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Discussion Starter #41
Rip kit and turbo inlet
We replaced all of the intercooler piping with the Snabb reverse intercooler piping kit. There has been some debate whether RIP kits reduce turbo lag and increase throttle response and power...but I just really like the way they look. The Snabb kit we ordered came with the the larger elbow to fit the 3 inch throttle plate. We ordered the black silicone hose kit but were shipped the blue by mistake. We were anxious to to finish the build so we kept the blue. I did have to modify the over the engine pipe where it connects to the turbo. The K24 turbo compressor discharge comes out at an angle rather than straight up like the TD-04. The compressor exit side of the Snabb pipe has a short straight section, a slight bend, another short straight, and then a bend to go over the engine. I had to cut out the slight bend between the two short straights to get the pipe to line up with the turbo. I had my friend Joe weld the 2.5 inch aluminum pipe back together after I cut out the bend. I hated to cut the beautiful aluminum over the engine pipe but Joe made it look like it was always that way.
We also installed the Snabb Performance Fresh Air Pipe fitted to the K24 turbo. This time the silicone hoses came black...Oh well. In addition, we installed the larger 3 inch MAF housing from the Volvo 960. I should have taken the MAF when I got the throttle plate from the 960 at the junk yard. I couldn’t find another used one and bought a aftermarket one off ebay for $25 putting the original sensor in the aftermarket housing. I wanted to keep the look of the stock air filter housing and found that the air-box lid from a ‘99-‘00 S/V70 with the lpt engine has a 3 inch hole that accepts the 960 MAF housing perfectly. It’s too bad it doesn’t say “TURBO” like the original box.
One thing I wish we would have done at this time was to replace the intercooler with a Snabb or Do88 intercooler.







Joe has some serious welding skills!






 

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Discussion Starter #42
The shift knob is from some random Audi we found in the junkyard. It fit like a glove once I cut the skinny part off the top of the shift lever...and it has the proper shift pattern! The shift boot is a $15 aftermarket ebay special. It’s just tucked into the console hole for now until I can come up with a better way to mount it. I think the combination of the floor mounted P1 shift assembly and the slightly shortened lever make the shifter significantly shorter than the stock manual 850. This was welcomed as I think the stock shifter is a little too tall.



We will probably replace the shift knob at some point but I kind of like the round ball.
 

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Discussion Starter #43
It’s alive!
And it’s fitting this Frankenstein sparked to life around Halloween.
Like the German monster this Swedish beast is a mixture of others pieces and parts.
The car: ‘96 850 Platinum sedan
The engine: B5254T4 from a ‘06 S60R
The transmission: M56 from a ‘07 S40
Intake manifold: N/A manifold from a ‘94 850
Throttle plate: ‘96 960
Air filter housing lid: ‘99 S70
Engine mount bracket: ‘99 V70 XC
Clutch/brake pedal assembly: ‘95 850
Power steering lines: ‘00 V70
Coolant reservoir: ‘99 S70
A/C compressor: ‘00 V70
Lots of new parts as well...

 

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Get an 05+ ps reservoir. Doesn’t leak, fits better, improved design.
 

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I was scrolling through pics and the wife noticed the RIP kit on it.

She was like "What's that? Mine doesn't look like that."

I explained it to her and she replied with "I like it. Can we do it to my car?"



*sigh*
 

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Discussion Starter #46
Get an 05+ ps reservoir. Doesn’t leak, fits better, improved design.
I didn’t use the reservoir from the S60R as it had connections for a power steering cooler which the 850 doesn’t have. I did however eventually replace the reservoir with a new OEM unit.
 

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Discussion Starter #47
Here are a few early tune 3rd gear (and a little bit of 4th) datalog pulls. The car has been running great and has been problem free. The tuning process takes some time so you need to be patient. Aaron at Vast is very knowledgeable and helpful (and busy). It might be a day or so for a response but he always gets back to you. He looks over the datalogs, makes some adjustments and send a new tune to download to the car.
The videos are from November 2018 or about 3 weeks after we finished the first stage of the build. The weather changed to winter in Michigan shortly after this. Winter tires and wet roads postponed 3rd gear pulls and further tunes for a little bit. Jake continued to put miles (and smiles) on it over the winter as it is his daily driver. It’s amazing how the manual swap changed the driving dynamics of the car. The M56 from the S40 has a pretty short final drive which is nice for acceleration but not the best for fuel economy. It really revs when on the highway.

