Rare but nobody cares, Volvo V40 T4 CD Track... car?
Discussion
R95 EGN - A car i spent far too much on, to just ultimately let it sit and then decide that turning it into something it shouldn't be is a much better idea. And in the long run spend even MORE money!
I bought this car from a guy who owned a few of them, after doing no research into them whatsoever. Just wanted a 'quick' ish estate, found this accidentally and bought it. Probably far too impulsive.
Whilst being a fairly high maintenance car it never actually let me down. I always got from point A to point B, whether that was with less oil then i started, no boost etc etc etc but it got me there. General T4 issues which i had the brunt of fixing as it had been owned by an elderly person who i have a feeling never actually surpassed 3k RPM. It was never boosting right when i first got it, turns out it the clamp going around the turbo was missing - impressive. Also accounted for the clunking on stopping and pulling away. This then created the large oil leaks due to crank breathing issues. And with age a FPR needed replacing blah blah blah blah. Money pit.
In my ownership up till now its had Bilstein B4 shocks and sport springs, some smattering of poly bushing, a semi-hybrid TD04-14t turbo, Induction kit and stainless cat back. Lots of service parts, coil packs, silicone pipes etc etc etc. Did try to uprate anything when it needed replacing.
The factory blow off, with a Ram Air cone is f
king obnoxious - one of the loudest i've heard on any car which is pretty amusing. Anyway, whilst i was enjoying the car it has it's issues, which is why it came off the road. Needs a smidge of welding, the airbag light was on (my fault, i fitted a GC8 Nardi wheel to it - as they're the same spline pattern), tyres and it needs to run on 99 octane - which whilst i know in it's previous life it probably never saw. I felt i was obliged to do so. And at the time i was doing nearly 400 miles a week in commuting alone.
The many shades of green are fantastic.
My buddy and i had a good chat, decided we should keep this car and decided upon this route for it. An obscure track car. And then...for about 8 months, she sat - being occasionally started and moved about (Good start eh?). Finally, we pulled our fingers out of our arse's and got stuck into the first step of weight saving.
Courtesy of the diet, we are back up to factory height
and it now looks like this...
The future steps will be cutting the SIPS out, door skins, roof skin, bonnet skin etc. Plastic windows. Shorten the exhaust down to a side exit. Bucket, cage, harness. Fuel cell.
Start looking at suspension and brake bits as some evo stuff is usable on this platform. But generally leave the power alone for the time being 200 odd bhp and 300nm is good enough.
The main goal, without a cage is sub 1000kg - maybe a tall ask. Got to have something to shoot for right?
I'm hoping over winter will be able to update this some more.
Edited by Scoobydrew95 on Tuesday 1st November 10:23
One of my guilty secrets is that I'd really love to make a replica of the S40 saloon prototype.
My mates think I'm mental but I think it looked awesome and if I had the time, money and space (hah! wouldn't we all love more of those?) I'd be all over wasting a lot of money building one.
[img]https://thumbsnap.com/sc/uVtqRX9c.jpg[/img
So good on you OP, I can sort of live my weird fantasy through you!
(long way of saying "Love it, I'm in")
My mates think I'm mental but I think it looked awesome and if I had the time, money and space (hah! wouldn't we all love more of those?) I'd be all over wasting a lot of money building one.
[img]https://thumbsnap.com/sc/uVtqRX9c.jpg[/img
So good on you OP, I can sort of live my weird fantasy through you!
(long way of saying "Love it, I'm in")
Ahh thank you all! I am ultimately just glad i get to keep the old girl.
I'm sure there will be some inspiration taken from the BTCC cars. There's a fantastic replica touring car in malaysia i believe.
This isn't the first T4 track car in the UK but i think it might be the only Phase 1? Others tend to be 1.5s or 2s as they're mapable via OBD compared to the early cars and more common (Last i checked there was supposedly only 7 manual T4 v40s CDs left - few more Saloons and autos though). And i don't know if others have gone quite as far in terms of weight reduction though. The interest in using the phase 1 car is, its a 1.9 over the later 2.0s. Is non VVT-I again compared to later cars and the rods...if i remember correctly are forged. However again, other then a sports cat - don't want to touch the power too much. Shes on 180k miles and i don't want to stress the engine further at this point. Mind the reduction in weight will probably help in ways.
