There were several goals established when the twin cam project first began.  At the top of the list was creating an naturally aspirated engine that would not sacrifice the benefits of Volvo's long runner intake.  Four valve engines are well known for their excellent breathing characteristics at higher RPM.  The B234 intake was designed to extend the power curve further down into the rev range so the car would not seem anemic at lower speeds.  Therein lies the problem.  A stock B234 intake will clear the master cylinder, but will not leave sufficient room for an efficient air intake, even with the short, 960 throttle body. 

 

Turbo fans have developed several solutions to the clearance problem.  Shorter, custom fabricated intake manifolds are available the leave plenty of room for the stock master cylinder and brake booster.  Some people have also taken to cutting two inches out of the intake runners of the stock manifold.  Of course there were no 240 turbos after 1985, so such modifications, including the custom manifolds and turbo installation, would be impossible to certify in California without certifying the new intake first.  A very pricey proposition.  Certainly there is always a way around that, but we chose a different route, based on wanting to keep the stock intake.

 

Our first stab at creating room for the master cylinder was a partial failure.  We created a fixture to offset the master cylinder down and to the right, where it tucks below the intake system.  Elegant, strong and sturdy, very neat to look at.....and a failure.  Not enough study was done on the physics of levers, and we were left sadly without full braking power.  The car is driveable, and we've enjoyed it so far, but not a long term solution.  Currently we are desiging a two stage hydraulic system to activate a remotely mounted master cylinder. 

 

The development of the brake M.C. fixture is still worth sharing!