Volvo 940 shooting for 300 bhp build

Hello and welcome to my thread.

Always wanted a volvo 940 and the time game with one coming up at a cheap price so took the plunge and bought it
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Decided to do the usual and chop the springs for now and took two coils off the front and 3 off the back then jubilee clipped them in place to stop them falling out.

done a burnout in one wheel blaze mode. Was Good laugh and spun up good

 

A started the build a few months back and have been compiling parts and photos.

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Bought a boost controller

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Got a cheap boost gauge from eBay which is surprisingly accurate

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I then bought a spare car with no engine or box interior missing ect from a friend for £50 quid.
Went about taking the front suspension struts off to make coilovers. The front setup of these is similar to a e30 escort Capri ect. The hub and strut are one peice and as such off the shelf items are expensive

 

So coilover plan as follows.

First Step. Get some free e39 ta technic coilovers of my good friend Paul.

Second. Make them fit.



Cut the strut off leaving a little stub

 

Give the ta technic coilovers a little measure.



Make a sleeve. I couldn't get any thick wall tube that was the right size so had to make it out of solid bar. Took some time but at least I knew they would fit perfect



Make a couple of collars for pinch bolts.



Do some tig weld. Not by me



Cut in half so they work





Mig weld them on. Done by me.



Little lick of paint and on they went.

Only possible due to the fact my good friend is rather smart and has all the tools a man would ever want. Most of the work I done myself and he guided me along the way.
The man in the hat is good. The other guy is just me.

 

Next was of course the clutch died.

The car was 130 bhp and then went to around 180 with the boost raised and killed It.

These cars come with a duel mass originally so first was to source a solid flywheel



It's a common upgrade to get rid of the duel mass but you have to change to a diesel clutch. Being an old car these are hard to get a hold of so bought one from classic swede as he is a parts dealer.
After strippings the car to find it didn't fit. Him trying to source me another and leaving me in the dark about it all a little I ended up cancelling the order 2 weeks after getting mucked about. Have bought parts before from him and has always been spot on.

So next was to look for an alternative. Found that 850 t5 clutches would work as the spline is the same and this is what ttv supplies for there solid to t5 flywheel



So because I don't have a lot of money. Decided I would just make my own.






Got mine on the lathe and started working away. Had about 30mm to take off. At 0.6 of a mill a time it took a while.



Got it flat eventually.



Scribed a line for the new clutch plate to sit on as it was wider hence taking all the material off. Plus the 850 flywheels are flat.



Drilled and tapped the holes and bolted it up.



Clutch on. Went for a run. Perfect. Didn't balance the flywheel after lathing it down and there is no vibration what so ever. Was super happy and cost £55 for the flywheel rather than ttv £300. So all in all a winner.

 

Why does it matter what ratio my diff is ? Thought they were all the same apart from g80 locker.

 

I may revive this if people are interested ?

Cheers.

 

so tested the clutch with a good burnout on the open diff. seems to pull good with boost raised so onwards and upwards

 

ok so won a cheap turbo on ebay and decided to sell my bike to fund this and make it better. drifted an mx5 for a year with coilovers and a welder so decided this would be my build with more power as 115bhp was good fun but held me back at certain points on the track .

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i know the exhaust housing is a bit large but at this point i thought £25 for a turbo that size was good and if it needed rebuilt i can do it at a later stage

 

so next step was to take it along to my friend niall at originiall fabrication in wallyford,east lothian. i have a few fabrication friends but he was the go to guy for exhaust work as its incredible quality work for the price.

i showed him the standard manifold as i was hoping he could mill the flange flat as a common thing everyone does and to have the crack at back welded and add in peice for external gate. alot of people port them out too.

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he had a look and said it was a poor design that wouldnt flow great, i know alot of people still use these with big turbos but to get the most out of the turbo it was recommended we done a custom manifold and 3" exhaust.

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lovely equal length twin scroll manifold

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3" exhaust had to be pie cut as it curls round the back of the manifold and keeps it all the same size for good flow

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centre section is nice and straight haha, just the way it worked out, nice and easy to replace as this is the bit that gets scraped and dented.

 

Turbo is a t04b