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> My 591 Bhp 854 Project Car
volvo500bhp
post Nov 8 2009, 02:46 AM
Post #21


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Drives: 854 T5-R




(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2184.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2185.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2186.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2187.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2188.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2182.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2183.jpg)
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volvo500bhp
post Nov 8 2009, 02:47 AM
Post #22


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With the inside being finished, it was time to start on the outside

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2204.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2203.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2201.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2199.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2197.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/Picture_583.jpg)

I of course had no stereo, so the antenna mast was not needed

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2228.jpg)

I popped in again after the major paint was done

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volvo500bhp
post Nov 8 2009, 02:48 AM
Post #23


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Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2229.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2231.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2234.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2221.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2225.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2220.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2219.jpg)

It was then the turn of the bonnet boot lid and the doors
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volvo500bhp
post Nov 8 2009, 02:49 AM
Post #24


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Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2218.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2217.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2215.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2212.jpg)

The car was given a full machine polish and the final prep began

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2251.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2252.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2258.jpg)
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volvo500bhp
post Nov 8 2009, 02:50 AM
Post #25


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Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2259.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2261.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2257.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2245.jpg)



At the same time, we had started a relocation to much larger premises for the business:

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/100_3129-1.jpg)


(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/100_3132.jpg)


……..so the car took a back seat for several weeks while the move was completed over the long easter weekend. The final stages of the move were completed over the weekend the Peril was delivered to the new unit looking like a new pin. I was over the moon with the job - the car looked better than new. It was great to have the car painted in all the small areas that Volvo never paint - it had several layers of lacquer to make it shine…..
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volvo500bhp
post Nov 8 2009, 02:51 AM
Post #26


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Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2287.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2288.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2290.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2281.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2283.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2276.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2278.jpg)
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volvo500bhp
post Nov 8 2009, 02:52 AM
Post #27


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2279.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2270.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2274.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2269.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2268.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2264.jpg)




I had been arranging the many, many boxes of Peril parts and now due to the larger building I had my very own engine build area and lots of racking and shelving to store all the Peril parts during the re build. This was a great help and enabled me to sort out the different areas of the car - fuel system, brakes, engine intake etc etc .
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volvo500bhp
post Nov 8 2009, 02:53 AM
Post #28


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2541.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2537.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2535.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2534.jpg)

I also took over one of the ramps - a four poster, which made the Peril so much easier to work on.

I had at first decided to re build the engine ready to be refitted – I would then concentrate on the rest of the car. I have never had to dial new cams into an engine so this was a new practice for me. A trigger disc was purchased for the crankshaft to measure the true Top Dead Centre (TDC) of the piston - as the new cams are custom made there is no easy setup and as the block was decked and the head given a very light skim, the standard Volvo timing marks were no use to me.

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2428-2.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2435-2.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2439-2.jpg)
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volvo500bhp
post Nov 8 2009, 02:54 AM
Post #29


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2499-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2501-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2533.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2531.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2538.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2420-1.jpg)

I had a spare cam cover so thought I would use it as a test cover to make sure I could properly dial in the cams. At the machine shop I use they do a few Volvo engines so we decided to share the cover so that they can easily set up the shims on the later heads for solid lifters. They made such a lovely job of the liners they had made for me, I was happy to let them share it.

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volvo500bhp
post Nov 8 2009, 02:54 AM
Post #30


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Drives: 854 T5-R




(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2542.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2543.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2545.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2704.jpg)


While the tubular manifold which had been made for me was in storage, I had noticed that the ceramic coating was starting to come off. This was a shock as the manifold had only done 1500 miles since the silver coating so the company I used (Zircotec) were called and they kindly came over to inspect the coating. They where also shocked to see the state of it and kindly offered to strip and re coat the manifold – this was a great relief to deal with such a decent company that are true to their word and just want happy customers.

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2718.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2719.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2720.jpg)

I decided to have the manifold re done in the charcoal finish this time
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volvo500bhp
post Nov 8 2009, 02:55 AM
Post #31


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/S1051874.jpg)

I then added the rest of the parts to the engine including the turbo (GT35 with a ported shroud and external wastegate).

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/S1051874.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2556.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2558.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3095.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3096.jpg)
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volvo500bhp
post Nov 8 2009, 02:56 AM
Post #32


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3097.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3102.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3103.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3104.jpg)

The engine was now complete so I slowly but surely started to sort out the wiring inside the car ready for the dash to be refitted - all the time being very careful not to scratch or damage the paint work!