Maybe for reference as well, will get it fired up and get some better pictures and some videos of it running/doing flyby's.
I'm sure there will be some inspiration taken from the BTCC cars. There's a fantastic replica touring car in malaysia i believe.
This isn't the first T4 track car in the UK but i think it might be the only Phase 1? Others tend to be 1.5s or 2s as they're mapable via OBD compared to the early cars and more common (Last i checked there was supposedly only 7 manual T4 v40s CDs left - few more Saloons and autos though). And i don't know if others have gone quite as far in terms of weight reduction though. The interest in using the phase 1 car is, its a 1.9 over the later 2.0s. Is non VVT-I again compared to later cars and the rods...if i remember correctly are forged. However again, other then a sports cat - don't want to touch the power too much. Shes on 180k miles and i don't want to stress the engine further at this point. Mind the reduction in weight will probably help in ways.
Maybe for reference as well, will get it fired up and get some better pictures and some videos of it running/doing flyby's.
Well done, always very keen on non obvious track specials.
I remember another one of these featuring on PH a few years back. Don’t think they had gone as far with theirs but was definitely set up for track.
I’ve had several V40s including a T4 and a diesel. Really quite good but mostly forgotten now.
Good luck with yours, will he following with interest.
I remember another one of these featuring on PH a few years back. Don’t think they had gone as far with theirs but was definitely set up for track.
I’ve had several V40s including a T4 and a diesel. Really quite good but mostly forgotten now.
Good luck with yours, will he following with interest.
ballans said:
Well done, always very keen on non obvious track specials.
I remember another one of these featuring on PH a few years back. Don’t think they had gone as far with theirs but was definitely set up for track.
I’ve had several V40s including a T4 and a diesel. Really quite good but mostly forgotten now.
Good luck with yours, will he following with interest.
Even if it maybe harder, the odder and non obvious the better. I remember another one of these featuring on PH a few years back. Don’t think they had gone as far with theirs but was definitely set up for track.
I’ve had several V40s including a T4 and a diesel. Really quite good but mostly forgotten now.
Good luck with yours, will he following with interest.
Yeah, i've chatted with the guy a few times. Very cool car! Phase 1.5 so different engine etc.
Surprisingly good vehicles, before buying mine got the chance to drive a Panama yellow S40 T4 touching the 300bhp mark, certainly made the eyes bulge.
Cheers - hopefully we don't blow it up on the first outing, whenever that might be.
ballans said:
Completely agree, you’ve got have a challenge!
Glad I wasn’t imagining the other track V40. I’m getting on a bit and my memory does have a habit of tricking me.
How earth did they get the power down with 300bhp? Even my diesel v40 could get a bit wayward.
There's also a very heavily modified S40 track car, with some aero bits but again - not sure they're going to our levels of butchery! Glad I wasn’t imagining the other track V40. I’m getting on a bit and my memory does have a habit of tricking me.
How earth did they get the power down with 300bhp? Even my diesel v40 could get a bit wayward.
HA. Tentatively. They're not too bad in 3rd gear +. It does of course spin up but it seemed predictable to an extent. 1st gear in a standard T4 is pointless.
There's one in the uk which i think is pushing close to the 500 mark? And then over in Europe cars well towards the 800 figures. Once you've shimmed the blocks you can go fairly far with these it seems.
LandieMark said:
I had a Phase 2 T4 SE new in 2000 and kept it 7 years. I liked the car, but it was an unreliable money pit. The auto gearbox ultimately grenaded itself and I cut my losses.
Interesting choice as a track car. They don't handle at all badly for an FWD car IIRC.
I'll be honest, there was always something that it needed but again, always got me where i needed it too. We hope that we can remove some of the breathing stuff, to help reduce those issues. Of firing oil everywhere. Very glad i had a manual one, not sure i could have coped with a auto in that. Do seem to produce lots of issues. Interesting choice as a track car. They don't handle at all badly for an FWD car IIRC.
Handling wise, it wasn't bad at all! The Bilstein's really made it a fun drive, having independent rear suspension too. Think the brakes could do with some work, always felt they weren't enough. Specially on big stops.
An entirely poor update, as i was a little to giddy to take photos.
When i wrote the first post, the car had been parked for 4 months. And Saturday was the first day it's been started and moved since around June.
