Introducing: Mordacai, A Diesel Reborn

[Eli]

http://www.randomflash.net/bricks/wp-content/uploads/2009/12/IMG_1594-Cropped-1024x696.jpg

That's right, I've finally got it on the road. I thought I should makes Mordecai's debut.

For those of you that don't know the story:

I Wrecked my Bertone (http://forums.turbobricks.com/showthread.php?t=145560) Thread 08-22-2008

Searching for a 245 shell (http://forums.turbobricks.com/showthread.php?t=147593) Thread 09-13-2008

245 Found (http://forums.turbobricks.com/showthread.php?t=154512) Thread 11-25-2008


After I bought it it sat in my garage for 6 months. I removed the B21 and M46, then completely overhauled the suspension, installed my D24T and M46 on Oct. 1st 2009 in preparation for Jim's Farm Meet. It's still taken me this long to get everything ironed out and it inspected.

Most of the suspension and the engine and transmission came from my Bertone, but there has been quite a bit of updating/improving in this install. My TurboDiesel 2.0.

For the whole story in way too much detail you can check out my blog:
Randomflash.net/Bricks (http://www.randomflash.net/bricks)

Before:
http://i195.photobucket.com/albums/z290/EliMailey/IMG_0193.jpg

After:
http://i195.photobucket.com/albums/z290/EliMailey/IMG_1596Cropped.jpg

Before:
http://i195.photobucket.com/albums/z290/EliMailey/IMG_0588.jpg

After:
http://i195.photobucket.com/albums/z290/EliMailey/IMG_1575.jpg

Spec list so far:
Body: '79 245 236K

Engine: D24T 209K miles, eBay Intercooler, N/A intake, K&N cylinder air filter, E-fan, converted to turbo gasser oil cooler, custom baffled breather vent, Side exit exhaust.

Transmission:M46 Mileage unknown

Suspension: All Poly Bushings, 25mm Sway bars, 82+ Strut tubes, Ipd lowering springs, Bilstien HDs, Boxed control/trailing arms(Yoshifab), GT Strut to firewall braces, SAM strut brace. Kaplhenke sway bar endlinks (not yet installed).

Brakes: Converted to vented rotors in the front, Stainless steel brake lines, new junction box.

Exterior: Converted to Flathood+Single road headlights, installed Airdam.

Interior: Later style 245 seats, 81+ dash/turbo gauge set-up (not yet installed)


I am thrilled with it so far. Still needs some adjustment on the transmission/engine mounts (everything vibrates at idle), and the glow plugs need to be wired correctly. I also want to install that 81+ dash and get my gauges in there. Then my Vegetable Oil conversion... It's still very much a project.

Other then that it's great!! I love driving it, handles well, and has decent power. I can't wait to see what sort of mileage I can get out of it.


A Huge Thank You to everyone for there support in getting me this far. You know who you are.

(This thread can also be found on Turbobricks)

[Jason]

Wow looks sweet. Gonna throw a couple D24T.com decals on there I hope??

Jason

[EvoStevo]

Still lookin' sweet. I keep looking at your pictures to motivate myself. Can't wait to see what comes next!

[77volvo245]

Nice build Eli, still waiting to put a D24t in my 240. With the redblock oil cooler, what double threaded cylinder pipe did you use? (the one that goes into the block). I tried the VW one but there is not enough threads. I even tried to use one from a B21FT and still it's not enough.

Are you still running the stock rear end from that 79 wagon?

[Grubby]

Did you use a diesel spec m46, or modify a gas m46? I am putting a d24t into a 200 series and have a gas m46 and a diesel bell housing, but just found out the output shafts are different sizes? Any help on how to make this work?
Thanks.
P.S. beautiful car!

[Slobodan]

Grubby. about the M46. Do you mean the input shaft on the transmission is a different size? Or the where the drive shaft bolts up?

On the input shaft there is just a simple collar that adapts it to fit the VW/Audi pilot bearing.

And the Yokes interchange. Every M46 is pretty much the same. Exceptions being on the B21F-MPG models 1st gear was super low geared. Coarse splines on early transmissions and funky shifter linkages.. Then later all aluminum with P-type or J-type OD.. either way everything pretty much bolts up.

[piper109]

I would be interested to know how you dealt with the suspension cross member and the D24T oilpan ?

cheers,

Steve

[Eli]

Wow looks sweet. Gonna throw a couple D24T.com decals on there I hope??

Jason

Thanks Jason, Decals are coming soon. I still need to make up my mind about where to put them. I am thinking the front bottom of the rear side windows, right behind the rear doors. On both sides. But we'll see.

Nice build Eli, still waiting to put a D24t in my 240. With the redblock oil cooler, what double threaded cylinder pipe did you use? (the one that goes into the block). I tried the VW one but there is not enough threads. I even tried to use one from a B21FT and still it's not enough.

Are you still running the stock rear end from that 79 wagon?

Thanks! The redblock oil cooler is a very nice addition, much better then vw the oil to water cooler in my opinion. Running the oil lines of the sandwich plate is a little tight by the alternator, but it is doable. As for the double threaded pipe, I believe I used the one from the redblock, but I don't remember for sure. I do remember it was so long that I even had to cut it down. The oil cooler I adapted was from a B23, that might be the difference.

Good luck!

I've got the stock rear from my '79 Bertone in the wagon. I am not positive what gear ratio is in there, but I am thinking of swapping in one that is even higher. This engine has got so much torque I find myself driving around in higher gears all the time at 1.5-2.5K. Why do you ask?

I would be interested to know how you dealt with the suspension cross member and the D24T oilpan ?

cheers,

Steve

Hey Steve, I used a modified D24 Oil Pan. I posted about it Here (http://www.d24t.com/showthread.php?p=1712#post1712). This is what I would recommend others do as well, if they have the option.



P.S.
You can also check out my intercooler install in the thread I just made:
How'd you intercool your D24T? (http://www.d24t.com/showthread.php?p=1910)

[Volvo_242_Diesel(Finland)]

I like this car too... very nice! :)

[cuaz64]

Great project. Can you write more about you intercooler setup?

[Eli]

I like this car too... very nice! :)

That means a lot coming from a guy with a D24T as nice as yours. Thanks very much.

Great project. Can you write more about you intercooler setup?

I wrote about it in a thread I made: How'd you intercool your D24T? (http://www.d24t.com/showthread.php?p=1910)

If you have any questions about it, I'd be happy to answer them.

[77volvo245]

I've got the stock rear from my '79 Bertone in the wagon. I am not positive what gear ratio is in there, but I am thinking of swapping in one that is even higher. This engine has got so much torque I find myself driving around in higher gears all the time at 1.5-2.5K. Why do you ask?

I was just curious, My 740 D24T with a M46 has a auto rear end that is geared way to high, feels like 3.90s. My tach doesn't work so I don't know for sure what RPMs Im doing at highway speed. I would like to find 3.54 or 3.73. Your gasser rear end out of your 79 wagon should be 3.91.

[piper109]

I too have a 740 with D24T and M46. It used to have the ZF autobox.
I can confirm that the rear axle is 3.91. At 80 mph (130 kph) the engine is turning 3700 rpm. It does not seem to mind and I get 31 mpg.
My other car has a 3.73 with the detroit locker. It has the ZF and its taller than stock. I like the locking axle so I am not going to change it.

Steve

I was just curious, My 740 D24T with a M46 has a auto rear end that is geared way to high, feels like 3.90s. My tach doesn't work so I don't know for sure what RPMs Im doing at highway speed. I would like to find 3.54 or 3.73. Your gasser rear end out of your 79 wagon should be 3.91.