My Volvo 854 T5-R 591 hp/524 ftlbs project the story so far.

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:04 pm

I also decided to run the car with a dump valve for safety reasons as I did not want to risk damage to the turbo, ie blades bending etc. I would only ever recommend that a dump valve is run with the larger types of turbo, as I had found many years ago when I had brought an Escort Cosworth with one fitted and was advised to remove it to improve the throttle response! I did remove it and it was never refitted!

ENGINE MOUNTS

I had been having problems with the engine mounts - not really a surprise as they are working over time for me. I looked at what could be improved and thought it would be a good idea to send a bulkhead mount to Powerflex, a poly bush company to see if they could make me a stronger mount (in yellow of course) and also a new top engine mount (which only seemed to come in purple - they made it for me in yellow!).

I also had the lower gearbox torque mount made for me in poly as well which would help with the rearward movement of the engine under high load. I also had an idea one day while looking under the bonnet of some very high powered Evos

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:07 pm

At the same time all other items that were not needed (where possible) were removed and the wiring was hidden as much as possible. I stripped the rear doors of everything other than the door locks and locked the rear windows shut as I would not have any rear passengers to worry about any more.

ROLL CAGE

I had been thinking for a while about having a roll cage fitted to make the car as strong and safe inside as possible in case the worst ever happened, as I had planned to do a few top speed runs in the car

The cage would run over the roof line and down behind the dash area with a strengthening bar across the doors and a rear diagonal bar. In the rear support plates had to be made and fixed in the floor behind the front seats and plates for the front bars below the dash area.

I had to make sure that the screen view was not disrupted by the cage, so it had to be fitted as close as possible to the windscreen pillar. I had studied a few other designs of cages - quite a lot of them are in your line of vision when driving on the road - I

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:12 pm

I also decided to run the car with a dump valve for safety reasons as I did not want to risk damage to the turbo, ie blades bending etc. I would only ever recommend that a dump valve is run with the larger types of turbo, as I had found many years ago when I had brought an Escort Cosworth with one fitted and was advised to remove it to improve the throttle response! I did remove it and it was never refitted!

ENGINE MOUNTS

I had been having problems with the engine mounts - not really a surprise as they are working over time for me. I looked at what could be improved and thought it would be a good idea to send a bulkhead mount to Powerflex, a poly bush company to see if they could make me a stronger mount (in yellow of course) and also a new top engine mount (which only seemed to come in purple - they made it for me in yellow!).

I also had the lower gearbox torque mount made for me in poly as well which would help with the rearward movement of the engine under high load. I also had an idea one day while looking under the bonnet of some very high powered Evos

Rob S · Post by **Rob S** » Wed Mar 31, 2010 7:14 pm

Good reading how it's come on since seeing it on VPCUK Russ, inspirational stuff.

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:17 pm

TO THIS

Its amazing how many very powerful cars are running on a very poor standard of wiring. Many people put lots of extra load on standard wires that are not designed for such things. My great friend spent over 70 hours on the wiring alone - this gives you some idea of how much work has gone into such a thing.

FULL RE-PAINT

As the Peril had had various parts of paintwork done over the years, we decided to completely repaint the whole car - the roof was needing some paint, the interior and cage had to be painted, and I also wanted to change the front wings as I had been a little over enthusiastic with the grinder on the inner lip - I had needed to make as much room for the wheels and tyres as possible - what I should have done is had the arch

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:21 pm

With the inside being finished, it was time to start on the outside

I of course had no stereo, so the antenna mast was not needed

I popped in again after the major paint was done

It was then the turn of the bonnet boot lid and the doors

The car was given a full machine polish and the final prep began

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:22 pm

At the same time, we had started a relocation to much larger premises for the business:

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:23 pm

I had been arranging the many, many boxes of Peril parts and now due to the larger building I had my very own engine build area and lots of racking and shelving to store all the Peril parts during the re build. This was a great help and enabled me to sort out the different areas of the car - fuel system, brakes, engine intake etc etc .

I also took over one of the ramps - a four poster, which made the Peril so much easier to work on.

I had at first decided to re build the engine ready to be refitted

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:24 pm

While the tubular manifold which had been made for me was in storage, I had noticed that the ceramic coating was starting to come off. This was a shock as the manifold had only done 1500 miles since the silver coating so the company I used (Zircotec) were called and they kindly came over to inspect the coating. They where also shocked to see the state of it and kindly offered to strip and re coat the manifold

591 bhp volvo 850 · Post by **591 bhp volvo 850** » Wed Mar 31, 2010 7:32 pm

I then added the rest of the parts to the engine including the turbo (GT35 with a ported shroud and external wastegate).

The engine was now complete so I slowly but surely started to sort out the wiring inside the car ready for the dash to be refitted - all the time being very careful not to scratch or damage the paint work!

After what seemed a very long time I managed to re-wire the new dash (AIM) and get rid of the wood effect part

I had brought a few sheets of carbon fibre to help tidy up the dash and glovebox area with the four switchs I would need to have the launch control/anti lag/heater fan/traction control I had two spares too in case I wanted to add more items to the car .

Rod also added a low level light for the water injection.