Nice 940, very tastefully done and I read your progress with interest - we have a 1994 945T that is also being slowly modified, staying with the auto transmission though. Something you might want to consider is that matrix oil cooler, Volvo more or less went cheap on that over the older 740 turbos with their separate oil cooler mounted up by the radiator.
In the process of mounting a 1992 - 94 960 cooler ( mounted under the lower radiator support ), you also need the earlier oil filter adapter housing and then have some oil lines made up. The problem with those integrated oil coolers is that they can fail leading to coolant mixing with the oil and of course the coolant hoses themselves. I should add that you also need the metal feed pipe at the back of the water pump from a 2/7/900 series non turbo ( or earlier turbo 740 ) and the coolant drain petcock or similar sized plug as the later 940T used both the pipe and the coolant drain location as circulation points for the oil cooler.
That 960 oil cooler fits perfectly with no modifications - hoping to have ours set up soon.
Also, you might want to try locating a pair of aluminum forged control arms, saves a good amount of weight - need the later style sway bar links as well. Just suggestions of course - the 1995+ control arm reinforcing plates are a good idea too, good to see you installed those.
It never hurts to spend more money, right?
Thanks for the kind words. I do believe I've finally gotten my oil cooler situation leak free but thanks for the suggestion. I'll keep that in mind if it ever becomes an issue again. I didn't want to go to an older setup because I didn't want to swap radiator,intercooler, etc to bolt in the older oil cooler, but that 960 placement sounds good.
I've never heard of the aluminum control arms, but found this interesting thread on the subject:
http://forums.turbobricks.com/showthread.php?t=203440
It seems their is controversy on if they are strong enough for larger sway bars.
Now that I've gotten a couple hundred miles on the car, she is driving very well. Boost feels good through all gears. Pulls well to 6k. Sat in traffic for a half hour yesterday, and car behaved well.
Besides what i mentioned a couple posts back, she is still facing a sporadic high idle issue. While tinkering under the hood today, I discovered this.
<a href="http://imgur.com/xREuppH"><img src="http://i.imgur.com/xREuppHl.jpg" title="source: imgur.com" /></a>
Notice the corrosion. I replaced a leaky t valve thing for the windshield wiper fluid already. I imagine this ground strap has been getting leaked on for some time. Also, not hooked up to anything. Unbolted the 10mm nut holding the other side and discovered this.
<a href="http://imgur.com/krmVwvZ"><img src="http://i.imgur.com/krmVwvZl.jpg" title="source: imgur.com" /></a>
Neither end was hooked up. It was only bolted on at the firewall. It's been in rough shape for a long while it looks like.
<a href="http://imgur.com/toGaSdf"><img src="http://i.imgur.com/toGaSdfl.jpg" title="source: imgur.com" /></a>
Anyways, where do these get bolted to? Intake and exhaust manifolds? They are not present on our 90 745 turbo, nor is the black box they connect to..