480 Limited Evolution

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justtank
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480 Limited Evolution

Post by justtank » Mon Feb 04, 2019 1:58 pm

For lack of a better name... I have begun Ripping my 480 Twin tone apart for its enormous upgrade and overhaul.

The car as stock - The woefully slow Na 1.7 B18EP - Spax lowering springs - Rota Alloys (too wide for the rear arches but has given better traction due to larger footprint) the interior was fully redone with help from my sister. Plus 50 shades of green and silver + beginnings of rust on arches :shock:

Upgrades as follows (for those interested) Pictures and YouTube video to be uploaded soon.

-B18FT Turbo engine. Undergoing a full rebuild (all new seals/ gaskets, piston rings, replacement head from a Renault 5GT tuner, had all stem seals and new valves done.
-JC5 gearbox from clio 172 as stock m54 won't last all that long. I can't find an M59 unit that's not stupid money.
-Uprated F7R oil pump as im ditching the stock sandwich cooler (you'll see why in a minute) need the extra oil pressure.
-Standard turbo was uninteresting and isn't far off needing a rebuild... so I opted for a rebuilt Holset HX25 (wastegateless design) with T2 flange so bolts onto stock manifold. Fast spool and newer technology, td04 variant used on the scoobys/ evo's quite a bit larger but wont cause all that much more lag.
-Tial 40mm Wastegate as turbo doesn't have an internal one.
-GAZ coilovers + Full Polybush set + new wishbones which will be reinforced! need to be done or snappage occurs :sick:
-Mocal 12 row oil cooler + oil filter adapter as holset turbo is not watercooled like the stock garrett, only oil so figured better cooling will be required.
-Stage 2 or 3 black diamond clutch.
-Omex 600 ECU and loom. Ditching the stock ECU's and other unreliable components (MAF, idle Control valve etc) can control the torque by gear to limit wheelspin when accelerating.
-480 turbo brake calliper upgrade + drilled/ slotted disks.
-AIR conditioning retrofit from Cranna's 480 GT (i can't stand the heat in these cars when its summer) Wish me luck.

The plan is to run respectable power, be a comfortable yet good handling car with decent shove (Around 200 BHP mark) as i don't want to be ripping the engine apart again for a long time afterwards.

Too much to list so these are the concentrated points for now. More to be posted soon as im planning a roadtrip with this car around August, times running out :bla:

Will try to document and video what I can as there's not much up to date info with upgrades going to this length. Pictures no longer work etc.

Stay tuned!

Image
Image
Image
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

Ortovox77
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Re: 480 Limited Evolution

Post by Ortovox77 » Mon Feb 04, 2019 2:52 pm

This will be really interesting to follow.
Specifically the engine tuning and suspension since I have one 480 Turbo that I want to tune also.
By the way what GAZ coilovers are you going to use? I have tried to find some coilover kit from a known manufacturer but have not found anything.

By the way the Two tone is really cool

BR Jonas
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

jifflemon
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Re: 480 Limited Evolution

Post by jifflemon » Mon Feb 04, 2019 3:55 pm

looking forward to this....

(also did a quick edit of your thread to get the images to show!)

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justtank
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Re: 480 Limited Evolution

Post by justtank » Tue Feb 05, 2019 8:55 am

Ortovox77 wrote:
Mon Feb 04, 2019 2:52 pm
This will be really interesting to follow.
Specifically the engine tuning and suspension since I have one 480 Turbo that I want to tune also.
By the way what GAZ coilovers are you going to use? I have tried to find some coilover kit from a known manufacturer but have not found anything.

By the way the Two tone is really cool

BR Jonas

You won't be able to find them on GAZ's site as Dai gets them special order through Classic Swede. If you don't mind waiting a while for them.
Here's the link: https://www.classicswede.co.uk/Full_on_ ... 15871.aspx

Yeah the two tone is different. It's taken me a while to come round to the green colour, but looking at that car in the sea of German grey and white you see nowadays. The little green car just stands out and you get so much attention at car meets its unreal. The odd look from the younguns and the older lot have that "omg i remember those" expression! Just need to sort the paintwork out next. But thats last to do, no point sorting that till the modifications are complete.

Coilers and polybushes were dispatched yesterday from the order i put on in Novemeber, GAZ can be slow! but worth the wait i assure you.
Last edited by justtank on Tue Feb 05, 2019 9:00 am, edited 1 time in total.
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

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justtank
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Re: 480 Limited Evolution

Post by justtank » Tue Feb 05, 2019 8:56 am

jifflemon wrote:
Mon Feb 04, 2019 3:55 pm
looking forward to this....

