 flywheel on right, note the much larger surface area for the friction plate compared to the regular LS clutch/flywheel on left. LS7 clutch retains stock feel but can support good horsepower in heavy cars no problem... This car will be much lighter than say a VE Commodore.

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pic upload

Tailshaft has come in now also.

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