E30 Zone

I have a twin plate racing clutch with the 29mm 10 spline BMW plates plus a lightweight flywheel for the M20 engine for sale. Clutch is 7 1/4" and flywheel matches. Plates are sintered metallic and were specced for 450lbft. Flywheel made by TTV. Clutch made by Super Clutch. I'm in Farnham in Surrey....

Been slowly fabricating the feed pipes to the pump. The brass fittings are strainers.

The pressure feed is built into one of the brackets I machined a while ago.

Next up is to rebuild the sump around the pump.

Make a sump, cut it up. And all day long, you'll have bits of sump everywhere.

Need to make a mini sump for the pump and fabricate the suction plumbing.

Also need a way to connect the suction and pressure feeds to the dry sump tank.

Hooray! I made actual parts that fit other parts for the dry sump today! :D 20220924_164035.jpg 20220924_164044.jpg 20220924_164050.jpg This is the third design of dry sump pump drive. One design was to stand the pump on end and drive it off the old pump mechanism. One was to drive it by chain off t...

They're 310mm discs. Really wanted to fit the 325mm discs from an E46 but they just fouled everything 😕 Got an old tyre fitted to a wheel today. 205/40R17 on a 8J17 ET20 wheel is a tiny bit of a stretch but I'm confident it won't rub anything. Will go wider on the rear. Will need something like a 40...

20220724_163709.jpg 20220724_163650.jpg Made a prototype strut socket so I can check ride height. Just need to get some old scrap tyre fitted to a wheel and see how it sits. There's a jack under the end of the TCA in the pics above, suspension is supporting the weight of the car! Quite springy whic...

Edging closer to finishing!

Machining is a fantastic waste of material! And when you pay a machinist, they use even more material to speed up the process!!

Just need to tap two holes and this side is done!

Good progress today, minor mishap when a tool flew apart though!

Wonder if the E90 and E30 have the same ABS pulses per revolution of the wheel

Devil's in the details, took ages to run fillets around the pockets today!

Got flood coolant rigged up, hence the ducky shower curtain

Doesn't look much different, but took another 10mm off yesterday

Couldn't help cutting some more this evening!

Woo! Progress!

It's got it's limitations, no motor feedback to the controller and can't do rigid tapping, but aside from that, it's amazing!

I use one of these, called a DDCSV3.1

Quite a remarkable bit of kit considering the cost which was about 200 quid.

Machine had Chinese closed loop stepper motors, although I'm not so super happy with them.

For tool paths I use Fusion 360.

Managed to get one of the caliper brackets completed, then the machine started playing up so currently trying to resolve that!

How do you like the splash guard

Not a silly question at all! Unfortunately the E30 hub can't be drilled for 5x120 as the bolt patterns overlap, think this is why you don't see simple adapter plates. The standard hub is too small for 5x120 as well. I looked at custom hubs but you can't buy off the shelf bearings to fit the E30 spin...

If you buy just the hats from Rally Design, you have to get them machined just to fit the disc as they're oversized all round!

With a kit, it should just bolt on

Got these both to the same state now! Might be tempted to put the little retaining screw on though!

Rally Design supply a kit with the same disc and calipers for a reasonable price: https://www.rallydesign.co.uk/product_info.php?products_id=15226 Ready to bolt on 😊 Sure a friendly local machine shop would add some cosmetic details for not too much money after that. Only reason I'm doing all this i...

Half a set of brake discs done!

Couldn't help myself, had to add those scollops, hats just looked so plain otherwise!

Final iteration of the design removes the caliper mount from the upright in the interests of saving material. Got the brake discs this week and knocked up a prototype hat to check clearance to the suspension. All looks fine with good clearance. Also tried the track rod and tie rod from an E90, just ...

Have done quite a bit of development on this project and am ready to start firming things up in metal. PXL_20220109_134243766.jpg PXL_20220103_162754793.jpg PXL_20220103_162618274.jpg PXL_20220103_161451612.jpg PXL_20220103_161429640.jpg Lots of prototype bits of timber just to make sure everything ...

As far as I understand it, and I decided the E36 route wasn't right for me having done lots of reading about geometry compromises, any old E36 suspension will bolt on and maybe look about right if you move the wheel around in the arch using offset bushes and top mounts, but the geometry won't be rig...

Pleased with this, shut is full boost on small turbo, open is full boost in large turbo

In between regulates small turbo boost.

Woo, wastegate for the little turbo pretty much complete!

Modified the pneumatic cylinder which actuates the air valve this weekend, and made up the bracketry for it. All getting a bit squashed over this side of the engine bay, not too many components to make now. PXL_20211009_153846745.jpg PXL_20211009_153842284.jpg The air valve handles part of the trans...

Made an adapter for the air inlet to the little turbo and welded it on today, starting to look finished this bit of the puzzle!

Needs lots of tidying inside though!

Hopefully it'll take the heat! Eek! Having finished the filter housing, moved on to the Air Diverter Valve (ADV) assembly. Have fabricated this, made it from glass fibre and carbon over the years, but don't think I ever fitted these attempts to the car.... space is TIGHT! Got everything fitted to th...

Air filter enclosure almost complete.
Last layer of carbon on the lid and it's done.
Uses an E90 M3 air filter.

Because it wouldn't be one of my projects if I didn't try at least two options out.....I'm looking at an alternative route! :D To start, I've got hold of some SUPER high quality CAD for the E30 strut and also an E36 strut. Looking at making a single piece aluminium adapter instead of the steel angle...

Few code tweaks and the control system seems to work pretty well for a first stab, have also modified the main wastegate to fail safe. My control system relies on having positive pressure. Plan is for that pressure to come from a pump and the turbos when on boost. PXL_20210626_151540385.jpg So in th...

Decided to take a break from machining suspension parts and experiment with the turbo actuators. Have decided on pneumatics with digital control. Like all good experiments, this one begins with a jury rigged pump running off the lathe, a solenoid valve, a couple of Arduinos, a position sensor and a ...

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Twin plate clutch and flywheel for M20

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Possible new route to 5 stud front suspension

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D

Re: Possible new route to 5 stud front suspension

Re: Twin Seq. Dry sumping for beginners :D

Re: Twin Seq. Dry sumping for beginners :D