(also did a quick edit of your thread to get the images to show!)
Cheers, wasnt all that sure which selection would input the images.
My bad :wall:
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

Ortovox77
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Re: 480 Limited Evolution

Post by Ortovox77 » Tue Feb 05, 2019 4:19 pm

justtank wrote:
Tue Feb 05, 2019 8:55 am

You won't be able to find them on GAZ's site as Dai gets them special order through Classic Swede. If you don't mind waiting a while for them.
Here's the link: https://www.classicswede.co.uk/Full_on_ ... 15871.aspx

Yeah the two tone is different. It's taken me a while to come round to the green colour, but looking at that car in the sea of German grey and white you see nowadays. The little green car just stands out and you get so much attention at car meets its unreal. The odd look from the younguns and the older lot have that "omg i remember those" expression! Just need to sort the paintwork out next. But thats last to do, no point sorting that till the modifications are complete.

Coilers and polybushes were dispatched yesterday from the order i put on in Novemeber, GAZ can be slow! but worth the wait i assure you.

Aha but then it's the coilover kit I emailed DAI about. It's the only coilover kit I have found in my many hours of search so far for the volvo 400.
I have been thinking about getting them but haven't seen any feedback from anyone using them. Also in Sweden GAZ is not so well known so I was not sure how the quality was compared to brands like Bilstein and KW coilovers.

But you seem positive about GAZ so this makes me lean more to ordering a kit for the summer and stop the search :) .
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

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justtank
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Posts: 12
Joined: Wed Oct 04, 2017 1:02 pm

Re: 480 Limited Evolution

Post by justtank » Tue Feb 05, 2019 5:34 pm

Ortovox77 wrote:
Tue Feb 05, 2019 4:19 pm
justtank wrote:
Tue Feb 05, 2019 8:55 am

You won't be able to find them on GAZ's site as Dai gets them special order through Classic Swede. If you don't mind waiting a while for them.
Here's the link: https://www.classicswede.co.uk/Full_on_ ... 15871.aspx

Yeah the two tone is different. It's taken me a while to come round to the green colour, but looking at that car in the sea of German grey and white you see nowadays. The little green car just stands out and you get so much attention at car meets its unreal. The odd look from the younguns and the older lot have that "omg i remember those" expression! Just need to sort the paintwork out next. But thats last to do, no point sorting that till the modifications are complete.

Coilers and polybushes were dispatched yesterday from the order i put on in Novemeber, GAZ can be slow! but worth the wait i assure you.

Aha but then it's the coilover kit I emailed DAI about. It's the only coilover kit I have found in my many hours of search so far for the volvo 400.
I have been thinking about getting them but haven't seen any feedback from anyone using them. Also in Sweden GAZ is not so well known so I was not sure how the quality was compared to brands like Bilstein and KW coilovers.

But you seem positive about GAZ so this makes me lean more to ordering a kit for the summer and stop the search :) .
I've been for a ride in Fraser Crannas F7R swapped 480 using the same coilovers and i can confirm that they are a quality set. Handles like its on rails man. Just had delivery of them (will upload pics soon) beautiful. Quality materials and adjustable dampening and camber plates if your into that kind of thing. But its nice to have if your want to track the car.
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

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justtank
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Re: 480 Limited Evolution

Post by justtank » Tue Feb 05, 2019 8:47 pm

Image

Image

Im still trying to figure out this image linking system, apologies but here's the coilovers, polybushes and external oil filter/cooler adapter.

really impressed so far.

(edited, figured it out now cheers haha)
Last edited by justtank on Wed Feb 06, 2019 12:54 pm, edited 1 time in total.
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

Alan 480
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Location: Aberdeen

Re: 480 Limited Evolution

Post by Alan 480 » Wed Feb 06, 2019 12:41 pm

i think you need the [/i m g ] bit at each side of your picture :-)

so you press the wee picture then paste the link in the gap?
Alan

480 ES 2litre, C30 1.8ES, SS1 + more

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justtank
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Re: 480 Limited Evolution

Post by justtank » Wed Feb 06, 2019 12:55 pm

Alan 480 wrote:
Wed Feb 06, 2019 12:41 pm
i think you need the [/i m g ] bit at each side of your picture :-)

so you press the wee picture then paste the link in the gap?


Nice one mate, looks to have worked. Noob to this forum my bad!
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

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brinkie
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Re: 480 Limited Evolution

Post by brinkie » Wed Feb 06, 2019 2:17 pm

Sounds like a proper upgrade to me :) I am very curious about the total part cost incurred (not counting labour) and the final result on a rolling road or track!
Robert.

Present cars: 1994 Volvo 480 GT 2.0i Vase Green, 2010 Volvo V70 2.0F Momentum Mystic Silver
Past: 1981 Talbot-Matra Murena 2.2 Rouge Mephisto, 1995 Volvo 480 GT 2.0i Paris Blue

jifflemon
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Re: 480 Limited Evolution

Post by jifflemon » Wed Feb 06, 2019 2:45 pm

Question about the coilovers - and please understand this is nether criticism, or expecting you to know the answer.....

Spring length; There seems to be quite a lot of thread available on the strut, so why not a longer spring? I'd have thought that shorter springs could coil bind easier on compression (severe bumps) and loose contact with either end when the suspension goes into droop (coming off a bump) causing severe slamming when the suspension comes back down and the spring makes contact again with the spring perches.

