Project Turbo 6 cylinder Volvo Wagon
 

I got a little break between customer jobs and managed to get started on the new header for my own car. I built a manifold for it for a Holset Hy35 and it kinda sucked. 6-into-1 innto a T3 flange. :P


So the new one is a twin scroll T4 setup. Pretty rough yet obviously, but I like the layout so far.



Attachment 12810

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Re: New Manifold for my Own Car
 

Looks cool... dose fireing order take part in the design, or is i just the first three go to one colector, and the other three go to another??

Re: New Manifold for my Own Car
 

Ya exactly right, firing order is a big part of it for twin scroll. Luckily, 6 cylinders do not have the "awkward" pairing that most 4 cylinders do (having to pair 1-4 and 2-3 in most cases). The correctly pairing is actually 1-2-3 and 4-5-6. So that is convenient, 6 cylinders and twin scrolls are a match made in heaven.

Re: New Manifold for my Own Car
 

getting in to see this. i have an E36 M3 that i am interested in boosting eventually.

what engine is that. looks toyotaish, but im not very familiar with anything but honda and bimmer. i used to work at nissan, but we never saw any inline 6 stuff

Re: New Manifold for my Own Car
 

pretty sure thats a nissan, they always got that cam advance thing on the gear

Re: New Manifold for my Own Car
 

nissans have the intake and exhaust on the other sides

i am thinking older toyota, maybe early 80's??

Re: New Manifold for my Own Car
 

fwd volvo engine mounted rwd?

Re: New Manifold for my Own Car
 

fwd inline 6? never heard of it

Re: New Manifold for my Own Car
 

http://www.familycar.com/RoadTests/V.../Engine-md.jpg

looks the same.

Re: New Manifold for my Own Car
 

Ya rawr is right - it is a Volvo S80 T6 engine (FWD, twin turbo, 24v, 2.8L inline 6) turned 90 degrees and stuffed in an '83 volvo 240 wagon. Narrowed 31 spline posi Ford 8.8 rear end, widcened 7.5" in the back with 285/40 18's on Work VS-XX.

http://www.pbase.com/capnbondo/image/90754891/large.jpg

http://www.pbase.com/capnbondo/image/90754896/large.jpg

The first version of the motor I am only aiming for 400whp. With rods and a tremec trans "version 2" will be around 600whp. Version 3 will be the worlds first volvo wagon capable of entering into orbit aorund the earth. :P O0 ;D

Re: New Manifold for my Own Car
 

------' awesome car man...That ---- is sweet...Keep this updated for sure...

Re: New Manifold for my Own Car
 

looks great, love the car too.

Re: New Manifold for my Own Car
 

Thats ------- tits right there!

Re: New Manifold for my Own Car
 

What are you using for a tranny? I thought that was a volvo engine right when I saw the valve cover.

Re: New Manifold for my Own Car
 

looks good so far. make sure you bevel those pipes and wirebrush them!

Re: New Manifold for my Own Car
 

Ha thanks guys, it does a good job of keeping me out of trouble and relatively broke like a good project should I guess. :S
The transmission is what is known as an "M90" - basically a volvo 960 is a RWD volvo with a 6 cylinder that has the same bellhousing bolt pattern as the FWD s80 motor. It's a 5 speed manual (brought in form the UK, we didn't get 5 speed 960's here. 8) They're good to 400hp but not really much more.) So yeah, for 600hp I'll be running something else, not worth breaking a somewhat rare tranny. Probably a TKO so I can choose a set of tasty ratios.


Good point Aaaron- in the pic of the collector, the pipes aren't beveled or deburred. I bevel and deburr during fitup (as per the completed runners). I do it later on incase I need to do any minor tuneup to any cut ends. Keeps me from having to deburr and bevel twice.

I don't wire brush until I am ready to weld, otherwise it just tends to get oils and crap on it while I am doing fitup of other pipe- so I wire brush *right* before welding.

Re: New Manifold for my Own Car
 

do you use any special method of beveling the ends or just use like a bench grinder or belt sander type deal. i guess what i am asking is if there is some special tool for doing that or if its always by hand

Re: New Manifold for my Own Car
 

Bad ass project keep the updates coming.We never get to see many Volvos especially my fav the old school brick wagons :y

Project Turbo 6 cylinder Volvo Wagon
 

Thanks guys-

I would have made a project thread long ago if I'd thought anyone would care. LOL.

Maybe a mod could change the thread title to:

"Project Turbo 6 cylinder Volvo Wagon" ? Maybe I should PM CSaddict. Then I'll just put my pics from when I narrowed and set up the rear end, etc in here.


I don't do anything special for beveling. A belt sander is probably the easiest way to do it, but I don't have one (yet). I find it a bit awkward to get a bevel nice and even on the bench grinder, so I actually use a 40 grit flapdisc in a 4.5" angle grinder. I also find it's worth it to buy decent quality flapwheels - epsecially the stainless steel specific ones are excellt for "tuning up" your cuts during fit up.

Re: New Manifold for my Own Car
 

Hawt sex.

Re: New Manifold for my Own Car
 

+1 Palming the nose of a 4 1/2" angle grinder for beveling! :D
Got two bench grinders and two belt sanders. Don't like wasting the time on any of them. I oughta get one of those huge coarse blue wheels anyone know what they are? Was in a shop that welded some chrome-moly awhile back and whatever it was ate the dogshit out of that stuff.

