E30 Zone

For a glimpse of phase 1 click here
http://www.bimmersport.co.nz/forums/ind ... ntry161415

Removing the old m20b25 in prep for engine bay cleaning
Phase 2 started tonight
On the hoist.

Ray and brendon unbolting gearbox mounts.

Out it comes

Video
http://www.youtube.com/watch?v=uC1d3c9zwW8[/url]

Dirty engine bay

Date with a water blaster

Clean engine bay in prep for removing of all brackets and engine bay paint prep.

Result!
http://www.youtube.com/watch?v=FoYjvwVcq5I[/url]
Next is s50b32 mock up and getting ready for the engine build.
After this we have the interior strip out and roll cage install.

Dragged these pics up from an old post.

The s50b32 has had a bit of a hard life outside and unfortunily had water in cylinder 1 which has caused a bit of pitting. The crank also hand a bit of minor rust on it but nothing that a bit of machining wont fix.

Rust in Cylinder 1


s50 block (note 3.2ltr cylinder walls are pretty thin as standard in the ole iron block)


Head


Double Vanos and cams which is going to be blanked off and removed in favour of a locked adjustible timing gear system.


As it stands cylinder 1 is being bored to 18thou to check that the pitting doesnt extend over the 20 thou (.5mm) bore we are looking to do.

Standard pistons are 86.4mm we will take it to 86.9mm.

Bought a new toy today. 37k's .. basically only run in

More toys turned up...

DTM Short Shifter



Spherical ball race bearing / Alloy plate


DTM Shifter and s50 -> e30 loom adapter

Its been 5 weeks in the making and fair bit of CAD work plus mock up from westy's e30/e46 flywheel / pressure plate setup (cheers tony).. I bring you the billet s50b32 single mass flywheel.

It weighs in at 6.23kgs and had the dual mass ring gear put onto it to match my starter setup.



Old s50 dual mass vs the new single mass (quite the difference)




Should rev like a bitch now...

Sorted out the clutch / pressure plate today ..


Went for Carbon / Kevlar instead of a metal composite to keep the drive train rattles down and will be a little nicer to drive in traffic. Perfect mix of hard core driving / track days and heavy street and ablility to drive in rush hour without glazing up the clutch.





I had a 3035 ft pound pressure spring mated to a new OE sachs housing. Is good for 450rwhp.



All assembled ...







Off to be balanced tomorrow

Update:

Sorry for the lack of photos on this one .. Will click some off tomorrow, forgot to bring the memory card up in the camera.

So just to tidy up the last post, I had the pressure plate / clutch and flywheel and pressure plate bolts all balanced.
Not much was needed to be removed and suprisingly the Sach pressure plate housing was apparently a 9/10 balance .. which was nice to hear.

Ok so today was pretty epic.

The brake booster was removed and the new laser cut brake booster relocation plates worked perfectly. Thanks to Brendon for getting the measurement bang on and Ollie for sorting the CAD and laser cutting.
Thanks to westy, he fabbed up and welded an extension to the brake booster swing bracket from the brake push rod. Just need to get the e34 brake push rod into it.

All in all the Brake booster was moved around 60mm to allow the s50 plenium to fit.

Tomorrow the z3 2.8 3.0 ratio steering rack goes in and e36 6 cylinder power steering pump and steering pump reservior goes in and will run the new brake lines.


Later in the week the 5 series sump and oil pick-ups go onto the new engine and we will attempt to shoe horn it and the gear box into place to check for final clearance.


Thanks to Ray and co, Westy and Brendon for today.

Some photos of the handy work over the past few days.

New hole cut in the firewall


Firewall side relocation plates. There is a plate on each side of the firewall 3mm thick stainless.


Booster installed (yet to be painted still mocking up) Brake lines are still to be done properly ran out of time today.


The brake swing bracket on the interior side which has been extended to handle the move.


E34 brake pedal push rod was re threaded with a tap and dye set today and installed. It fitted perfectly.



New z3 Steering rack which we found out was a 2.8 lock to lock ratio one! .. win. A date with the degreaser and a hose, it came out new


Installed


15mm Spacers installed into the rack. Will investigate maybe putting these at the bottom to lift the rack to reduce bump steer however this all depends weather it will clear the engine, wont know that till the engine goes in.




Thats all for today ... more friday going to plan.

Another successful day.

Tidying up the brake lines and swapping the e34 sump / new revised s50 pump / e34 pick from the 'old' engine to the new one.

Brake line tidy up, Brendon managed to work some pretty cool solutions, like the e36 square brake fluid reservoir.




While brendon spent literally all day in the engine bay I lined up both the S50b32's and started work on swapping the oil pans and oil pumps.





S50b32 oil pick ups from the new engine to come out.



Little sh*t of a oil sprocket nut .. known for coming off. Left hand thread.



Pump removed .. noting the pick up support bracket is connected to the main bearing cap bolts. I removed these and re torqed them back up with my new toy.







New oil pump and pick up





Cleaning up the sprocket shaft and sprocket for loctite blue and torqued.











And one last stupid photo ...

We couldnt figure out weather to make a 3 engine 6wd e30 ... that and thought there isn't a photo anywhere where you would see 3 s50b32's in one spot

Quite a bit has been done to the engine over the past few days.

While it may look the same, the final modifications to the engine were finally completed today.



Polished up the heat shield



Everything double checked torque wise on the bottom end and the new oil pan gasket and e34 oil pan is finally bolted on and torqued.



High temp gasket silicon added to the metal joins on the block face.


