- 1 LucaCarMods has made great growth over the past year and unfortunately had little time for the Volvo 245 1UZ V8 project and therefore the swap kit.
LucaCarMods has made great growth over the past year and unfortunately had little time for the Volvo 245 1UZ V8 project and therefore the swap kit.
Of course we are very happy with this growth but it also means that certain projects have been on hold. Recently LucaCarMods purchased an advanced 3D Scanner that can accurately scan objects up to 0.02mm.
What does a 3D scanner have to do with the kit? At first you would think pretty little, but nothing is less true. The 3D scanner allows us to easily reverse engineer parts. In other way, making a 3D copy of a part on the computer in CAD (computer aided design) software.
Below you will find a photo series of what is possible with a 3D scanner. In this example, the engine compartment of the LCM 242 has been scanned and an OM606 Mercedes diesel engine block with the Einscan Pro 2X 3D Scanner.
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The huge advantage of this is that this 3D drawing can already be looked at on the computer whether the engine fits and alignment can be done digitally. All this ensures that all exact sizes are clear and motor mounts or other products can be developed on the computer without being near the car.
Developing an engine mounts
Another option is to create a solid engine mount on the 1UZ by mounting 2 plates and weld a piece of flat stock between them. These solid engine mounts are then scanned for size and the products have been developed on the basis of this.
Below you can see the scan of such solid engine mounts, as can be seen it is purely for the dimensions (do not pay attention to the “welding” these are without having sight on the weld or piece). The 3D scan can still be made in much higher detail and better finished but that is not necessary in this situation because we need the size purely. (the holes are reference points that you need to paste on to the object.)
With this scan, all bolt holes are very clearly mapped. With this scan alone you can do pretty little, a smart piece of software makes the scan usable for reverse engineering.
Here, all cylindrical forms, planes (surfaces you want to be able to draw on later in CAD) and other important things can be recognized and set up. The cylinders (bolt holes) have a deviation of 0.09mm in diameter in this scan; more than enough for us to work with.
We then export this file to a IGES file with the various cylinders and planes in it, the other things of the scan are not needed here in this case. These do not have added value when developing the engine mounts.
Now that all bolt holes, distances and angles have been mapped, an engine support can be developed that is likely to need only 1 or no prototype. Drawing the engine mounts happened in Autodesk Inventor of Fusion 360.
Below is an example of the finished product (in mirror image)
This engine mount can be mounted directly on the original subframe points where the original engine is also attached and on the 1UZ. After checking the entire assembly, we also place the 3D scan over the drawn product to see if the measures held actually corresponds to the designed product. If this is the case, a 3D printed version can be made or the steel variant directly.
The motor mounts will use shore 95A polyurethane rubbers which absorb the forces of the 1UZ 4.0 V8 engine in the Volvo 245.
The 1UZ Volvo 240 gearbox mount
With the 1UZ V8 engine, the rubber of the automatic gearbox is a few cm further backwards than the engine supplied standard in the Volvo 240. Unfortunately, drilling new holes does not offer the desired result and therefore it has been chosen to redevelop a gearbox support.
A design has been chosen based on the original part. The new gearbox bracket is firmer and thinner; the latter is important so that there is enough space for an exhaust system on both sides.
Volvo 240 Mechanical Fan to Electrical Conversion
Both the LS400 (where the 1UZ engine comes out) and the Volvo 240 both have a mechanical fan attached to the engine. This entails some disadvantages:
- Loss of power
- Takes up a lot of space
- Cools less during idle
The main reason in this swap is that there is simply not enough space in the engine compartment to use a mechanical fan. To tackle this, a fan shroud has been chosen to develop where a high power 330mm SPAL fan can be mounted on. An important aspect was again here that it can be used with original Volvo parts. This fan shroud fits on the original Volvo 240 Radiator.
Here again, a 3D scan has been used to check the fitting of the designed product. In all 4 corners, rubber flaps will be rivited. This allows the driving wind to flow better through the radiator at high speeds; At low speeds these rubber flaps are closed and the fan does all the work.
What’s still on the schedule
With the above products and the already developed products such as a throttle cable kit and the GPS speedometer modification for the original instrument panel, the product range has already been quite expanded. The goal of LucaCarMods with this swap is to make it as easy as possible for Volvo enthusiasts to provide their beloved Volvo 240 with a 1UZ 4.0 V8 engine. Because of this, there are a number of other products that we will develop within a few weeks.
- Plug and Play Wiring Harness Offer for 1UZ Engine
- Drop in oil sump for the 1UZ Volvo 240 swap
- Custom drive shaft or a drive shaft adapter
- Cooling lines
- Automatic shifter mechanism where the original Volvo shifter can be used on the 1UZ engine
With these items we think we have a kit which will be for about 95 plug and play where all the research and development has been done by us and the customer can easily provide his or her Volvo 240 with a beautiful 1UZ V8!
The already developed products are expected to be in stock in February and ready to be shipped worldwide.
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