1983 240 6.0L LS2 V8 conversion



  • You 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
  • alphaxMichael (@alphax) Melbourne
    edited April 2018
    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.

  • alphaxMichael (@alphax) Melbourne
    edited April 2018
    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 :-)


  • Where do you get the bare plastic quick disconnect fuel fittings?
    Whenever i go looking i only find the alloy ones for $$$$
    I think you need to add i was in an s80 with three wheels getting pulled backwards and was told to "hold on shit is about to get real".
  • alphaxMichael (@alphax) Melbourne
    edited September 2016
    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.
  • Vee_QueVee_Que (@Vee_Que) South Eastern suburbs Melbourne.
    Efihardware is good to deal with!
  • I'm glad you're sticking with the factory beige. The best sleeper colour for sure.
    '88 245
    '88 245 turbo
  • Ex850RSnoopy (@Ex850R) Somewhere Over the Rainbow. Melbourne.
    Good progress and done properly.
    Bloke , I admire your work.
    cancer sucks
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    EFI Hardware are fantastic to deal with. Very knowledgeable and happy to help.
    Likes good coffee & motorsport. Builds stuff. Occasionally races stuff.
    f: https://www.facebook.com/DvsPerformanceParts
    twitter & instagram: ashd61 | w: http://www.dvs.net.au
  • alphaxMichael (@alphax) Melbourne
    edited April 2018
    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.

    20160911_125302.jpgphotos upload

    20160911_174736.jpgphotos 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.
  • alphaxMichael (@alphax) Melbourne
    edited April 2018
    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.


  • Ex850RSnoopy (@Ex850R) Somewhere Over the Rainbow. Melbourne.
  • edited September 2016
    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.
  • 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.

    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.
  • Can't wait to see this on the road!
  • Can't wait to hear this on the road!
    previous: 67 Mini Deluxe, 84 BMW 318i, 04 Hilux, 74 KE20 w/ 4age turbo, 06 Ford XR6T, 12 Isuzu Dmax
    current: 08 Volvo V50 T5 AWD, 16 SS Sportwagon
  • Thanks guys.. Still a lot to do, but It's getting to the pointy end now
  • alphaxMichael (@alphax) Melbourne
    edited April 2018
    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.

    sway_bar.pngimage hosting gif

    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.

    20160920_221142_001.jpgpic upload

    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.

    20160920_222608.jpgpic upload

    20160920_222718.jpgpic upload

    Tailshaft has come in now also.
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    It's coming along well.
    I see you used the RX7 FD caliper, rather than the FC - any fitment issues?
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