Now, it could be that length because you can't physically use the rest, or that longer springs in the poundage that their at are not available - I'm just curious!

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justtank
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Re: 480 Limited Evolution

Post by justtank » Wed Feb 06, 2019 10:47 pm

jifflemon wrote:
Wed Feb 06, 2019 2:45 pm
Question about the coilovers - and please understand this is nether criticism, or expecting you to know the answer.....

Spring length; There seems to be quite a lot of thread available on the strut, so why not a longer spring? I'd have thought that shorter springs could coil bind easier on compression (severe bumps) and loose contact with either end when the suspension goes into droop (coming off a bump) causing severe slamming when the suspension comes back down and the spring makes contact again with the spring perches.

Now, it could be that length because you can't physically use the rest, or that longer springs in the poundage that their at are not available - I'm just curious!
I had no choice in the springs, you get what you buy. 480s aren't very heavy remeber. But it's not be all end all, can just change the spring. I was looking into putting a smaller softercoil to sit ontop like my s60 has with its KW vairent coilovers.

I bought them after experiencing them in another car and had no issues doing many speeds on Scotland's windy roads. Never had i thought a 480 could handle the way it did. Hats off to cranna for an excellent job. Will need strut brace as the body flexes and adjustable panhard bar to go on the rear.
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

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justtank
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Re: 480 Limited Evolution

Post by justtank » Wed Feb 06, 2019 10:55 pm

brinkie wrote:
Wed Feb 06, 2019 2:17 pm
Sounds like a proper upgrade to me :) I am very curious about the total part cost incurred (not counting labour) and the final result on a rolling road or track!
So far with 2 cars consolidating into 1 (first car was rotten) I have spent around 7k £ on this particular 480 so far, but I'm having to aquire tools to do jobs I'd rather learn to do myself, this I'm adding into the equation. Saved myself a whole lot of money especially the interior most places charge about 3/4 k but I got away with 250 for just materials. Took months to do though!

Projecting around 9/11 k once finished. Im needing the arches widening slightly on the rear and doing all this and not having a full respray wouldn't do it justice. Also my guage cluster decided to break so may have to send this one over to you Robert :hopping:
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

Alan 480
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Location: Aberdeen

Re: 480 Limited Evolution

Post by Alan 480 » Thu Feb 07, 2019 12:37 pm

justtank wrote:
Wed Feb 06, 2019 10:55 pm

Projecting around 9/11 k once finished. Im needing the arches widening slightly on the rear
I think that Fraser (Cranna) just removed the return lip so he could fit wider wheels/ lower etc, but maybe your wheels are just too wide?
if it had been teh SS1 then you just warm with a hot air gun and pull gently, sorted, not so easy with steel (and fuel filler location ! )

but going for front coil-overs sorts the lack of front lower spring pans, see Arthuy's thread, (viewtopic.php?f=19&t=34997&start=260#p216533) he is looking for a pair!!
Alan

480 ES 2litre, C30 1.8ES, SS1 + more

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justtank
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Re: 480 Limited Evolution

Post by justtank » Thu Feb 07, 2019 3:29 pm

Alan 480 wrote:
Thu Feb 07, 2019 12:37 pm
justtank wrote:
Wed Feb 06, 2019 10:55 pm

Projecting around 9/11 k once finished. Im needing the arches widening slightly on the rear
I think that Fraser (Cranna) just removed the return lip so he could fit wider wheels/ lower etc, but maybe your wheels are just too wide?
if it had been teh SS1 then you just warm with a hot air gun and pull gently, sorted, not so easy with steel (and fuel filler location ! )

but going for front coil-overs sorts the lack of front lower spring pans, see Arthuy's thread, (viewtopic.php?f=19&t=34997&start=260#p216533) he is looking for a pair!!
Fraser has rolled the lip back, I have done the same, one side worked okay until you had more than 2 people in the car. However there was a bit of rust on the driver side which caused it to not roll correctly. Im having them cut out and rewelded again properly so that they will accommodate the wheels, I want the extra grip with the wider tyres, should mean less wheelspin, which is why I went bigger.
VOLVO 480 SE - Twin Tone - B18FT Swap - HX25
VOLVO 480 Celebration 1/480
VOLVO S60 2012 D5 R-Design

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brinkie
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Re: 480 Limited Evolution

Post by brinkie » Fri Feb 08, 2019 12:09 pm

justtank wrote:
Wed Feb 06, 2019 10:55 pm
Also my guage cluster decided to break so may have to send this one over to you Robert :hopping:
Send it over, I'll make it like new again :)
Robert.

Present cars: 1994 Volvo 480 GT 2.0i Vase Green, 2010 Volvo V70 2.0F Momentum Mystic Silver
Past: 1981 Talbot-Matra Murena 2.2 Rouge Mephisto, 1995 Volvo 480 GT 2.0i Paris Blue

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