Just a quick up date on the engine build, The bottom end is std rebuilt 440 turbo, with the 300 sump and mounts. The head is 440 turbo, but i have ported an polished it, on std valve sizes. This is now all built up on the stand in the garage, with the ancillaries all fitted an ready to go.
As I think I mentioned before, the 440 manifolding (inlet and exhaust), wont go anyware near a 300 engine bay. The turbo goes were the brake master cylinder goes, and the throttle housing ends up in the heater box. OH dear, time to get the grinder out!!
To get round this, I cut the manifold flange off the exhaust manifold ( with a hack saw, NOT recomeded, it took forever!!)
I then got some cast iron arc rods and welded it back together with the manifold the other way up. This puts the turbo at the front of the engine. The outlet flange has been cut off and replaced with a flange I had made to suit the t3 turbo (ex montego) The inlet manifold I made a steel plate to blank the std throttle location. Then cut the other end off, and had a angled alloy tube welded in the hole. Then I cut a cavalier inlet manifold up for it's throttle body and flange. The flange was then welded to the alloy pipe. The cavalier throttle also has the advantage of being twice the size of the volvo one
I then bolted the manifolds to the engine, only to find the exhaust manifold hit the inlet manifold long before it got anyware near the gasket ARSE!! Then had to cut the manifold off the flange again (which now had loads of hard as nails weld all over the bits i was cutting)
and angle it down to clear the inlet and re weld. now its all over and done with and the engine is ready to go in the car as far as possible.
On the management side, I have fitted saab 9000 turbo injectors, and a 4x4 cosworth throttle potentiometer. I have a 2.5 bar map sensor waiting to go, and the omex came with its own coolant and air temp sensors. Now all I have to do is put it in the car and get it running by the 10th of aprill!!!!!!!
