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 Post subject: Another 242 project
PostPosted: Mon Oct 12, 2015 2:16 pm 
Hiring a japanese chess champion as ECU

Joined: Wed Mar 15, 2006 8:28 pm
Posts: 484
I bought this 242 a year and a bit ago and haven't touched it since buying it. I spent a couple of years looking for a clean 242 shell to build up for autocross, and the road track which is 15 minutes from my house. I ended up finding a car locally (figured I'd be going to the southern states to get one). Car is a 1980DL, carbed car, no sunroof. It was painted back in 2010 (its some Dodge SRT brown colour.) Car was originally poo brown.

The goal is more track orientated rather than street- though I'll probably drive it to work and car shows in the summer, comfort isn't a huge priority- though- I want to keep my back seat so I can strap the kids in and take them for rides. Hoping to get my oldest son out in the garage helping me, but he is only 4.5 and doesn't care.

Overview of the build-

Engine- 350WHP
16V Turbo B230
John V rods and pistons (probably)
nathaninwa intake manifold.
nathaninwa exhaust manifold- tubular, pulse paired, twin tial gates (should be here in a week or two)
New Garrett Turbocharger, T3/T4E, 50Trim Compressor, StageIII .78 AR Turbine Divided T3 V-Banded housing- should be here in a week or two

Cylinder head-
YoshiFab timing belt adapters
YoshiFab valve springs
I'll clean the head up, have the chambers pressure tested, head checked over
New lifters.

EMS-
I have a MS2 V3 box that I ran on my old 242, which I then sold to Rockmotion- who then sold it to Sol, and then I bought back. I've thought about just going up to MSpro- but for now, I think I'll run the one I have.
YoshiFab CAS adapter with Mitsu sensor and hi-res disk

Fuel system-
I haven't thought about this too much, but my thoughts are a
DW300 in tank pump, with 1000cc injectors.
6AN line from pump to fuel rail.

PCV

YoshiFab block adapter, canister set up (have)

Cooling
Do88 Aluminum radiator (group buy currently happening)
Nathaninwa modified water pump for use with the header (should be here soon)

Intercooler- seriously considering getting the Do88 Group-A replica intercooler.

Transmission
I have a T5 from a mustang, but its the 3.35 ratio. I really want the 2.95 gear set. I'm considering buying a gear set and rebuild kit if I can't find someone who has a 2.95 box.
JohnV flywheel (have)

Rear diff
Pulled a 1031 from a late 240. Will rebuild it, paint it, and I might spend the money to get a wavetrac diff. I'd like to find a 4.10 gearset to go with the 2.95 transmission gears.

Brakes-
Homers Porsche Big brake kit (have)
6 piston front calipers (need to track down a set)
4 piston rear calipers (need to track down)
SR/VR 13" rotors (have)

The shell
I'm stripping it down now. Plan is
Seam weld
Remove all redundant wiring
Upgrade fuse panel and relocate to somewhere dry. I might just rewire the entire car.
Group-A front end (longer term)
USA bumpers
Only rust is one rocker panel- will replace the panel
Push out fenders.
Two supportave front seats
Switch to black interior
switch dash to late style
Custom gauge pack

Wheels and tires-
Undecided- sort of thought I'd get some Kodiak rims (17x9).
Tires will be 255/40-17 Front and rear.
To be able to drive it next summer I might just run some Pegs.

Suspension-
Coil overs- undecided on shocks/struts (will be short struts though)
Roll correction spacers (Have)
Undecided spring rates, sway bars.
Poly bushings in the front (eventually, some stronger a-arms)
Adjustable heim jointed torque rods and pan hard rod
Kaplenkhe trailing arm bearings (have)

I have quite a bit of work ahead of me, I have a bunch of stuff already. I'd like to get it driving next summer, then the following winter strip it down to a shell again, do the body work, paint it and fix anything I break.

I have a bunch of things to do around the house that will cut into the build funding (New garage door), just bought a Millermatic 211 welder, I need a compressor. Hopefully next summer I can start building a shop on my land.

Onto the pictures!
Image

Image

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 Post subject: Re: Another 242 project
PostPosted: Tue Oct 13, 2015 1:24 am 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Thu Dec 29, 2005 12:29 am
Posts: 1786
Location: Eating tofu and legumes in my hippie shack
Nice! Can't wait to see this progress Jordan!

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 Post subject: Re: Another 242 project
PostPosted: Tue Oct 13, 2015 1:34 pm 
First volvo in outer space
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Joined: Fri Dec 14, 2007 1:46 pm
Posts: 1590
Location: East L.A.
Agreed, looks like a cool project. =D>

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Jim

66 122S (Garage Queen)
89 244 (Hers)
90 745Ti (Mine)
89 744 (SOLD/Bought back for other daughter)
78 242GT (Project... LOL)
91 244 (Don't Ask!!)


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 Post subject: Re: Another 242 project
PostPosted: Tue Oct 13, 2015 9:30 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
Posts: 2955
Location: Lethbridge, AB
Looking good. Sounds like a good plan (the injectors are huge for your power goals) - but the rest sounds great. I've decided to go with the 450/250# spring rate split as it yields a 2.2/2.5 hz split - I'm currently at 1.9/2.2 hz on 300/180# springs. Getting a spare set of billies revalved to match and have later struts for the front. James on T-Brix (KJets on a plane) was my source for these and he sells to Kaplan - cut out the middle man.

Lots of pics of the exhaust manifold when it comes in please!

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Coburn Performance - OCD comes naturally.


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 Post subject: Re: Another 242 project
PostPosted: Thu Oct 15, 2015 10:00 pm 
Hiring a japanese chess champion as ECU

Joined: Wed Mar 15, 2006 8:28 pm
Posts: 484
Manifold and turbo shipped yesterday!