Having daily driven it for 2 years and knowing how temperamental it could be. Was particularly unhappy when left for more then a week. So i was dreading going back to it.
Pulled the bus round, jumped it and it caught on the first spin. Stumbled then died. 2nd time, did the same. 3rd time it caught and went to high idle. No smoke, wasn't miss firing. Nothing.
We let it get up to temperature and then started moving it about. Mother fker, i forgot how good this thing sounds. Truly is one of the loudest *woosh* and PSSSHHT* i've heard on any car. Considering it's only got an air filter and cat back on it.
Considering it's on 20mm lowering springs, it sits very high.
We wanted to move it, to start doing some investigative work.
A: Get the dashboard out
B: Check how extensive the rust is.
Because i can't be bothered to retype the above, i'm gonna start with B.
There was a little more then hoped but less than had anticipated. Theres a small hole by passenger sill. And both the back parts of the sill are pretty buggered. I knew that, one of the reasons she was parked up and set to track car duties. Thankfully we can buy rear arch pairs for 70 quid and sills for 50.
So will be purchasing these in the near future. However not 100% on the requirements for a track only car in terms of outer sill integrity?
A: Removing the dash, not generally too hard however a few shocks. The HVAC is absolutely huge. Like monstrous (Obviously we will be keeping the dash just gutting it). The plastic steering column shroud, lower part is approx 1kg on its own. Ridiculous.
Don't break the window switches as you then can't use the window. Luckily there is one on each door. Plus an additional 4 switches in the centre. Thanks Volvo!
Anyone in the south, near Dorset got some cheap buckets for this? We need two. Any early mitsubishi evo parts, suspension wise?
Again, apologies for the lack of photos. Will try and get some in the coming weeks and when next attacking it.
But good news is, it's running happy. We have a rough plan in our heads. And funds required for the project should be available soon.
When i wrote the first post, the car had been parked for 4 months. And Saturday was the first day it's been started and moved since around June.
Having daily driven it for 2 years and knowing how temperamental it could be. Was particularly unhappy when left for more then a week. So i was dreading going back to it.
Pulled the bus round, jumped it and it caught on the first spin. Stumbled then died. 2nd time, did the same. 3rd time it caught and went to high idle. No smoke, wasn't miss firing. Nothing.
We let it get up to temperature and then started moving it about. Mother f
ker, i forgot how good this thing sounds. Truly is one of the loudest *woosh* and PSSSHHT* i've heard on any car. Considering it's only got an air filter and cat back on it. Considering it's on 20mm lowering springs, it sits very high.
We wanted to move it, to start doing some investigative work.
A: Get the dashboard out
B: Check how extensive the rust is.
Because i can't be bothered to retype the above, i'm gonna start with B.
There was a little more then hoped but less than had anticipated. Theres a small hole by passenger sill. And both the back parts of the sill are pretty buggered. I knew that, one of the reasons she was parked up and set to track car duties. Thankfully we can buy rear arch pairs for 70 quid and sills for 50.
So will be purchasing these in the near future. However not 100% on the requirements for a track only car in terms of outer sill integrity?
A: Removing the dash, not generally too hard however a few shocks. The HVAC is absolutely huge. Like monstrous (Obviously we will be keeping the dash just gutting it). The plastic steering column shroud, lower part is approx 1kg on its own. Ridiculous.
Don't break the window switches as you then can't use the window. Luckily there is one on each door. Plus an additional 4 switches in the centre. Thanks Volvo!
Anyone in the south, near Dorset got some cheap buckets for this? We need two. Any early mitsubishi evo parts, suspension wise?
Again, apologies for the lack of photos. Will try and get some in the coming weeks and when next attacking it.
But good news is, it's running happy. We have a rough plan in our heads. And funds required for the project should be available soon.
Things are ticking away very slowly on this. We have both had a few other large jobs to do on personal cars and our partners cars (i.e. stupid fking filter housing gaskets on a R56).
However we have found some appropriately 90s bucket seats - so next thing on our list is to get some bases and harnesses (anyone got some orange ones?
). And then continue the gutting. Still aiming for early 2024 to have it out on a track.
king filter housing gaskets on a R56).However we have found some appropriately 90s bucket seats - so next thing on our list is to get some bases and harnesses (anyone got some orange ones?
