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Old 11-07-2007, 02:06 PM   #1
Captain Bondo
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Default Official 245 T6 Thread- Quest for the Ultimate 265

I am stressed right now and had been holding out on building a "wore out the wagon" thread for years.

But anyways I thought I might put some of it all down in one place.

Background:

Car began life as a Californian 1983 240DL. I ave had it for a few years now, driven it some, but mostly it is apart for whatever reason.

The Highlights:

-Engine swap from a '99 S80 T6.

-Whiteblock M90H with hydraulic clutch conversion, 850R clutch

-Custom stainless 6-into-1 turbo header made by me

-Holset He351 (late style hy35)

-Custom fabricated and Narrowed Ford 31 spline 8.8" rear end with clutch type posi

-355x32mm Brembo GT front brakes

-18x9 front and 18x10.5" rear Work 3-piece VS-XX wheels, custom refinished body color. (Full lug conversion to 5x4.5") 235/40 front and 285/35 rear tires.

-Hand fabricated sheetmetal rear arches- widened around 2" per side

-Car fully refinished in metallic black base/clear high solids polyurethane paint (by me).

-homebrew bodykit

-Megasquirt with coil on plug

----------------------------------------------------------------------

That's the major aspects anyways. I need to find a way to post the pics in a non-chaotic way.
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Old 11-07-2007, 02:10 PM   #2
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As it sits currently:

http://www.pbase.com/capnbondo/header&page=2

Also there are pics of the nearly completed header there.

Geez I suck at pictures. I will push it out onto the driveway and take some decent ones the next time the weather cooperates.
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Old 11-07-2007, 02:11 PM   #3
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Default 8.8

This gallery is a fairly complete in terms of pics of the 8.8 rear end conversion:

http://www.pbase.com/capnbondo/88_swap
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Old 11-07-2007, 02:13 PM   #4
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you forgot the best part!


The extremely overbuilt swedish-tank of a clutch pedal you made!
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Old 11-07-2007, 02:14 PM   #5
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Go here http://www.pbase.com/capnbondo/paint_etc

for pics of all kinds of random stuff including:

-M90 disassembly/slipring welding,

-car in primer, plus some paint prep stuff

-coilovers

-when I had to put a 3/4" helicoil in the T6 block to fit an oil filter stud

-couple pics of the strut brace I made

yee haw.
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Old 11-07-2007, 02:17 PM   #6
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I thought I had pics of the custom clutch pedal but I can't seem to find 'em. Anyways ya I am quite proud of that beastie.
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Old 11-07-2007, 02:19 PM   #7
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Awesome! Gotta follow this one.

BTW, does the xB have a rear spoiler? Can you see how close it is to fitting the 745 if it does?
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Old 11-07-2007, 02:20 PM   #8
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Quote:
Originally Posted by Captain Bondo View Post
I am stressed right now and had been holding out on building a "wore out the wagon" thread for years.
Don't you mean 'whore'?
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Old 11-07-2007, 02:23 PM   #9
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Originally Posted by towerymt View Post
Don't you mean 'whore'?
Ya I did, but I guess they both fit.
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Chris, I think it might have a spoiler (wife's car, I pay as little attention to it as possible. ). I'll measure it for ya.
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Old 11-07-2007, 02:43 PM   #10
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Man, that manifold looks like it was a LOT of work...good job.
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Old 11-07-2007, 02:49 PM   #11
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Inspiring, so you did all the painting in your garage?
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Old 11-07-2007, 05:28 PM   #12
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In the pics the car can be seen in 2 garages, the one where I painted it and my own. I used to rent a garage before the wife and I bought our house a few months ago.

But ya, I essentially painted it in a regular, dirty-ass, rented double garage in a back alley with a 110v compressor, bad lighting, and an ancient SATA conventional (non-hvlp) spraygun.

The header was actually really easy to make. The hard bit is the planning and collector design. Probably 8 hours of head scratching and planning and 8 hours of fabricating total.
It'll probably take 8 hours to polish too, but I just do a bit here and there when I'm bored or waiting for some paint to dry or etc.


I have the glass back in and a few other litle things done, doin the heater fan at the moment. I'll try to post progress this weekend!
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Old 12-22-2007, 09:39 PM   #13
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http://forums.turbobricks.com/showthread.php?t=121841

just linking the latest thread. should link the other header thread too.

Anyways, the header pics are at:

www.pbase.com/capnbondo/header

Last edited by Captain Bondo; 12-23-2007 at 02:03 AM..
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Old 12-22-2007, 09:58 PM   #14
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LOL! The top link opens a place for me to make a new thread.

