Straight 5 build and chassis options
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    1. #1
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      Straight 5 build and chassis options

      Hey guys, new to these forums and still new to Volvo. In terms or Swedish engineering, I have owned 3 SAABs over the years (2 prior to GM "influence") and have loved them, and have also had a 2012 S60 T6 which had a great motor but I disliked the auto trans and the chassis was sloppy (was stock and had 100k on it so not necessarily the fault of the car). I have since sold that, still have a SAAB 9-5 wagon but am looking to do a Volvo build. SAAB has frustrated me and the Volvo 5 cylinder turbos are unique and very cool in my book, so on to Volvo perhaps. I have drooled over the boxy Swedish style for a long time and it's time to do something - I am really into the 700/900 series look but like the 200 series, 850, and later stuff like the S90 as well, all in sedan and wagon versions but may prefer sedan for this. I'm lurking around reading as much as I can but there's a lot of info here and I am a bit overwhelmed. That said, here's what I'd like to do:

      I'd like to build a turbo straight 5 to somewhere in the neighborhood of 350-400 whp with a manual 5 speed using Volvo parts (for the most part). Would it make the most sense to start with one of the 2.3 straight 5's like the B5234T? My neighbor has a non running '95 850 turbo I can swoop up for a few hundred bucks as a starting point if this is the right path. I've read from you guys the pistons are alright up to around 400 hp but you need rods? Can anyone point the way to some rod kits for these/similar motors so I can get an idea on investment? It's said that Volvo parts are very expensive (I assume these points are mostly regarding OEM), is this true for the older mid-90s models OEM and how about aftermarket? I needed an alternator for the S60 and OEM was around $1200 which I thought was completely insane. May be similar to Audi and Mercedes I don't know.

      My intention is to swap a built motor into a RWD 700/900 or possibly 200 series, but if it's hard to find a nice donor car or options are limited, I'll get by with a FWD (ie. keep the 850 is that's the route I go). AWD is enticing but those systems are mostly safety oriented vs performance, right? Mainly FWD anyway? Not sure if AWD would make much difference with that much power, plus the rear end mods that would be necessary? Could someone expand on the models that one of the better suited turbo motors would fit in without major fabrication? I'm worried about engine/trans mount compatibility, I could weld mounting points but would like to avoid major fab if possible - are there kits for fitment like this? My main interest is doing the engine build itself - one of the major reasons for pursuing all this is to expand my engine building capabilities, I have done a lot of work in the past but never done anything bottom end. For the 700/900 and maybe 200 series is it easy to fit manual transmissions from other Volvo models? What manual transmissions works best for higher power output and what mods are needed other than clutch? What are the best handling (or easiest to get handling good) out of the 200, 700, 850, 900 series? I assume not the 200 but there seem to be a lot of good available parts.

      So in a long winded way, my question for this crowd is really if you could do a 350 to 400 hp (maybe higher) build with a straight 5, manual trans, going into any of the available chassis, what would you do if budget and spare time is a definite consideration? What motor and manual trans, what mods, and what chassis would you choose?

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    3. #2
      Senior Member ScottishBrick's Avatar
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      B5234t9. Port the head if youre gonna do any engine work. K24. IC. SMF. T56 960 oil pan cut to fit. I'd put it in a 940, find a NA regina one to accept the donor. Ford 9". Poly everthing, sways and bracing.
      2003 V70 T5 - Mystic/Graphite - M56LK - 195k - "O-Three"
      1999 V70 T5 - Pewter/R Graphite & Alcantara - AW42 - 290k - Work Wagon
      1999 V70 T5 - Nautic/R Graphite & Alcantara - M56H - 174k - Rescue
      1999 V70 T5 - Emerald/Graphite - M56H - 119k - Garage Queen
      2000 V70 T5 - Mystic/Graphite - AW42 - 238k - Moms Unicorn
      2000 S70 GLT SE- Mystic/Graphite - AW42 - 212k - Sisters

    4. #3
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      I'm planning a whiteblock swap into my '78 240.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