). And then continue the gutting. Still aiming for early 2024 to have it out on a track. As ever, st gets delayed and things left to rot for months on end whilst life gets in the way.
However! Yesterday, we moved the old girl and resurrected the project.
Here's a typical x40 key. Absolutely shagged and held together with hopes and dreams.
The car has sat still for months and months. In preparation for this, we took a spare battery and jump cables. As OBVIOUSLY the battery in the car (whilst disconnected) would be flat. In a mere hope we just hooked the negative terminal up. No spark or noise. Ugh. Just for laugh lets see if it even does anything.
Ignition on - fuel pump screams into life. Ooo interesting...
Twist the key for starter - a genuine half turn of the engine and it fking started. It NEVER behaved this well for me when i was daily driving it. Didn't stumble, stutter or make any complaints. Anyway Tab Magic batteries. What wonderful things!
Just gotta get the tyre pumped up and drive it over to the garage. This car has just an absolute awesome sound experience, there's so much induction and turbo noise. Pops and bangs from over fuelling. An exhaust noise which i can't quite put my finger on.
And here, in this lovely heated garage is where the project will rest and be worked upon. I am terribly grateful to have this access and space for it.
First thing on the agenda, sunroof out! 6 bolts and it dropped away, was thankfully very easy. The hole will be filled with an ali sheet. I would like to bevel and recess it but i don't think we have the tools to do so. Time will tell! But it weighs approx 15kg, so good to get it out.
Another small job, just removal of the rear wiper. Simple task but again another 1kg.
The goal is sub 1000kg without a cage. I guess time will tell whether that's doable.
I completely forgot to take some photos as was selling some bits that we were pulling off. But we removed the front bumper to bin the crash bar as 1/3 had rotted away. Made an absolute mess of the floor. Living near the coast did absolutely no favours to this car. Poor thing.
Now it's in the garage, we can worry about things like the seat frames and getting it heading towards some track work. It'll need tyres all round, oil service, brakes i think and some other bits and pieces.
I think late 2024 is more realistic.
t gets delayed and things left to rot for months on end whilst life gets in the way. However! Yesterday, we moved the old girl and resurrected the project.
Here's a typical x40 key. Absolutely shagged and held together with hopes and dreams.
The car has sat still for months and months. In preparation for this, we took a spare battery and jump cables. As OBVIOUSLY the battery in the car (whilst disconnected) would be flat. In a mere hope we just hooked the negative terminal up. No spark or noise. Ugh. Just for laugh lets see if it even does anything.
Ignition on - fuel pump screams into life. Ooo interesting...
Twist the key for starter - a genuine half turn of the engine and it f
king started. It NEVER behaved this well for me when i was daily driving it. Didn't stumble, stutter or make any complaints. Anyway Tab Magic batteries. What wonderful things! Just gotta get the tyre pumped up and drive it over to the garage. This car has just an absolute awesome sound experience, there's so much induction and turbo noise. Pops and bangs from over fuelling. An exhaust noise which i can't quite put my finger on.
And here, in this lovely heated garage is where the project will rest and be worked upon. I am terribly grateful to have this access and space for it.
First thing on the agenda, sunroof out! 6 bolts and it dropped away, was thankfully very easy. The hole will be filled with an ali sheet. I would like to bevel and recess it but i don't think we have the tools to do so. Time will tell! But it weighs approx 15kg, so good to get it out.
Another small job, just removal of the rear wiper. Simple task but again another 1kg.
The goal is sub 1000kg without a cage. I guess time will tell whether that's doable.
I completely forgot to take some photos as was selling some bits that we were pulling off. But we removed the front bumper to bin the crash bar as 1/3 had rotted away. Made an absolute mess of the floor. Living near the coast did absolutely no favours to this car. Poor thing.
Now it's in the garage, we can worry about things like the seat frames and getting it heading towards some track work. It'll need tyres all round, oil service, brakes i think and some other bits and pieces.
I think late 2024 is more realistic.
Another few weeks...months...time has passed and some genuine progress has been made.
Without fail, this car continues to start for the first time - every time. Which i am genuinely surprised about.
My photos this time are a little thin on the ground as completely forgot to do so.
Firstly we went to the tip, to get rid of any thing that was just broken, not salvageable or just in the way. We also collected some fuel for it as it's not had any since before i made this thread. 6L of esso supreme!