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2729.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2735.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2741.jpg)

After what seemed a very long time I managed to re-wire the new dash (AIM) and get rid of the wood effect part
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volvo500bhp
post Nov 8 2009, 02:57 AM
Post #33


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Drives: 854 T5-R




(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/S1051840.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2904.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3108.jpg)

I had brought a few sheets of carbon fibre to help tidy up the dash and glovebox area with the four switchs I would need to have the launch control/anti lag/heater fan/traction control I had two spares too in case I wanted to add more items to the car .

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3982.jpg)


Rod also added a low level light for the water injection.

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_4619.jpg)


I also started on the engine bay refit adding all the pipes/and wiring looms to the car - they would mostly live inside the chassis legs

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3141.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3142.jpg)
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volvo500bhp
post Nov 8 2009, 02:58 AM
Post #34


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Location: Surrey UK
Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3144.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3145.jpg)




REMOTE BRAKE SERVO

A new part I had to have fitted to the car was a remote brake servo this was something I had started to look into when I first realised I would need a pedal box assembly , as I did wonder how it would be to drive with the car without servo assistance but for a time was happy with the brake feel and found the brakes worked very well all you had to do was press the pedal a bit harder!!

I had pointed out to me a unknown to me a grey area of the mot rules that state if a car leaves the factory with a servo it must have one fitted so I had no choice but fit one I did not want to be running an illegal car so was happy to look into a solution.

I did even check with vosa about the details and found it to be correct there must be hundreds of rally etc cars that don’t run a servo without a problem but wanted to be safe. I then looked into what I needed to do I was not sure if I needed a single servo or a duel servo (I have two master cylinders) so searched long and hard to find a duel servo system this proved very hard and no-one I spoke to in the rally/historic race world knew of such a thing (or the MOT rule !!)

In the end I had a real piece of luck :

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2736.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2727.jpg)


I found a company that made just what I needed I quickly ordered one and set about working out where to fit it I had spent much time getting the inside of the car how I wanted it to look so did not want it in view .

The new unit turned up and I set about deciding where to put it I found that it would just fit nicely into the old glove box area so was very pleased to hide it ,I was looking forward to trying out the brakes with the new set up .

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2736.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2727.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3106.jpg)


MORE FINISHING TOUCHES
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volvo500bhp
post Nov 8 2009, 02:58 AM
Post #35


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As the subframe is now seen so much, I thought I would have several parts and brackets powder coated in silver and a few in black

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1991.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1995.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1894.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1897.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1898.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1906.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1907.jpg)

I also fitted the new alloy sub frame bushes that my local machine shop made for me - I was sure this would make a big difference to the front of the car, as under power you could feel the subframe trying its best to leave the front of the car !!!


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volvo500bhp
post Nov 8 2009, 02:59 AM
Post #36


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3120.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1679.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1641.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1681.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_1683.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2089.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2091.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2092.jpg)
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volvo500bhp
post Nov 8 2009, 03:00 AM
Post #37


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(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2095.jpg)

I started to add the wishbone arms etc to the subframe ready for the engine and gearbox to be added

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2094.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2906-1.jpg)

I bought new gear control cables and added some brass bushes to the ends to help the gear feel

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_2905.jpg)

And poly bushed the lower torque rod

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3150.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3146.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3147.jpg)

This pic shows the longer bolt I have used for the pick up for the traction control I run on the Sm4

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volvo500bhp
post Nov 8 2009, 03:00 AM
Post #38


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Member No.: 64,357
Status: Offline
Location: Surrey UK
Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3138.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3140.jpg)


ENGINE GOING BACK IN

I was now getting ready for the engine and gearbox to go in. I used some very large straps as I did not want an error while lifting the engine onto one of our work trolleys. I first removed the subframe and fitted the steering rack etc to it ready to meet the engine and box

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3350-1.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3355-1.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3356-1.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3357-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3358-1.jpg)
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volvo500bhp
post Nov 8 2009, 03:01 AM
Post #39


Member
*

Group: Members
Posts: 57
Joined: 8-November 09
Member No.: 64,357
Status: Offline
Location: Surrey UK
Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3359-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3361-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3364-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3354-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3349-1.jpg)

I covered the engine bay sides with cloths just in case of a slip:

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3365-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3367-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3366-1.jpg)

In she goes !!!!!!!!!
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volvo500bhp
post Nov 8 2009, 03:02 AM
Post #40


Member
*

Group: Members
Posts: 57
Joined: 8-November 09
Member No.: 64,357
Status: Offline
Location: Surrey UK
Drives: 854 T5-R



(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3368-1.jpg)

(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3370-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3371-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3372-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3373.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3374-1.jpg)
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3375-1.jpg)
Andy and the team decided to put a small sign in the shot for a joke
(IMG:http://i79.photobucket.com/albums/j152/500bhpvolvo/The%20Peril/100_3377-1.jpg)
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