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Building 2 350/650hp 16v B230F redblock Volvo engines
http://forum.diyefi.org/viewtopic.php?f=15&t=2667
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Author:  Fred [ Thu Jul 27, 2017 1:23 pm ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Last night:

https://twitter.com/FredCookeNZ/status/ ... 5186992128
https://twitter.com/FredCookeNZ/status/ ... 6589315073

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Tonight: Pulled the cam cover off, and fished out the bits of smashed cam cover, and pulled the timing belt covers off, and attempted to remove the pulley, but failed.

https://twitter.com/FredCookeNZ/status/ ... 9497210880
https://twitter.com/FredCookeNZ/status/ ... 5883729920
https://twitter.com/FredCookeNZ/status/ ... 7429213184

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Author:  Fred [ Fri Sep 15, 2017 2:35 pm ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Pulled the trigger on the balance of the parts for this build yesterday evening! And tonight I pulled the trigger on another parts order, one item dedicated to the lower power 16v build, two for the ute, and the balance in tools, books, etc. Can't wait to fill a couple of pages with detailed parts photos when it all arrives on my doorstep :-D

Author:  Fred [ Thu Sep 28, 2017 12:06 pm ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Tonight I learned about why it's important to include Yoshifab billet lower timing sprockets in your B230F 16v shopping cart:

https://yoshifab.com/store/billet-steel ... -gear.html

https://twitter.com/FredCookeNZ/status/ ... 4131911680
https://twitter.com/FredCookeNZ/status/ ... 3454979072
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https://twitter.com/FredCookeNZ/status/ ... 7337561089

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On top of that, the oil pump drive wasn't very healthy: https://twitter.com/FredCookeNZ/status/ ... 9525149696

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Author:  Fred [ Sat Oct 14, 2017 9:28 am ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Chucked some wheels under B234F number 3 the other night and tucked it into the back of the BMW temporarily:

https://twitter.com/FredCookeNZ/status/ ... 0327303169
https://twitter.com/FredCookeNZ/status/ ... 7128738817

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Author:  Fred [ Mon Oct 30, 2017 5:18 am ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Most of the parts for the output of this thread arrived! Enough for two 16v B230F builds:

  1. ~300hp @ crank (less than 400, more than 250, TD05HR-16G limiting factor)
  2. 500-750hp @ crank (limited by manifolds, cams, plumbing, fuel supply, and ultimately block strength, goal is 9s or 10s with a very stock look)

Pics:

https://twitter.com/FredCookeNZ/status/ ... 3393675264
https://twitter.com/FredCookeNZ/status/ ... 7775027200
https://twitter.com/FredCookeNZ/status/ ... 3704423425
https://twitter.com/FredCookeNZ/status/ ... 5460076544
https://twitter.com/FredCookeNZ/status/ ... 6490710016
https://twitter.com/FredCookeNZ/status/ ... 5501802496

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All that's missing at this point aside from my labour/time is:

1) Pistons for the big-power build
2) A second 16v phenolic insulator (not required until install/fit time)
3) Two YoshiFab CAS adaptors (not required unless going sequential or wanting more RPM than FreeEMS can provide on 60-2 right now)
4) A hone for the bare squirter block above to match the fresh pistons/rings (big-power build only)
5) A minimal skim for the head to promote good seal on the gasket of choice (likely the stock elring unit, at least for the low power build)
6) Valve clearance pockets machined into stock pistons or B234F pistons installed (low power build only)

Should get some quality garage time in over the next year or so putting all of this together and fabricating the required manifolds and/or adaptors! Looking forward to it :-D

Author:  Fred [ Thu Nov 02, 2017 10:15 pm ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

For reference, serial numbers of wastegates: https://twitter.com/FredCookeNZ/status/ ... 9394767873

Also relevant to this thread, supplier of choice for most things Volvo: https://twitter.com/FredCookeNZ/status/ ... 2988339200 (the balance from DaveBarton, IPD, probably Skandix, and maybe Kaplhenke)

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Pulled the exhaust manifold and exhaust-side balance shaft and housing off this last night. Baby steps.

Would be good to extract any value/parts from it and ditch the block and anything else unwanted.

Pics/tweets/etc:

https://twitter.com/FredCookeNZ/status/ ... 6500736000 4
https://twitter.com/FredCookeNZ/status/ ... 7495909376 2
https://twitter.com/FredCookeNZ/status/ ... 0361922561 4

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Author:  Fred [ Sat Nov 04, 2017 11:44 am ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

More pulling apart today/tonight, and one fairly sizable f*ck up (ruined a cam), and one pleasing discovery: Cheap camshaft regrinds within a few minutes drive from my place :-D

https://twitter.com/FredCookeNZ/status/ ... 8950462464
https://twitter.com/FredCookeNZ/status/ ... 1783487488
https://twitter.com/FredCookeNZ/status/ ... 4691859456
https://twitter.com/FredCookeNZ/status/ ... 3681852416
https://twitter.com/FredCookeNZ/status/ ... 4209544192
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https://twitter.com/FredCookeNZ/status/ ... 8931924992
https://twitter.com/FredCookeNZ/status/ ... 3258441728
https://twitter.com/FredCookeNZ/status/ ... 7572168704

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Author:  Fred [ Sun Nov 05, 2017 9:06 pm ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

To seal the two head halves (and the 3 exposed end cam caps) an anaerobic sealant is required. Options appear to be:

1) Volvo OEM IF available, need to check but whiteblocks up to early 2000s likely use the same stuff
2) Loctite 515, optionally with activator (7649 or 7471)
3) Permatex 51531 Anaerobic Flange Sealant

Funny how every Permatex part number is just a loctite one with two extra digits! :-/

Additionally the correct way to apply these is with a very small very short haired paint roller, or the official Volvo tool.

Apply solely to the top part with a roller, ensure oil passages are clear of it, lower onto a very clean/dry lower head, and torque down in the correct pattern to the correct amount immediately. Then fire an electric heater at it and keep it around 100C for as long as possible, waiting a total of 24 hours min, ideally more, before applying ANY oil to the passages (think gravity from wet cams/lifters).

Attached is an interesting datasheet about the 515 sealant.

Attachments:
File comment: Loctite 515 datasheet
Loctite-93791_515EN.pdf [63.96 KiB]
Downloaded 1 time

Author:  Fred [ Mon Nov 06, 2017 9:55 am ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Tonight's disassembly/inspection progress:

https://twitter.com/FredCookeNZ/status/ ... 9824484353
https://twitter.com/FredCookeNZ/status/ ... 3783949312
https://twitter.com/FredCookeNZ/status/ ... 8753697792
https://twitter.com/FredCookeNZ/status/ ... 7155294208
https://twitter.com/FredCookeNZ/status/ ... 8600090624
https://twitter.com/FredCookeNZ/status/ ... 1475810304
https://twitter.com/FredCookeNZ/status/ ... 9212367877
https://twitter.com/FredCookeNZ/status/ ... 5232104448
https://twitter.com/FredCookeNZ/status/ ... 3505047552
https://twitter.com/FredCookeNZ/status/ ... 3466027008

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Mostly encouraging. Here's some motivation to continue on: https://www.youtube.com/watch?v=M0bPvSw4PsY

Author:  Fred [ Tue Nov 07, 2017 11:28 am ]
Post subject:  Re: Building a 500hp hybrid red-block Volvo engine

Just a note on the lower power TD05HR-16G setup for the gold wagon: It'll need a divided wastegate output setup something like these:

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