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2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

This topic is in the MVS Volvo Repair Database » 2004 S60R -- Yamaha V8 Conversion!
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jonesg
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Post by jonesg »

I agonize whether to install a cigarette lighter.
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RickHaleParker
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Post by RickHaleParker »

Bolted in:
IMAG0003.jpg
Active
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2017 Ford PIU. 3.5l, Twin Turbo, 365 Hp.
............................
Past
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. ( Killed by a plastic radiator. )
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion ( I moved, the project did not )
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0. ( Transmission dead after sitting for a winter )
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bmdubya1198
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Post by bmdubya1198 »

Exciting! This is where the fun starts.
07 XC90 V8 AWD Sport Titanium Grey/Black 235k
92 245 White/Beige 249k
91 944 Turbo 175k
…and a bunch of other stuff
Sold-
00 V70R Venetian Red/Charcoal M56 Swapped
03 S60 2.4T
00 S70 GLT
98 V70 GLT
93 944
98 S90
95 850 GLT
01 S60 2.4T
05 S60R M66
08 S40 2.4i
88 744 Turbo M46
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RickHaleParker
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Post by RickHaleParker »

I am using the hard A/C lines from the XC90. The XC90 has two Evaporators. The S60 has only one. I cut off the excess lines figuring I could braze some Aluminum end caps on like I did decades ago. Looked high and low for the end caps. It is like they been vanished from existence. Any alternative ideas or sources for Aluminum end caps?

Small tube is 9.5mm (3/8") Dia. Large tube is 16MM (5/8") Dia.
IMAG0010.jpg
Active
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2017 Ford PIU. 3.5l, Twin Turbo, 365 Hp.
............................
Past
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. ( Killed by a plastic radiator. )
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion ( I moved, the project did not )
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0. ( Transmission dead after sitting for a winter )
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RickHaleParker
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Post by RickHaleParker »

jonesg wrote: 20 Jun 2020, 08:26 I agonize whether to install a cigarette lighter.
Is it like the Paper or Plastic decision ... Electric or Butane?
Active
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2017 Ford PIU. 3.5l, Twin Turbo, 365 Hp.
............................
Past
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. ( Killed by a plastic radiator. )
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion ( I moved, the project did not )
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0. ( Transmission dead after sitting for a winter )
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volvolugnut
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Post by volvolugnut »

RickHaleParker wrote: 22 Jun 2020, 20:08 I am using the hard A/C lines from the XC90. The XC90 has two Evaporators. The S60 has only one. I cut off the excess lines figuring I could braze some Aluminum end caps on like I did decades ago. Looked high and low for the end caps. It is like they been vanished from existence. Any alternative ideas or sources for Aluminum end caps?

Small tube is 9.5mm (3/8") Dia. Large tube is 16MM (5/8") Dia.

IMAG0010.jpg
Machine your own end caps from Aluminum bar stock. Easy for anyone with a lathe, even a hobby lathe.
volvolugnut
The Fleet:
Volvo: 2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple Volvo parts cars.
Mercedes: 2001 E320, 1973 280, 1974 280C, 1989 300E, 1988 300TE, 1979 300TD, parts cars.
2009 Smart Passion
Ford: 1977 F350, 1964 F150 (2), 1938 Tudor Sedan
Farmall tractors: 1956 400 Diesel, 1946 A
John Deere 214 lawn tractor about 1977 model
And others.
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RickHaleParker
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Post by RickHaleParker »

volvolugnut wrote: 25 Jun 2020, 13:21 Machine your own end caps from Aluminum bar stock. Easy for anyone with a lathe, even a hobby lathe.
I do not have a lathe not even a hobby lathe.

On the small one I found a socket cap screw that self threaded into the tube. However it is steel. I never brazed aluminum to steel so I do not know if that will work out. Thinking about sealing it with Loctite red. Then see if a can find the right size bolt to do the larger one.
Active
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2017 Ford PIU. 3.5l, Twin Turbo, 365 Hp.
............................
Past
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. ( Killed by a plastic radiator. )
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion ( I moved, the project did not )
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0. ( Transmission dead after sitting for a winter )
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volvolugnut
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Post by volvolugnut »

How about this cap from McMaster Carr?

volvolugnut
Attachments
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The Fleet:
Volvo: 2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple Volvo parts cars.
Mercedes: 2001 E320, 1973 280, 1974 280C, 1989 300E, 1988 300TE, 1979 300TD, parts cars.
2009 Smart Passion
Ford: 1977 F350, 1964 F150 (2), 1938 Tudor Sedan
Farmall tractors: 1956 400 Diesel, 1946 A
John Deere 214 lawn tractor about 1977 model
And others.
Top
User avatar
RickHaleParker
Posts: 7206
Joined: 25 May 2015, 14:30
Year and Model: See Signature below.
Location: Kansas
Has thanked: 8 times
Been thanked: 980 times

Post by RickHaleParker »

volvolugnut wrote: 25 Jun 2020, 17:11 How about this cap from McMaster Carr?
Those are Copper. Copper - Aluminum junctions are highly susceptible to Galvanic corrosion. That green stuff that grows near the soldered joints of Copper water pipes.
Active
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2017 Ford PIU. 3.5l, Twin Turbo, 365 Hp.
............................
Past
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. ( Killed by a plastic radiator. )
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion ( I moved, the project did not )
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0. ( Transmission dead after sitting for a winter )
Top
User avatar
RickHaleParker
Posts: 7206
Joined: 25 May 2015, 14:30
Year and Model: See Signature below.
Location: Kansas
Has thanked: 8 times
Been thanked: 980 times

Post by RickHaleParker »

Options:
  • 1. Roll the dice with Loctite red.
    2. Roll the dice with aluminum brazing on Aluminum- Steel.
    3. Abandon the whole idea.
IMAG0021.jpg
Active
1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2017 Ford PIU. 3.5l, Twin Turbo, 365 Hp.
............................
Past
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000. ( Killed by a plastic radiator. )
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion ( I moved, the project did not )
2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0. ( Transmission dead after sitting for a winter )
Top
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