Main goals of the day were dash board completely out, heater matrix out, rear doors emptied. We also had hoped to get the roof filled in but myself and Dan are genuinely hopeless at getting things done in a good time frame.
Getting all the window mechanism, loom, window out of the doors wasn't too difficult. pretty much a case of unbolting what you see, dropping the glass down so you can unscrew it, remove the rubbers and get to some connectors. First side took me an hour, second about 15 minutes.
Hoping fronts are a fairly similar process it looks to be.
Selling on all these bits to people as it seems they are in demand!
With the glass out, we can then get some plastic in place.
Whilst i was doing this, Dan was suffering up front removing the coolant to then do the heater matrix. With a very busy engine bay, unfortunately many things had to be removed to access the pipes going into the cabin. He was less than impressed.
I think for ease we might go to an aftermarket intercooler, as the OEM system whilst effecient enough is a hindrance when any work may need to be done. Something to look into for the future!
Some good news though - finally managed to source a set of the original alloys for this car! Gasparos. I think they are cool as fk. Really adds to the werthers original vibe that this car exudes. Best news is, they're free! Well, im trading my craters for them.
I'm hoping the next update will be some plastic going into the windows? Roof going on? Stupid large spoiler being fitted? Who knows!
Without fail, this car continues to start for the first time - every time. Which i am genuinely surprised about.
My photos this time are a little thin on the ground as completely forgot to do so.
Firstly we went to the tip, to get rid of any thing that was just broken, not salvageable or just in the way. We also collected some fuel for it as it's not had any since before i made this thread.
6L of esso supreme! Main goals of the day were dash board completely out, heater matrix out, rear doors emptied. We also had hoped to get the roof filled in but myself and Dan are genuinely hopeless at getting things done in a good time frame.
Getting all the window mechanism, loom, window out of the doors wasn't too difficult. pretty much a case of unbolting what you see, dropping the glass down so you can unscrew it, remove the rubbers and get to some connectors. First side took me an hour, second about 15 minutes.
Hoping fronts are a fairly similar process it looks to be.
Selling on all these bits to people as it seems they are in demand!
With the glass out, we can then get some plastic in place.
Whilst i was doing this, Dan was suffering up front removing the coolant to then do the heater matrix. With a very busy engine bay, unfortunately many things had to be removed to access the pipes going into the cabin. He was less than impressed.
I think for ease we might go to an aftermarket intercooler, as the OEM system whilst effecient enough is a hindrance when any work may need to be done. Something to look into for the future!
Some good news though - finally managed to source a set of the original alloys for this car! Gasparos. I think they are cool as f
k. Really adds to the werthers original vibe that this car exudes. Best news is, they're free! Well, im trading my craters for them. I'm hoping the next update will be some plastic going into the windows? Roof going on? Stupid large spoiler being fitted? Who knows!
The wheel swap fell through unfortunately not that he told me. So the hunt for awful oem wheels continues.
Now we are into winter, am going to continue cracking on with the T4. The AC system is something which needs coming out. So started with the pretty manky condenser and piping.
Next week will be the pump and will then run a non A/C pump belt.
Whilst the photo isn't the clearest, it shows that there's a lot disconnected.
3rd rotation of the engine and it sprang into life. Incredibly impressed. Sounds fairly healthy too.
We have also since acquired a load of sheet metal, in the form of a mk2 octavia vrs. So that will be our sunroof, rust patches and and anything else that requires metal covering it. I think as well i have a lead on some free lexan which would be a mega help.
Anyway, hopefully will have some more serious updates in coming weeks and not just some ste photos of not much.
But it IS going ahead.
Now we are into winter, am going to continue cracking on with the T4. The AC system is something which needs coming out. So started with the pretty manky condenser and piping.
Next week will be the pump and will then run a non A/C pump belt.
Whilst the photo isn't the clearest, it shows that there's a lot disconnected.
3rd rotation of the engine and it sprang into life.
Incredibly impressed. Sounds fairly healthy too. We have also since acquired a load of sheet metal, in the form of a mk2 octavia vrs. So that will be our sunroof, rust patches and and anything else that requires metal covering it. I think as well i have a lead on some free lexan which would be a mega help.
Anyway, hopefully will have some more serious updates in coming weeks and not just some s
te photos of not much. But it IS going ahead.
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff