The "new" '97 854 T5---and it's green! - Page 2
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    1. #36
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      Got a deal on these that I couldn't pass up.


      Now to decide if I wait to install them when I get to the manual swap, or just get them in sooner, rather than later.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

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    3. #37
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      So, when I was under the car doing the Delta Link bushing replacement, I saw this.


      My less than 2-year-old Maximizer exhaust was looking pretty crusty.



      I guess I shouldn't be surprised, seeing as they used mild steel instead of aluminized tubing.

      I've got a buddy who does some powdercoating, and had been talking up the Cerakote costings he uses on some motorcycle exhausts.
      He said he could clean these up and shoot them, so I figured why not.
      This system is still solid, just getting a bit crusty.

      He cleaned it up and it didn't turn out too bad.


      I even had him coat the R manifold I have for the car (Still deciding on what turbo to go with).


      I dropped the stuff to him before we went on vacation, but it wound up taking a couple weeks longer to get the materials in and get it done.

      While I waited, I went ahead and installed some blue injectors and a flashed M4.4 MY98 ECU ('98 T5).
      I didn't get to start the car until this evening, and as soon as it started, I could tell something wasn't happy. It was definitely missing.
      It sounded like it was running on 4 cylinders, so I pulled injector plugs until I found the culprit (#5). These were a set of used injectors, but was told they were "good". Guess that was 80% true. No biggie.

      I thought I was going to have to swap the original injectors back in, and then I remembered I have an '04 B5254T4 engine in the garage...with greens.
      So, I swapped those and re-flashed the ECU values accordingly. Fired it up, and it was smooth. After figuring out I needed to disable the diagnostics for the baro sensor (which the '97T5 doesn't have), I re-flashed again and we should be good to go for now.

      The greens are a bit of over-kill currently, but they won't hurt anything at the moment.

      I'm still figuring out the tuning portion, but being able to make these kind of changes/adjustments is nice.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    4. #38
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      Well, the car ran great for all of half an hour this morning. That's when it decided to start dumping coolant. I guess it was still running great then, but I wasn't going to run it for very long. Got it home before it got hot, though.

      Looks like the coolant hose under the turbo. I think I have a set of the do88 hoses in the garage, so that's good. It's a pain in the ass to get to, but at least I have the parts on hand.

      At least it didn't happen tomorrow while the wife was driving it.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

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    6. #39
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      Quote Originally Posted by Chuck W View Post
      Looks like the coolant hose under the turbo. I think I have a set of the do88 hoses in the garage, so that's good. It's a pain in the ass to get to, but at least I have the parts on hand.
      Mine just went a few months ago. I lost enough coolant to light my low coolant light up and to my surprise when I stopped to look the puddle was on the ground under my outer passenger cv boot. When I popped the hood it looked like someone was taking a leak in engine bay.

    7. #40
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      So, yeah. The old hose basically split in two.



      These were in the garage



      which should've been a 1/2 hour job. However, seeing as the elbow hose is poorly formed and fits for crap on the big end (WAAAAY under-sized), I spent an hour just with wrestling it onto the coolant pipe, only to find that the hose clamp then wouldn't fit and I had to pull it all back out to fit a new clamp.

      I'll try again tomorrow after work.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    8. #41
      Senior Member JaredR's Avatar
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      Sounds like the Do88 hose is kind of a fail?

      I was super tempted to go with the silicone hoses but ended up going Genuine Volvo.
      1995 850 T-5R Estate. AW50-42LE. Cream Yellow/Graphite. 297k.
      1997 850R Estate. B5234T9/M66D. Bright Red/Graphite. 270k.
      2007 S60 T5. M66W. Black Sapphire/Arena. 140k.
      Instagram: Jared's Volvo Page

      Past: |1997 855R. Bright Red/Light Beige. AW50-42LE. Totaled by wayward construction equipment. || 1996 854R. Black Stone/Graphite. AW50-42LE. Parts car || 1995 854 TURBO. Polar White/Tan. AW50-42LE. Parts car. |
      Dad: 1997 V70 T5 SE. AW50-42LE. Frost Green/Oak. 212k.Mom: NEW! 1999 S70 GLT Pewter/Oak. 101k. Past: 2004 V70 NA. AW55-50SN Ruby Red/Tan 269k. Sold to markj

    9. #42
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      Quote Originally Posted by JaredR View Post
      Sounds like the Do88 hose is kind of a fail?