When you say James supplies Kaplenkhe, what does he supply? Strut tubes or the re-valved billys?

I have a set of struts from a late car. I was planning on cutting the housing down and re-threading (AllisonCustoms on turbobricks has the tap for making the threads). After I read about you re-valving the Bilsteins, I thought I'd possibly do the same- seems to work out cheaper than Koni Race inserts. Looks like I could just have some Saab Bilsteins valved to match. Your spring rates are exactly the rates I was considering.

Jordan


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 Post subject: Re: Another 242 project
PostPosted: Fri Oct 16, 2015 8:28 am 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
Posts: 2955
Location: Lethbridge, AB
James supplies the strut cores for Ben.

I don't think I'm going to go a lot lower (maybe another 1/2 inch) so I'm fairly certain I won't need cut down tubes or shorter inserts. I am still planning on winter driving the car. We'll see what a stiff car is like in the snow this year. The only reason I haven't sent stuff to Bilstein yet is that I'm still working up the courage to see if I'm willing to go all in on this and go to 450/250 or if I should stay sane and go 350/200. Meeting with Matt and Dale on the weekend - not sure if they'll try to talk any sense into me or not (I'm guessing not :lol: :lol: they're supportive like that). I may have to walk down the street and talk to Greg - he's probably the best at forcing me to be realistic. I know that 300 on the front for street driving is just fine, doesn't bother me a bit. But moving to 450 is a crap load of spring...but then I thought 300 was going to be outrageous.

Valving is going to be a bit of a crap shoot but the numbers are posted on Dave Barton's website and I'm going to go with whatever the Bilstein guys recommend given my spring and use.

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 Post subject: Re: Another 242 project
PostPosted: Sat Oct 24, 2015 6:19 pm 
Hiring a japanese chess champion as ECU

Joined: Wed Mar 15, 2006 8:28 pm
Posts: 484
Got the turbo, exhaust manifold, waste gates and modified water pump.

The waste gates are interesting- water cooled (doesn't have to be used). The manifold is nice and the weld quality is really nice (this is a "nathaninwa" exhaust manifold with twin Tial 38mm waste gates- all Vbands.

I'm going to have to hammer in the strut tower slightly, to get the rear most waste gate to clear.

I threw a block in the car with the lower half of the 16V head.

Have some pictures.

Image

Image

Image

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 Post subject: Re: Another 242 project
PostPosted: Thu Oct 29, 2015 2:36 pm 
Vmax 200mph w00t!
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Joined: Mon Apr 19, 2010 4:21 pm
Posts: 265
Location: Saskatoon, Sk
Subscribed :mrgreen:

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 Post subject: Re: Another 242 project
PostPosted: Tue Dec 08, 2015 9:50 pm 
Hiring a japanese chess champion as ECU

Joined: Wed Mar 15, 2006 8:28 pm
Posts: 484
So, wrong time of the year for any project work. Work takes priority during tire season. 330+ hours last month. It's just now starting to slow down.

Parts showed up.

I bit the bullet and bought the Do88 group-A replica intercooler. I also bought their over size aluminum radiator.

I thought I had pictures of both but I don't. Here is the intercooler- it's massive.
Pen for a little reference.

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 Post subject: Re: Another 242 project
PostPosted: Tue Dec 08, 2015 9:52 pm 
Hiring a japanese chess champion as ECU

Joined: Wed Mar 15, 2006 8:28 pm
Posts: 484
Ah, and I've got Nathaninwa starting to work on the intake manifold. I also got a set of Saab short strut inserts from him with proper 240 gland nuts. I might see it by Christmas. Porsche calipers are waiting at my parents in Vancouver I come out at Christmas.

Jordan


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 Post subject: Re: Another 242 project
PostPosted: Tue Dec 08, 2015 10:53 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Jun 14, 2006 4:19 pm
Posts: 2955
Location: Lethbridge, AB
Whoa - that IC is awesome.

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 Post subject: Re: Another 242 project
PostPosted: Wed Dec 09, 2015 8:40 am 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Wed Dec 21, 2005 8:40 pm
Posts: 3345
Location: Calgary, Ab
Yes, with proper tanks.

330 hours last month? That's insane!!!


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 Post subject: Re: Another 242 project
PostPosted: Wed Dec 09, 2015 10:26 am 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Thu Dec 29, 2005 12:29 am
Posts: 1786
Location: Eating tofu and legumes in my hippie shack
Fantastic!! I'm hoping to buy the regular intercooler from do88. Does the quality look good?

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 Post subject: Re: Another 242 project
PostPosted: Thu Dec 10, 2015 12:54 pm 
Hiring a japanese chess champion as ECU

Joined: Wed Mar 15, 2006 8:28 pm
Posts: 484
330 hours was a lot. Too much. Now I hurt. The beginning of this month would have out me on course for 400 plus hours, but thankfully we've slowed down.

The intercooler is VERY nice. The welds are great, the tanks are cast and are smooth with no sharp transitions. I believe it's powder coated. I was expecting raw aluminum. It is bar and plate.

My one concern is the beads on the pipe inlet/outlet aren't very high. Sort of worried about blowing pipes off. If I do, I'll add more material.

The radiator is also very nicely made. It's really thick but still has every factory connection, support, guide etc that the factory rads have.

I'll try to take some more pictures in the coming days.

Jordan


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 Post subject: Re: Another 242 project
PostPosted: Thu Dec 10, 2015 1:42 pm 
Haha, I just built a W24 Octo-Turbo, now what?!
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Joined: Thu Dec 29, 2005 12:29 am
Posts: 1786
Location: Eating tofu and legumes in my hippie shack
Sounds nice! Sweet!

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