Cutout a sacraficial paper sleeve to tape around your pipe when beveling if you can't keep the bevel even enough for you.






Project is golden. Volvo FTW.

Re: New Manifold for my Own Car
 

What benifit is there to beveling the ends?? is that what provides the flater welds? :S

And is it worth doing on just a flux core, always up for improvment techniques

Re: New Manifold for my Own Car
 

you will get better penetration for one. im sure it has a lot to do with the flatness of the welds too. i have never tig'd a manifold only mig'd, so i can say for sure.

this is my method of beveling or grinding almost anything for that matter. i have this exact model. i love the area of the 1" belt that has no back plate for deburring. it leaves a nice finish

http://65.118.245.21/product/delta-d...nder-SA180.jpg

Re: New Manifold for my Own Car
 

very hot project indeed. for some reason I've always had a soft spot for a volvo wagon.

pics of rear end setup would be awesome, good choice on the axle too btw

Re: New Manifold for my Own Car
 

now i see why you dont have time to help me :P

sick ride cant wait to see it in person

Re: New Manifold for my Own Car
 

i ---- better welds than that.

Re: New Manifold for my Own Car
 

joke...

Re: New Manifold for my Own Car
 

Thanks again guys. Beveling the pipe does 2 things- it allows you to get more penetration with less heat. To actually weld right through 0.109" thick pipe withough a bevel would require more current than stainless really likes. I can get 100% penetration with around 80amps instead of the ~110 it would take without a bevel. And it does give the weld puddle "somewhere to go" With stianless the puddle has a tendency to "wander" around even with a bevel.

A quick comment on the welds on the collector- in case anyone was wondering, i didn't brush those after welding. They are that silver as-is. People are used to seeing the "rainbow"- but silver/gold is actually a BETTER weld. The collector tends to act like a gas "funnel" and I get really good coverage.

Atticus- I'll take care of ya man. Next month I am doing intercooler piping for an EVO X, intercooler piping for a Volvo 850, 2 Acura exhaust systems and 6 headers (!!!) in december. PART TIME! I still have to work my day job in there too. LOL. Business is crazy. Plan it to go full time fabricating in the summer. Plan on early Jan we'll cut you up some pipe.

Cheers guys, I'll slowly convert this to a project thread- get some pics of the fender widening, rear end, 14" brembo kit on the front, etc over the next week or so.

Re: New Manifold for my Own Car
 

Man if I could grow a 3rd nut I would cut it off a give it away to be able to weld like that!

Nice work Captain......................... that thing is going to get ya to the grocery store in a hell of a hurry, every one loves a fast wagon at the drag strip as well.

Lots of good info on this thread, really cool stuff.



Attachment 12752

Re: New Manifold for my Own Car
 

----, i would give away one of my current ones to weld like that. i have no need for kids, they just suck away your turbo money

Re: New Manifold for my Own Car
 

I hope you dont mind but the rear end view of yoru car made me instantly touch myself.

Re: New Manifold for my Own Car
 

Volvo Death Wagon v2.0

Re: New Manifold for my Own Car
 

the blue/green bench grinding wheels are for sharpening tungsten carbide tooling. They also work exceptionally well in sharpening your tungsten. (obviously) No more huge groove in the center of your normal wheel if you keep it in the same place all the time.

Im pretty sure that the correct gas coverage when welding stainless is actually the purple blue oil in water look. Ive gotten gold and silver welds when using the wrong filler rod though... just a thought, i'd check your rod and your els and make sure they are the same. Your welds are tight though, almost as nice as that volvo. I havent been on in awhile, do you have a build thread for that thing?

Re: New Manifold for my Own Car
 

haha, I love the death wagon!!!

Re: New Manifold for my Own Car
 

The weld should be clear stainless to a gold color in the HAZ. When the bead itself is discolored into blue hues it means you're playing with your pedal a god-aweful lot. Anywhere else, poor gas coverage. (alot of times this can come from too little pre-post flow) The banding outside the weld area is the HAZ - heat affected zone.
We got taught the same thing Engloid said several times on the matter. Doesn't matter what color it is - brush it off. It shows the area is devoid of chromium (among other things) at the surface.


I called their tool crib lady, she said they're blue Norton wheels. Gotta get me one it's the premium line LoL

Re: New Manifold for my Own Car
 

Awww yes finally you TBricker's make your way over to the HMT side O0

Re: Project Turbo 6 cylinder Volvo Wagon
 

Post more pic's and I will sve it with the rest of the builds. BTW I changed the title for you.

Re: New Manifold for my Own Car
 

Don't we all.

Kickass looking project. Can't wait to see how it turns you out.

Re: New Manifold for my Own Car
 

+1

You should make the back seat into a bed, cause that thing is gonna get you so much ass

Re: New Manifold for my Own Car
 

What kind of car sluts do volvos pull? I know hondas pull white trash/asian sluts, American cars pull tweeker sluts, BMW and Merc pull affluent poser euro sluts, VW's pull wanna-be affluent euro poser sluts, Subarus pull guys with beards, but Volvos? Academic sluts?