      I was super tempted to go with the silicone hoses but ended up going Genuine Volvo.
      It'd be fine if I wasn't trying to do it under the car. It wouldn't be too bad if I had the engine on a stand while installing the hose. There's just so little room to work when everything's in place.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    10. #43
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      Got back under the car after work, before the rain started. A little dish soap aided things along nicely.

      One main issue I have with these do88 hoses,aside from the big end being too tight, is that the big end is also really about 5-6mm to short to where it necks down to the smaller ID. There is barely enough length to got the hose over the barb and get a clamp on it.

      Got the lower hose installed and got the old upper one out right as the heavy rain started to come down. Had to stop work for the evening.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    11. #44
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      Hoses installed. Cooling system refilled. New battery (old one was toast and needed to be replaced).

      No leaks. Flashed ECU is working fine.

      Glad to have my car back again.

      (Until I take it apart again for the next round up mods/updates)
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    12. #45
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      Frak...

      Somehow I missed that the Columbas won't fit over the 302mm brakes (Without a bunch of grinding on the calipers).

      I just mounted brand new tires on my Columba winter wheels...
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    13. #46
      Senior Member JaredR's Avatar
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      Quote Originally Posted by Chuck W View Post
      Frak...

      Somehow I missed that the Columbas won't fit over the 302mm brakes (Without a bunch of grinding on the calipers).

      I just mounted brand new tires on my Columba winter wheels...
      just get some other 16s
      1995 850 T-5R Estate. AW50-42LE. Cream Yellow/Graphite. 297k.
      1997 850R Estate. B5234T9/M66D. Bright Red/Graphite. 270k.
      2007 S60 T5. M66W. Black Sapphire/Arena. 140k.
      Instagram: Jared's Volvo Page

      Past: |1997 855R. Bright Red/Light Beige. AW50-42LE. Totaled by wayward construction equipment. || 1996 854R. Black Stone/Graphite. AW50-42LE. Parts car || 1995 854 TURBO. Polar White/Tan. AW50-42LE. Parts car. |
      Dad: 1997 V70 T5 SE. AW50-42LE. Frost Green/Oak. 212k.Mom: NEW! 1999 S70 GLT Pewter/Oak. 101k. Past: 2004 V70 NA. AW55-50SN Ruby Red/Tan 269k. Sold to markj

    14. #47
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      Quote Originally Posted by JaredR View Post
      just get some other 16s
      That's only an option if I happen to stumble upon something cheap locally. Picking have been slim the past few months.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    15. #48
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      Quote Originally Posted by Chuck W View Post
      That's only an option if I happen to stumble upon something cheap locally. Picking have been slim the past few months.
      What exact size/brand of tires are they?
      Current - 2000 V70R Venetian Red Pearl
      Past - 1998 V70 XC Emerald Green Metallic
      RIP - 1987 Mazda RX-7 White/Red (first car, many speeding tickets, blown rotary engine)

    16. #49
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      Quote Originally Posted by Chicago_Wagon View Post
      What exact size/brand of tires are they?
      I mounted Falken Ziex ZE950 205/55-16 94W's.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    17. #50
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      Quote Originally Posted by Chuck W View Post
      I mounted Falken Ziex ZE950 205/55-16 94W's.
      Damn. All Season. When you mentioned they were your winter wheels, I thought they would be winter tires too. And, we might arrange for me to buy them to turn my Satelites into a winter setup. Someone else might confirm, but don't Perfos clear? They're not too rare and have the same look. Just a thought.
      Current - 2000 V70R Venetian Red Pearl
      Past - 1998 V70 XC Emerald Green Metallic
      RIP - 1987 Mazda RX-7 White/Red (first car, many speeding tickets, blown rotary engine)

    18. #51
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      Quote Originally Posted by Chicago_Wagon View Post
      Damn. All Season. When you mentioned they were your winter wheels, I thought they would be winter tires too. And, we might arrange for me to buy them to turn my Satelites into a winter setup. Someone else might confirm, but don't Perfos clear? They're not too rare and have the same look. Just a thought.
      Yes Perfos clear 302s
      1996 854R | M56H | 16T | 268k