I clicked it, looked away for a minute, looked back and wondered what I was going to post about.
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Old 12-23-2007, 02:04 AM   #15
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. Thanks! Fixed.
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Old 01-05-2008, 03:10 AM   #16
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any updates in this new year???
looking to see this car's progress
its gonna be so damn dope
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Old 01-05-2008, 03:22 AM   #17
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Quote:
Originally Posted by Captain Bondo View Post
In the pics the car can be seen in 2 garages, the one where I painted it and my own. I used to rent a garage before the wife and I bought our house a few months ago.

But ya, I essentially painted it in a regular, dirty-ass, rented double garage in a back alley with a 110v compressor, bad lighting, and an ancient SATA conventional (non-hvlp) spraygun.

The header was actually really easy to make. The hard bit is the planning and collector design. Probably 8 hours of head scratching and planning and 8 hours of fabricating total.
It'll probably take 8 hours to polish too, but I just do a bit here and there when I'm bored or waiting for some paint to dry or etc.


I have the glass back in and a few other litle things done, doin the heater fan at the moment. I'll try to post progress this weekend!
It's amazing you got that paint job in a garage that felt as though it was going to collapse on itself.
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Old 03-22-2008, 11:29 PM   #18
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Bump.
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Old 03-24-2008, 10:38 PM   #19
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i wonder if that header will seal do you guys see the warps in that?
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Old 03-25-2008, 04:12 AM   #20
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i wonder if that header will seal do you guys see the warps in that?
His name is Kenny... you can ask him. Then it would be 1st person communication. When you do'll, he'll tell you that he took the manifold to the machine shop to get the flange surfaced... like he did here http://forums.turbobricks.com/showthread.php?t=119008.
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Old 03-27-2008, 07:58 PM   #21
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Yeah, wouldn't have expected it to seal without being faced.

Typically you can fixture the flange and weld it in such an order as to minimize warpage better than I did, but the piece was an awkward shape, and I knew I would want to have it faced anyways, so I didn't go crazy trying to fixture it as some of the welds were difficult enough to access as it was.

I still hold a faint hope that it will drive sometime this summer. I still have to do some pissing around with the rear brake lines, and I need a couple of sensors.

Otherwise it's needs an engine harness, an exhaust, IC pipes, driveshafts, and an interior and it's ready. Not bad really.


But the big news is this...

I have been sidetracked to do 2 things:

1)I am officially making a run of stainless 8v headers (with 16v headers potentially to follow).

2) I have works out how to make polyurethane castings of my airdam.

So this stuff will be eating up some time.


The header thread is going to be a big juicy showroom thread though. The "prototype" is being built based on Phil's (NorthShore Brick) sweet gunmetal 245.

It will be a bit of a promo for the future headers that will be sold, so expect some good header/stainless tig/fabrication pron starting in about 2 weeks!!!

I want to get my car done but I am stoked to do these headers. I think it'll be refreshing to work on somehting different for a few weeks.

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Old 03-27-2008, 10:56 PM   #22
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yesssssssssssssssssss
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Old 03-28-2008, 07:37 PM   #23
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Quote:
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2) I have works out how to make polyurethane castings of my airdam.
I need one immediately.
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Old 11-10-2009, 04:37 PM   #24
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OK I am bumping this ancient thread.

Here are links to the couple of larger threads that have been about this project over the last year or so:


The events leading up to me getting the car on the road for IPD last spring:

http://forums.turbobricks.com/showthread.php?t=160024

Retrofitting 960 cams an other BS:

http://forums.turbobricks.com/showthread.php?t=172380
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Old 11-10-2009, 04:46 PM   #25
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So since am reactivating the thread, I guess I should include a brief summary of where things are at.


So I daily drove the car most of the summer. The car was plagued with ignition problems right up until last month, when I discovered it was due to the MS board's ground plane not being able to flow the current necessary for 6 coils.

After fixing that, the car dyno'd at 388whp @ 16psi on the local mustang dyno.





The numbers are not spectacular, and it's laggy, but the car picked up 25hp going from 14.5psi to 17psi, so it has huge potential. I maxed out the #50's at that point.

I gt to the track and ran a 13.4 @113. A heavy dose of noobness and an overall lack of traction were evident, but like the dyno numbers, while I wasn't ecstatic with the results, they definitely are starting to show the car's potential I think.

A couple shots to close with:



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