68Beetle

As I installed everything, I came to realize there was a space issue. I had to "tub" the firewall with my 2lb mallet about an inch to fit the 2.25" downpipe.  I had previously bolted the manifold to the turbo, so I also had to tub the fender for clearance.  Then after I welded up the wastegate bracket, I saw there was less room than planned, so I took as much material off the bracket as I could then notched the alternator housing to prevent rubbing.

I ended up going to Home Depot to buy some PVC to use temporarily until I find an intercooler.

I sanded down the right side where there was major uglyness going on and applied bondo, about 6 layers were required to make it flat.

The passenger side rear door is stuck shut.  My buddy started body slamming it and all he did was dent the door, so we gave up for now.

I spent two weeks trying to find Volvo paint code 123 Shenandoah Green, and found that unless I spent $150, I could not even get touch up paint.  I ended up using satin black enamel to get the desired texture and I think it came out looking cool.

LOL DrKhanMD.  I wish I had thought of that, there is a cement company that is literally 100 yards from the dealer, so trucks roll through everyday.

I got a special rate through the glass company cuz I work at the dealer, about $150 installed.  Interesting sidenote is that some of the broand new Volvos are being shipped from the factory with windshields that are not fully sealed around the top, so in a rainstorm it is possible to push on the glass at the top with your index finger and water will start dripping in onto the steering wheel, and this means we are good customers of the glass company.

I brought home some shop supply ATF to fill the trans, because it was near empty, and this makes it hard to drive. I also flared a piece of brake line to replace a high pressure power steering pipe so now the power steering works again!  I bought the resident expert on mechanical fuel injection a half case of beer and he came over and assisted me on dissasembling and cleaning out the fuel distributor spider and warmup regulator, which took about four hours. Because this car has an out of tank high pressure fuel pump, it needs an in tank lift pump, and I actually found a new one on ebay.  The problem was it never came with the sending unit seal around the top of the tank, so I had to drive around for a while not filling it past 3/4 or it would slosh out the top.  Later on, I looked it up in the Volvo catalogue and found that there are three different sizes of o ring (67mm, 69mm, and 71mm) and there is no way to distinguish which one is correct.  I removed the sending unit, used a ruler to measure in inches (thats all I had), converted to metric, and came up with 70mm, of course. I guessed 69mm and it turned out to fit just fine.

There was no drivers side mirror, so I bought the cheapest fish eye mirror I could find at Advanced auto. I can't tell if the picture does it justice, it looked so comical in person.

I bought an exhaust manifold from a 91+ 740 turbo and headed off to the junkyard to find some tubing to install everything. I bought all the pressure pipes from three different cars. The turbo has the same flange, but the bolt spacing was slightly different so I used a rotary burr to enlarge one hole on the turbine housing.

I say "bought" because the state of VA requires a large tax to be paid if it is a gift, so I "paid" $5.

While getting it running, I found the fuel pump was not coming on, so I replaced it with one lying around in the shop. I repaired the leaky fuel line, which then sprung a leak 2 inches farther down so I repaired it again. It then leaked 2" past that so I cut out 4 feet of line and replaced it with all I could find in the shop, which was a high side aluminum A/C line. I used my fluid sucker doodad to remove 5 gal on 15 yo gas and an inch of rust scale and grime. Next step was to blow out the injectors and then I jumped it and it kinda ran!

Everyone in the shop at the time owed me favors, so one guy is lending me a set of 740 turbo wheels, the detailer polished and buffed it and another guy gave me a td-04 15G turbo from an 850 on the condition I would install it.

...aaand it was worth free.

I used to work at a Volvo dealer, and a customer had his old car towed in.  He said anyone who will fix and drive it can have it for free. I love starting projects, so naturally I "bought" the car.  The manager loved the idea of this so much he gave me until the start of business the next day to have it off the lot. My buddy and I were up til aboot midnight until it finally ran, then I drove it over to the employee lot to park it in my designated space.

A week later, the manager informed me that the owner of the lot we rent for employee parking wants this eyesore out of the lot by 10AM or he will tow it (and the tow company is his neighbor to the right). When does he decide to tell me? At 9:50am of course.  I rush to get the portable air tank to give the tires some air in the remote lot, just so I can drive it out.  When I get up there, three of four tires are flat, so I do as much as I can with the one air tank and drive it out of there with one tire still completely flat.  I drove it to the shop, took a tire from the used tire stack, and mount it up because the one tire shredded.  I drive it home as you see in this picture, smashed glass, running on three cylinders, no registeration/insurance, and brakes rusted so badly that the scale is preventing the pads from sticking to the rotor.

BTW this is my first time on the forums.