    19. #52
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      Quote Originally Posted by sventastic View Post
      Quote Originally Posted by Chicago_Wagon View Post
      Damn. All Season. When you mentioned they were your winter wheels, I thought they would be winter tires too. And, we might arrange for me to buy them to turn my Satelites into a winter setup. Someone else might confirm, but don't Perfos clear? They're not too rare and have the same look. Just a thought.
      Yes Perfos clear 302s
      These have been for sale FOREVER. A bit far for you but the seller might be talked down.

      https://muskegon.craigslist.org/wto/...021723509.html
      Current - 2000 V70R Venetian Red Pearl
      Past - 1998 V70 XC Emerald Green Metallic
      RIP - 1987 Mazda RX-7 White/Red (first car, many speeding tickets, blown rotary engine)

    20. #53
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      Quote Originally Posted by Chicago_Wagon View Post
      Damn. All Season. When you mentioned they were your winter wheels, I thought they would be winter tires too. And, we might arrange for me to buy them to turn my Satelites into a winter setup. Someone else might confirm, but don't Perfos clear? They're not too rare and have the same look. Just a thought.
      Yeah, we don't really get enough snow around here to warrant full winter tires. The Dunlops on my Neptunes are 3-season, so I need to have something else for the few months of winter/cold. I've had great luck with these and the similar Sumitomos on the wife's winter wheels. We just motor around and get where we need to be, snow or no snow.

      I'm not really looking to buy yet another set of wheels (Bought the Neptunes and 2 set of IPD Eros wheels the past few months).

      I made a trip to the PaP today, as a 2000 S70 had just come in, so maybe I might get lucky. Nope 15" wheels.

      Other than that, there were a couple 01-04 S60/XC70 with incomplete sets of nothing good, 2 S40's with OK wheels, but wrong offset, 3-960's with Mercurius 7-slots (Which would fit the car, but no idea if they'd clear the brakes), 1 S80 T6 with 17" wheels.

      I may just grind down a spare set of calipers for the time being.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    21. #54
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      OK, well while I debate on what to do about the front of the car, I spent the last part of my day off today working on the back of this thing.

      It's needed the Delta link bushings done for a while, and the PS rear caliper was kind of sticky/non-working.

      I'd replaced the PS outer delta link bushing a while back, but wrestled the DS one out today.


      The inner bushings were also in sorry shape.

      The DS was half broken

      and the PS one had its inner sleeve come loose.


      I'd cleaned up a a spare set of calipers so I threw threw those on with new pads/hardware with a lightly-used set of rotors I had sitting on the shelf from when I scrapped the '96GLT.


      I had a good set of take-off Bilsteins, so I threw them on while I was under there.


      I think I'm still going to "clearance" the spare set of calipers for the front. At least for the time being. I can always swap them out easily if/when I get another set of wheels that better clear the 302s.

      There probably won't be time for me to turn wrenches on this again until next month sometime, between house projects, holidays, surgery recovery, so who knows, I may stumble onto a cheap set of wheels.
      Last edited by Chuck W; 11-19-2019 at 06:47 PM.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    22. #55
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      So, I'm probably rethinking the 302 front brake conversion (for this car at least)

      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    23. #56
      Senior Member ScottishBrick's Avatar
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      Quote Originally Posted by Chuck W View Post
      So, I'm probably rethinking the 302 front brake conversion (for this car at least)

      Why?

      Brembos cause more financial and mechanical headaches than theyíre worth.
      2003 V70 T5 - Mystic/Graphite - M56LK - 206k - K24/Greens/Do88/Quaife/SMF/P2R Clutch/DW300C/H&R/Bilstein TC/316mm & 308mm Brakes - SteveO Tuned
      1999 V70 T5 - Pewter/R Graphite & Alcantara - AW42 - 299k - Daily/Work Wagon
      1999 V70 T5 - Nautic/R Graphite & Alcantara - M56H - 177k - Rescued
      1999 V70 T5 - Emerald/Graphite - M56H - 119k - Garage Queen
      2000 V70 T5 - Mystic/Graphite - AW42 - 243k - Moms Unicorn
      2000 S70 GLT SE- Mystic/Graphite - AW42 - 218k - Sisters

    24. #57
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      Because I can.

      Considering the price I paid for these and another set of front calipers (for the 240), the financial point is a bit moot. Even the costs of the adapters don't really swing things.

      We can transfer the 302 stuff to the wife's 855.

