480 Limited Evolution
Moderators: jifflemon, coyote1980, Rachel
480 Limited Evolution
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
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
-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
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!
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
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
-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
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!
Last edited by justtank on Wed Jan 08, 2020 12:33 pm, edited 1 time in total.
VOLVO 480 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
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VOLVO 480 - Celebration 1/480
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Re: 480 Limited Evolution
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
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
------------------------------------------------
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
------------------------------------------------
Re: 480 Limited Evolution
looking forward to this....
(also did a quick edit of your thread to get the images to show!)
(also did a quick edit of your thread to get the images to show!)
Re: 480 Limited Evolution
Ortovox77 wrote: ↑Mon Feb 04, 2019 2:52 pmThis 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 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
Cheers, wasnt all that sure which selection would input the images.
My bad
VOLVO 480 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
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
------------------------------------------------
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
------------------------------------------------
Re: 480 Limited Evolution
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.Ortovox77 wrote: ↑Tue Feb 05, 2019 4:19 pmjusttank 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 - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
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 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
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?
so you press the wee picture then paste the link in the gap?
Alan
480 ES 2litre 'Celebration' ? , C30 1.8ES, SS1
480 ES 2litre 'Celebration' ? , C30 1.8ES, SS1
Re: 480 Limited Evolution
Nice one mate, looks to have worked. Noob to this forum my bad!
VOLVO 480 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
- brinkie
- 480 Connoisseur
- Posts: 872
- Joined: Mon Apr 21, 2014 11:20 am
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Re: 480 Limited Evolution
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, 1999 Volvo S70 2.5 Europa, 2010 Volvo V70 2.0F Momentum
Present cars: 1994 Volvo 480 GT 2.0i, 1999 Volvo S70 2.5 Europa, 2010 Volvo V70 2.0F Momentum
Re: 480 Limited Evolution
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!
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!
Re: 480 Limited Evolution
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.jifflemon wrote: ↑Wed Feb 06, 2019 2:45 pmQuestion 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 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 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
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
VOLVO 480 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
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 'Celebration' ? , C30 1.8ES, SS1
480 ES 2litre 'Celebration' ? , C30 1.8ES, SS1
Re: 480 Limited Evolution
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.Alan 480 wrote: ↑Thu Feb 07, 2019 12:37 pmI 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!!
VOLVO 480 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
- brinkie
- 480 Connoisseur
- Posts: 872
- Joined: Mon Apr 21, 2014 11:20 am
- Location: The Netherlands
- Contact:
Re: 480 Limited Evolution
Send it over, I'll make it like new again
Robert.
Present cars: 1994 Volvo 480 GT 2.0i, 1999 Volvo S70 2.5 Europa, 2010 Volvo V70 2.0F Momentum
Present cars: 1994 Volvo 480 GT 2.0i, 1999 Volvo S70 2.5 Europa, 2010 Volvo V70 2.0F Momentum
Re: 480 Limited Evolution
Update to the project
Stockpiling parts and tools needed to get everything done. Old engine has been removed finally.
Acquired a diesel JC5 128 Gearbox from a renault 5 F7R swapped car, as i fancied better motorway engine speeds. This has already had a strengthened diff for the extra power so hopefully no breakage! Its been running 400 bhp and is in perfect condition so should be great for feeble 200 numbers
Next is welding and fitting new poly bushes.
Stay tuned
Stockpiling parts and tools needed to get everything done. Old engine has been removed finally.
Acquired a diesel JC5 128 Gearbox from a renault 5 F7R swapped car, as i fancied better motorway engine speeds. This has already had a strengthened diff for the extra power so hopefully no breakage! Its been running 400 bhp and is in perfect condition so should be great for feeble 200 numbers
Next is welding and fitting new poly bushes.
Stay tuned
VOLVO 480 Turbo - Limited Edition "MERLIN"
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
VOLVO 480 - Celebration 1/480
VOLVO S60 2013 D5 R-Design
Re: 480 Limited Evolution
looking good, not much room in engine bay for anything else!!!
Alan
480 ES 2litre 'Celebration' ? , C30 1.8ES, SS1
480 ES 2litre 'Celebration' ? , C30 1.8ES, SS1
-
- Can tell where the 480 was built
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Re: 480 Limited Evolution
"Over-modified 480 friends" woooo!
'91 480 ES 2.0l 16v 'Williams' Conversion - 212bhp/230nm
'90 940 GL 2.0l Estate
'08 XC90 D5 SE Premium
'90 940 GL 2.0l Estate
'08 XC90 D5 SE Premium