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    6. #4
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      Quote Originally Posted by ScottishBrick View Post
      B5234t9. Port the head if youre gonna do any engine work. K24. IC. SMF. T56 960 oil pan cut to fit. I'd put it in a 940, find a NA regina one to accept the donor. Ford 9". Poly everthing, sways and bracing.
      Just to clarify with all the acronyms, please let me know if I'm following as that was a lot of information. I had to look some of these up to figure it out. Your suggestion is to build on a NA 940 chassis with a regina fuel system, using a B5234 (the T9 is off the C70? what disadvantage is there using another 5234?), ported head, K24 turbo (off of an R?), intercooler, single mass flywheel, a T56 manual trans (these are off camaros and mustangs?), and a 960 oil pan. A ford 9" rear end and poly everything, were you suggesting something for the sway bars/bracing or just using poly bushings for them?

      Just for the sake of argument, would it be relatively more simple of an engine swap to use a NA I6 900 series and swap in a twin turbo I6 from an S80?

    7. #5
      Senior Member ScottishBrick's Avatar
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      Quote Originally Posted by woodsracer View Post
      Just to clarify with all the acronyms, please let me know if I'm following as that was a lot of information. I had to look some of these up to figure it out. Your suggestion is to build on a NA 940 chassis with a regina fuel system, using a B5234 (the T9 is off the C70? what disadvantage is there using another 5234?), ported head, K24 turbo (off of an R?), intercooler, single mass flywheel, a T56 manual trans (these are off camaros and mustangs?), and a 960 oil pan. A ford 9" rear end and poly everything, were you suggesting something for the sway bars/bracing or just using poly bushings for them?

      Just for the sake of argument, would it be relatively more simple of an engine swap to use a NA I6 900 series and swap in a twin turbo I6 from an S80?
      You got it pretty much right.

      Suggestions made were based off of your desire for 350-400 hp.

      The "T6" requires buying 5 cylinder parts, twice. You'll also have to make a turbo manifold since the twin turbos are a f*cking joke and make.....2 psi.

      I can only really think that a LS swap would be a cheap way to make a 400 hp rwd volvo. Still have to pick a strong rear end regardless.

      Motorwise, you wont need rods if you use a T9. They have the longest factory rods and thus a lightened rotating assembly, good for revs and boost.

      Turbos ect all can be easily enough adapted.

      The transmission is the issue. Volvo never made a RWD trans that will hold 250+ hp without serious mods. Especially a bolt onto whiteblock manual.
      2003 V70 T5 - Mystic/Graphite - M56LK - 195k - "O-Three"
      1999 V70 T5 - Pewter/R Graphite & Alcantara - AW42 - 290k - Work Wagon
      1999 V70 T5 - Nautic/R Graphite & Alcantara - M56H - 174k - Rescue
      1999 V70 T5 - Emerald/Graphite - M56H - 119k - Garage Queen
      2000 V70 T5 - Mystic/Graphite - AW42 - 238k - Moms Unicorn
      2000 S70 GLT SE- Mystic/Graphite - AW42 - 212k - Sisters

    8. #6
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      I saw this at a car show a while back. I’m not sure what turbo is on it but it looks like it came off a bus. I remember seeing a dyno vid where it put down 380+ wheel hp.
      [IMG][/IMG]
      [IMG][/IMG]
      I’m a huge fan of the Volvo 5 cylinder, especially the sound! But ScottishBrick is right that a LS swap would probably be cheaper.
      1996 850 Platinum/Charcoal Sedan, 195,000 miles, B5254T4/M56
      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
      2006 S60R, Silver/Nordkap, M66, 98,000 miles, parts car, SOLD
      1999 S70 GLT, White/Taupe, 138,000 miles, TOTALED RIP

    9. #7
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      Quote Originally Posted by HATTRICK2199 View Post
      I saw this at a car show a while back. I’m not sure what turbo is on it but it looks like it came off a bus. I remember seeing a dyno vid where it put down 380+ wheel hp.
      [IMG][/IMG]
      Photo album of the build HERE

      He's using a MaxxECU and e-throttle from a S60/V70.
      '97 854 T5 & '97 855 GLT(RN LPT swap/16T/ETC) (wife's)
      '78 264 (Future Whiteblock/T5 swap)

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