      I'm not worried about the mechanical side of things. Wrenching and tinkering is fun to me, and I've done this stuff before.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    25. #58
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      Quote Originally Posted by Chuck W View Post
      So, I'm probably rethinking the 302 front brake conversion (for this car at least)

      Ooooo! I'd love to figure out brembo brackets for the front, I should source R knuckles and draw it up in solidworks. I'd go with the Porsche brakes but I haven't found a set pop up in the 2-3 years casually looking.
      1998 V70R Mystic Silver/Graphite
      1996 RN Swapped 854R Bright Red/Graphite
      Family Fleet:
      2000 S40 1.9T White/Cloth
      COMING SOON: 2009 C30 T5 R-Design M66 Silver/Two-Tone

      Past:
      1998 V70 NA/m Classic Red/Light Gray

    26. #59
      Senior Member JaredR's Avatar
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      Quote Originally Posted by Zoinks View Post
      Ooooo! I'd love to figure out brembo brackets for the front, I should source R knuckles and draw it up in solidworks. I'd go with the Porsche brakes but I haven't found a set pop up in the 2-3 years casually looking.
      Been done and cleanly but....yeah, why? There are better alternatives that fit the car much better. We have a tendency in Volvoland to think anything that says "R" is good for everything, and it just isn't the case unfortunately.
      1995 850 T-5R Estate. AW50-42LE. Cream Yellow/Graphite. 297k.
      1997 850R Estate. B5234T9/M66D. Bright Red/Graphite. 270k.
      2007 S60 T5. M66W. Black Sapphire/Arena. 140k.
      Instagram: Jared's Volvo Page

      Past: |1997 855R. Bright Red/Light Beige. AW50-42LE. Totaled by wayward construction equipment. || 1996 854R. Black Stone/Graphite. AW50-42LE. Parts car || 1995 854 TURBO. Polar White/Tan. AW50-42LE. Parts car. |
      Dad: 1997 V70 T5 SE. AW50-42LE. Frost Green/Oak. 212k.Mom: NEW! 1999 S70 GLT Pewter/Oak. 101k. Past: 2004 V70 NA. AW55-50SN Ruby Red/Tan 269k. Sold to markj

    27. #60
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      People have different ideas and ways to build THEIR car. That's "why".


      I may be "new" to messing with the P80's (only the past 5 years), but I'm not new to messing with cars in general (30+ years). I installed C4 Corevtte brakes front and rear on my Merkur Scorpio for no other reason than because I could.


      If I need to, I'll just get a spindle, mock it all up in CAD and talk to a couple machinists I know. The bracket really isn't all that complicated, and the additional work to fit it is negligible.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    28. #61
      Senior Member JaredR's Avatar
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      Quote Originally Posted by Chuck W View Post
      People have different ideas and ways to build THEIR car. That's "why".


      I may be "new" to messing with the P80's (only the past 5 years), but I'm not new to messing with cars in general (30+ years). I installed C4 Corevtte brakes front and rear on my Merkur Scorpio for no other reason than because I could.


      If I need to, I'll just get a spindle, mock it all up in CAD and talk to a couple machinists I know. The bracket really isn't all that complicated, and the additional work to fit it is negligible.
      Attaching it to the car really isn't that hard. Been done and cleanly. The guys doing up the Platinum sedan right now have done the best job I've seen yet. I'd probably be pretty comfortable running that adapter. Just don't be that guy who welded new mounts onto his existing hub LOL.
      1995 850 T-5R Estate. AW50-42LE. Cream Yellow/Graphite. 297k.
      1997 850R Estate. B5234T9/M66D. Bright Red/Graphite. 270k.
      2007 S60 T5. M66W. Black Sapphire/Arena. 140k.
      Instagram: Jared's Volvo Page

      Past: |1997 855R. Bright Red/Light Beige. AW50-42LE. Totaled by wayward construction equipment. || 1996 854R. Black Stone/Graphite. AW50-42LE. Parts car || 1995 854 TURBO. Polar White/Tan. AW50-42LE. Parts car. |
      Dad: 1997 V70 T5 SE. AW50-42LE. Frost Green/Oak. 212k.Mom: NEW! 1999 S70 GLT Pewter/Oak. 101k. Past: 2004 V70 NA. AW55-50SN Ruby Red/Tan 269k. Sold to markj

    29. #62
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      Quote Originally Posted by JaredR View Post
      Just don't be that guy who welded new mounts onto his existing hub LOL.
      You obviously don't know me all that well.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    30. #63
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      This looks familiar...