Notice the knock detection at the 20 second mark
 

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Discussion Starter #48
Here are a few more datalog pulls from February 2019 including clips from the laptop. For some reason the wideband reading on the laptop was displaying higher than the gauge in the car. The injector duty cycle is getting close to the limit with the original green injectors. We will most likely upgrade these in the future...and possibly go to e85. Is the dw200 fuel pump big enough for e85?
 

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Discussion Starter #49
The wheels:
We kept the 18” Pegasus wheels from the Ghettolvo to use on the Platinum. Two of the wheels were poorly painted gold and were in pretty rough shape. The other two were decent but IPD replicas.



The oem pegs filling in as a engine stand.



The gold set after a chemical strip.




The IPD fakes.



I wound up having the oems sandblasted after the chemical strip...probably should have just had them sandblasted from the start. I hand sanded them as a final step to make them ready for paint.
Jake sprayed them with “Brass Monkey” plasti dip after new rubber was installed. We went with 225/40R18 Nokian zline a/s...to keep with the Nordic heritage lol.


 

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Discussion Starter #50
April 2019. Springtime in Michigan.
Time for phase 2 of the build.

 

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Nice nice nice. I see some coilovers...

Sent from my ONEPLUS A5000 using Tapatalk
 

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Discussion Starter #53
Phase 2:


One thing we soon found when doing the 3rd and 4th gear pulls was that the brakes were no longer up to the task of rapidly slowing the car from high speeds. We had salvaged the Brembo calipers from the Ghettolvo with the intention of using them on the Platinum, however I knew it would not a simple/bolt on job. Rear caliper brackets are easily available but the fronts are not.
Luckily Jake is a design engineer. Using a caliper and rotor from the Ghettolvo along with a knuckle I removed from a S70 at the junkyard and some inspiration from the internet he designed a bracket that looked like it would work. He had the part 3D printed so we could mock up and test fit the caliper to the knuckle. Modification to the knuckle was needed to get the calipers to fit. The steering stops were cut off and Time-Serts were installed in the caliper bolt holes. Once we were convinced it would work Jake had them CNC machined from a high strength alloy.











Braided stainless steel brake lines replaced the rubber hoses to the front calipers. I had to modify/move the mounting bracket to give the lines more slack they were too short to fit the larger Brembo calipers.
New OEM brake pads and rotors (330mm front and rear!) were installed along with a brake fluid change. The rear caliper brackets were sourced from IPD.

Bigger brakes=bigger wheels...the stock 16” Persus wheels will no longer fit.


In addition, the right rear wheel speed sensor was replaced which was causing an ABS and Tracs Off warning light to be on.
New OEM lower control arms were installed to replace the cheap aftermarket ones I had put on couple years ago whose ball joints already had play. Also, as part of the suspension refresh, the shocks and springs were replaced with a new set of BC Racing coilovers. We had to roll the rear fenders and trim the rear wheel liners to keep the rear tires from rubbing. Note: We have 15mm spacers on the rear wheels for aesthetic reasons only. I was pleasantly surprised with how well the car rides. It’s firm but not harsh. Frankly, I was expecting it to be much harder considering it also is rolling on 18” Pegs. The front tires will rub when approaching lock. I suspect it has more to do with the 225/40R18s than the lack of steering stops.
The braking performance in phenomenal. After performing several hard stops to bed-in the new pads/rotors I started to get light-headed. In fact, I didn’t feel all that well for about a half hour after lol.

May 2019


 

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Imagine if the 3D printed bracket was left on the car lol.

But that is pretty cool, definitely next level mechanic'ing going on. The 302mm BBK in my opinion doesn't make much of a difference.

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Nice adapter bracket. I've seen people doing some sketchy shiit to adapt P2R Brembos to P80s, so this is a pleasant departure from that!




Imagine if the 3D printed bracket was left on the car lol.

But that is pretty cool, definitely next level mechanic'ing going on. The 302mm BBK in my opinion doesn't make much of a difference.

Sent from my ONEPLUS A5000 using Tapatalk
what pads are you running
 

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Nice adapter bracket. I've seen people doing some sketchy shiit to adapt P2R Brembos to P80s, so this is a pleasant departure from that!






what pads are you running
Akebono Euro

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Now that I'm remembering, I recall you guys saying the akebonos were crap. Yeah I'll switch them out soon.

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Now that I'm remembering, I recall you guys saying the akebonos were crap. Yeah I'll switch them out soon.

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They're so bad that my dad hated them on his NA.....that car doesn't even go fast...
 

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Lollll.

Damn.

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