Assembly

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1980 Volvo 242

test-account
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Log
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Spec
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Projects
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2026 · PROJECT COMPLETE
GM Supersonic Blue repaint
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Complete a full color change from Volvo 477 Electric Silver Metallic to GM Supersonic Blue, including the bodywork and reassembly preparation required for the new finish.
2025
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The first drive on MaxxECU and the rebuilt engine was followed by a head-gasket failure. Later diagnosis found the TDC mark had been set incorrectly, leaving base ignition timing massively advanced. The head gasket was replaced.
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2025 · PROJECT COMPLETE
Eight-inch round headlight conversion
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Install the long-held 8-inch round headlight setup and refresh the surrounding exterior plastics.
2024
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The rebuilt B5234T reached first start before the end of 2024 after the crank and bearing work and MaxxECU conversion.
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NOV 14, 2024 · PROJECT COMPLETE
MaxxECU conversion
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Replace Megasquirt with MaxxECU Race and a new custom engine harness while retaining the five-cylinder turbo setup.
 S60 PWM cooling fan
 MaxxECU Race
 2007 S60R electronic throttle valve
 Saab electronic throttle pedal Hella 6PV 010 946‑141
 S60 PWM cooling fan
 MaxxECU Race
2022
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A freak oil-starvation incident damaged the bottom end. The car was later parked for bearing replacement as oil pressure continued to decrease.
2021
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Completed a weekend of driving through the Driftless Area in southwestern Wisconsin and to a cars and coffee event after the no-start issue was resolved.
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The extended cranking no-start was resolved after cleaning the bellhousing-to-block mating surfaces and chasing the fastener threads, which removed the interference affecting the crank-sensor signal. Megasquirt was reinstalled for driving.
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The car was driven 90 miles to Kelly Moss Road & Race for dyno tuning. The baseline was 274 whp and 282 wtq. Flex-fuel tuning on E85 reached 366 whp and 381 wtq, with boost peaking around 21 psi. A wastegate, fuel-pressure sender and fuel pump were also changed and the fuel-pump wiring was revised.
2020
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DEC 30, 2020 · PROJECT COMPLETE
Oversized-piston short-block rebuild
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Rebuild the B5234T short block again after bore wear and a low-oil event, using larger Wiseco pistons, new rods and fresh bearings.
 Maxspeeding 139.5 mm H‑beam rods
 Wiseco 81.5 mm pistons and rings
 NA camshafts
 Maxspeeding 139.5 mm H‑beam rods
 Wiseco 81.5 mm pistons and rings
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MAR 31, 2020 · PROJECT COMPLETE
GAZ suspension upgrade
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Replace the harsh Koni Race street setup with GAZ dampers and GAZ Gold front coilovers while retaining the developed 240 suspension geometry.
 Kaplhenke V2 QSRC spacers
 GAZ Gold front coilovers
 GAZ adjustable rear shocks
 Kaplhenke V2 QSRC spacers
 GAZ Gold front coilovers
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MAR 8, 2020 · PROJECT COMPLETE
Three-inch TIG-welded exhaust
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Replace the quickly fabricated original exhaust with a tightly fitted full 3-inch 304 stainless system using a catalytic converter and two Vibrant mufflers.
2019
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First drive after the forged B5234T bottom-end rebuild. The car covered 15 miles on break-in oil with engine speed kept below 4,000 rpm and throttle below 60 percent.
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JUL 18, 2019 · PROJECT COMPLETE
Forged B5234T bottom-end rebuild
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Replace the damaged high-mileage bottom end with a refreshed 1999 T5 block, forged pistons and H-beam rods after piston and ring-land damage.
 1999 S70 T5 B5234T block
 1999 S70 T5 B5234T block
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Completed another 50 to 60 miles of break-in driving after the forged-engine rebuild. The car was smoother to drive and the revised shifter felt better. The clutch release bearing was noisy, the transmission whined, and the engine could stall when the cooling fan switched on after running for a while.
2018
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2018 · PROJECT COMPLETE
Replacement cylinder head
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Replace the damaged B5234T cylinder head after coolant intrusion and head-gasket failure, including machine work and refreshed valvetrain sealing surfaces.
2017
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Oil consumption continued after the five-cylinder swap. PCV routing mistakes accounted for part of the problem, but oil remained throughout the intake system. Compression testing showed cylinders 1 and 5 somewhat lower than the others while further diagnosis continued.
2016
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2016 · PROJECT COMPLETE
B5234T five-cylinder turbo swap
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Replace the B230FT with a turbo five-cylinder whiteblock while retaining the Getrag 265 and adapting the engine, transmission, wiring, fuel, cooling and clutch systems.
 1998 850 T5 B5234T cylinder head
 Modified S70 fuel rail
 2007 S60R intake manifold
 1992+ 940 NA radiator
 ATP C30 cast exhaust manifold
 Turbosmart 38 mm external wastegate
 Garrett GTX3067R turbocharger
 CX Racing Evo VIII intercooler
 Gates Racing Kevlar timing belt
 Getrag 265 5‑speed transmission
 Volvo 260 Diesel passenger‑side engine mounts
 Mann ProVent oil separator
 Tilton 60‑1100 hydraulic release bearing
 1998 850 T5 B5234T cylinder head
 Modified S70 fuel rail
2015
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Dyno testing produced 246 whp and 268 wtq. Boost was about 16 psi during the run rather than the roughly 20 psi street setting, and the mixture was very rich.
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Drove to the Eurowerks show in Minneapolis. The car received the Sleeper award selected by local police and Broadway Auto Tech's Favorite. The reported 12,202 miles were distance accumulated since the first drive, not an odometer reading.
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Drove the 242 to the VCOA Midsommar meet in Hannibal, Missouri after installing the new front coilovers. The trip was part of a period of regular driving and continued chassis sorting.
2014
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The freshly completed B230FT-powered 242 headed west toward the iPd trip. The route reached Denver and continued toward Salt Lake City, with the car covering its first thousand-plus miles of the trip while still being sorted.
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APR 23, 2014 · PROJECT COMPLETE
Initial 242 conversion and B230FT setup
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Prepare the donated 242 GT shell, transfer the proven redblock drivetrain and supporting systems, and turn the rolling shell into a usable street car.
 2005 Porsche Cayenne V8 six‑piston front calipers
 S60R 330 mm brake rotors
 2005 Porsche Cayenne V8 six‑piston front calipers
 S60R 330 mm brake rotors