      Just waiting on some pads to show up to make sure everything is in the proper spot before I start to lock down dimensions.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    31. #64
      Senior Member JaredR's Avatar
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      That does indeed look familiar LOL
      1995 850 T-5R Estate. AW50-42LE. Cream Yellow/Graphite. 297k.
      1997 850R Estate. B5234T9/M66D. Bright Red/Graphite. 270k.
      2007 S60 T5. M66W. Black Sapphire/Arena. 140k.
      Instagram: Jared's Volvo Page

      Past: |1997 855R. Bright Red/Light Beige. AW50-42LE. Totaled by wayward construction equipment. || 1996 854R. Black Stone/Graphite. AW50-42LE. Parts car || 1995 854 TURBO. Polar White/Tan. AW50-42LE. Parts car. |
      Dad: 1997 V70 T5 SE. AW50-42LE. Frost Green/Oak. 212k.Mom: NEW! 1999 S70 GLT Pewter/Oak. 101k. Past: 2004 V70 NA. AW55-50SN Ruby Red/Tan 269k. Sold to markj

    32. #65
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      So, we're back with another familiar-looking picture.



      After dialing in dimensions, I whipped up a quick test sample at work today.



      Not overly pretty, but what was important was to check alignment and spacing.

      Pads are lined up


      And the rotor is centered


      However, to get things in the proper location, you need to do more than just cut of the steering stops.




      Only then does the R caliper nestle inboard enough to get the alignment correct between the pads and rotor. Looks drastic, but I'm not really concerned. The next one will have much less material removed, as I'll be able to know exactly what needs to be taken away to get things to fit.

      Now, my plan for making the real things is not make them all one piece and not use aluminum. I'll have the plate done out of steel (10mm thick) and have the spacer tubes machined separately. Then I'll clamp them together and weld them. Easier to machine that way.
      I'm also planning on installing M12 Time Serts into the spindle.

      Tomorrow, when I get a moment, I want to check wheel clearances with my Neptunes. *fingers crossed*
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    33. #66
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      So, we're back with another familiar-looking picture.



      After dialing in dimensions, I whipped up a quick test sample at work today.



      Not overly pretty, but what was important was to check alignment and spacing.

      Pads are lined up


      And the rotor is centered


      However, to get things in the proper location, you need to do more than just cut off the steering stops.




      Only then does the R caliper nestle inboard enough to get the alignment correct between the pads and rotor. Looks drastic, but I'm not really concerned. The next one will have much less material removed, as I'll be able to know exactly what needs to be taken away to get things to fit.

      Now, my plan for making the real things is not make them all one piece and not use aluminum. I'll have the plate done out of steel (10mm thick) and have the spacer tubes machined separately. Then I'll clamp them together and weld them. Easier to machine that way.
      I'm also planning on installing M12 Time Serts into the spindle.

      Tomorrow, when I get a moment, I want to check wheel clearances with my Neptunes. *fingers crossed*

      EDIT - Well, I actually had a moment to pull one of the Neptunes out to check. It's going to need like 19mm of spacer to get the caliper to clear the spokes of the wheel...

      Curious, I pulled down one of the IPD Eros wheels be picked up for the wife's 855. It fits, with no spacer needed.

      I wonder how she'd feel about the Neptunes on her car?



      There needs to be close to 38mm (1.5") of offset between the hub flange and the wheel spokes to get these to clear.
      Last edited by Chuck W; 01-24-2020 at 05:50 PM.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    34. #67
      Junior Member
      Join Date
      Aug 2018
      Posts
      76
      Nice! Yes, this looks familiar and is bringing back memories. We also had to remove material from the knuckle to get the R caliper into proper alignment. Itís really a non-issue as it is on the backside of the bolt hole used to mount the bracket to the knuckle. In fact, the 12x1.75x24mm Time-Serts we installed did not reach the area that was removed.

      I didnít mention this in the Platinum build thread, but after we installed the new brackets and calipers we found the lower bolt that fastens the caliper to the bracket would hit the lower control arm when turning the steering wheel less than a full turn from center. Your design may not have this but I wanted to make you aware of the possibility. To fix this we removed the brackets and had the caliper mounting holes counterbored about 10mm. We then secured the caliper to the bracket using internal hex cap head bolts for more clearance. In addition, I removed the plastic steering stops from the lower control arm to allow for more steering angle. Iím not sure this was necessary as the tires now rub on the inner fender liners when making sharp turns...although this may have more to do with the 225/40r18 Z-lines lol.
      I think the amount of modifications needed to the knuckles and control arms is why my son has not shared his design file. Heís an engineer and he would have preferred a more plug-n-play solution.

      Looks familiar. Arrows note holes that were since counterbored.
      [IMG][/IMG]

      Time-Serts
      [IMG][/IMG]
      1996 850 Platinum/Charcoal Sedan, 195,000 miles, B5254T4/M56
      2006 V70R Sonic Blue/Gobi, 151,000 miles, automatic (for now)
      1999 S70 GLT Black/Black, 238,000 miles
      2005 S40T5 M66 Silver/Black, 225,000 miles
      1995 850 GLT Sedan, Regent Red/Charcoal, 186,000 miles, been in family since new
      2017 VW GTI, Graphite/Tartan, 26,000 miles, DSG
      2009 Ford Flex SEL awd, Grey/Black, 140,000 miles Wifeís daily
      2004 Mercedes-Benz C320 4matic wagon, Black Opal/Grey, 215,000 miles
      2006 S60R, Silver/Nordkap, M66, 98,000 miles, parts car, SOLD
      1999 S70 GLT, White/Taupe, 138,000 miles, TOTALED RIP

    35. #68
      Junior Member
      Join Date
      Dec 2014
      Location
      Indy, IN
      Posts
      530
      Quote Originally Posted by HATTRICK2199 View Post
      Nice! Yes, this looks familiar and is bringing back memories. We also had to remove material from the knuckle to get the R caliper into proper alignment. Itís really a non-issue as it is on the backside of the bolt hole used to mount the bracket to the knuckle. In fact, the 12x1.75x24mm Time-Serts we installed did not reach the area that was removed.

      I didnít mention this in the Platinum build thread, but after we installed the new brackets and calipers we found the lower bolt that fastens the caliper to the bracket would hit the lower control arm when turning the steering wheel less than a full turn from center. Your design may not have this but I wanted to make you aware of the possibility. To fix this we removed the brackets and had the caliper mounting holes counterbored about 10mm. We then secured the caliper to the bracket using internal hex cap head bolts for more clearance. In addition, I removed the plastic steering stops from the lower control arm to allow for more steering angle. Iím not sure this was necessary as the tires now rub on the inner fender liners when making sharp turns...although this may have more to do with the 225/40r18 Z-lines lol.
      I think the amount of modifications needed to the knuckles and control arms is why my son has not shared his design file. Heís an engineer and he would have preferred a more plug-n-play solution.
      Thanks for the info and feedback. The clearance issue slightly changes things, but not too critical of an adjustment.

      Also, being an engineer, plug-and-play solutions are usually preferable, but sometimes you just can't avoid it. being someone who also turns all of their own wrenches, I'm not afraid to modify stuff. I just was trying to save the work of figuring out the numbers to get everything all lined up.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    36. #69
      Junior Member
      Join Date
      Dec 2014
      Location
      Indy, IN
      Posts
      530
      So, after waiting for about 4-5 weeks for any of the machine shops I work with through work to get back with me, I said screw it and went an alternate route to get the brackets done.

      Had a local waterjet business pop me out a few blanks of the profile. Took about 2 days to get my parts.



      I've already turned the spacers down from some old material I had in the garage, so those are set.

      I just need to set these things up on the mill and knock out the 4 holes and give a couple quick passes to get them to the proper thickness. Then I'll weld things together.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

    37. #70
      Junior Member
      Join Date
      Dec 2014
      Location
      Indy, IN
      Posts
      530
      Well, I grabbed one of the blanks and set it up on the mill Thursday.





      Did a quick test fit, to make sure that things all still line up properly.



      Looks like a success to me. I didn't have any M12 flatheads sitting around, so I'll need to get a box of them for the install.


      Just need to do the other side, weld the spacers on, and get them coated, and then we have brackets for the front (to go with the Yother brackets I have for the rear)


      Now to find a PS spindle and get the rest of the parts together.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/302's/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

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