Emmsions pump and hoses removed and bunged up. factory blank off plate and gasket also added.



Whats going on here New modified dipstick and supports. Sounds simple .. but it was a bloody mission to get it to curve correctly out of the sump and flush hug the plenium.



notice a bracket made up that clamps the dipstick tube and a swivil clamp towards the top which worked perfectly!



New cap bolts for the M cover (new one on the left) from the bolt shop .. I bought 6 with washers for $3.



Perfect clearance



Cover installed



One piss me off thing that happened today .. my intake plenium boot split .. which kinda pissed me off as while they aren't too expensive .. they generally have a two week turn around ex german for m parts. Can't win em all.





Next the engine goes in for mock up .. Ollie is sorting out some cad drawnings for the steering rack spacer .. but ill post that in another update sometime next week hopefully.

Big thanks to Ray for his help last night ... 1:00am finish.


Shifter install ...

To ready the car for the engine install we needed to install and locate the shifter.





Interesting to see that e30 already come with the front locators that you can just punch out. Almost as if BMW motorsport required this for the homologation for DTM shifters ?





Temporarily installed

Bugger I just lost the whole post which took me an hour to do :/ Ill re-type it

New Intake plenium boot



The gearbox which we found out was missing the gear selector sensor.



off to RealOEM to order..


Installed the engine mounts

Pulled the flywheel and pressure plat apart to install the flywheel onto the crank



We found that the bell housing flange plate is the same as a standard e36 plate.




Installing the Flywheel with $50 worth of new flywheel bolts and loctite




Done





Installation of the pressure plate which proved to be interesting. We actually couldn't get the gearbox on in the end with it on. Even though we used a clutch alignment tool I think it still may have been out by a little bit causing the gearbox input shaft to misalign the spigot bearing. Will sort it out later, for now we get the gearbox and engine in so we can check the clearances.

Done'ish'


Its hammertime



get in there bitch





Its tight



real tight




Like a nun even

O2 sensors just fit



Extractors vs the sway bar ... will have to modify




Money shots








Next is a date with the hoist and some fancy new engine brace which will allow us to hang the engine in mid air while we move the subframe to work on the clearance issues.

more on thursday.

Aligning the engine part 2

Fancy new jig which allowed us to remove the subframe







Some of the clearence issues faced



You cant really see it here but the number 6 pipe hits the firewall .. will pull it off and heat and bend it in two places .. one to clear the firewall and the next to clear the steering colum.



E21 gearbox cross member



final clearance for the booster ... heeeeeaps of room!




And finally a video showing the DTM shifter in action.

http://www.youtube.com/watch?v=pa5fo4iZfIg



sunday the next update ...

Update:

Next on the list was the intake plenium clearance. The heater pipes were in the road.



Brendon took around an inch off the pipes. to fit the new samco heater pipes. Yes .. bloody samco heater pipes. lol



Out the come. Tissue paper to stop my pet hate of coolant all over the carpet



Needed to shorten the pipes. And I wanted to test out my new dremel tool:) 33,000rpm cutting tools rule.



Test fit the hoses, had to sort out the gromet to fit the hoses. More dremel action. No photos on this, but I needed a face mask as it was like doing a burn out in rays workshop .. the smoke that came off it was insane.








Inside fitment



finished position .. will clamp it up when everything is put together




Next is the oil cooler and headers mock up. Also a shed load of parts inbound from BMW

Sorry for the lack of updates .. We have actually been working on the car just doing a lot of prep work and setting up for the new modified headers.

Quite a bit of cutting on the #6 pipe and re shaping. While keeping it eqaul length and no sharp angles was no mean feat. A friend of the missus has done all the welding work, having gone solo after spending his time working on some big budget race car projects in his time .. and his tig welding workmanship shows. Great to have some one like him on board.

4 areas of concern

1 #6 hits the firewall
2 Rear pipe collector touched the Sway Bar
3 #6 fowled the steering colum
4 Post collector long pipes need to be modified to hug the body better while retaining the correct length to the mid muffler as not to effect torque.

With out further ado.

Test fitting the new modified pipes.






Top view.




Underneath.




Shortened and reflanged to provide a more liner path. O2 sensors to be retapped into new secondary pipes.



Tig welded factory flanges .. super stoked on the job done so far.



Welded to factory outlet flanges.



This is before we installed the steering rack back in to check. you can see the lack of clearance we have to play with.. but we will get there




Now the steering doesn't quite clear the number 6 just yet .. so a little rework is going to be needed .. however we will have something later this week hopefully

This arrived yesterday all the way from the U S of A .. 7 week wait but well worth it.

No photos this time ... Still playing paddy cake with the headers vs steering rack input shaft vs steering coupling vs sway bar. Its pretty got darn complicated so we are shipping the car down the the welders workshop for him to complete.

While it's down there it will be getting a custom twin 2 1/4 inch mandrel bend stainless exhaust system to be welded up. Complete with X Pipe. Still sussing the muffler out .. but we are looking around two weeks for a test fire

A LOT of parts in bound from germany .. hopefully some of the last orders ... I feel sorry for Gary @ JC. My email to him today went something like this.

"Hey mate, Sorry to f**k up your friday afternoon .... "

erm .. Oh and I managed to drop the brake booster into be painted.

That and I curbed my right rear Works wheel on the e46 yesterday .... most of the way around ...

It will be off to Arrow wheels on moday to be sorted out. Its only curb rash .. but it broke my 2 1/2 year record of not stuffing them.

Oh and a massive thanks to Ashkan for the lend of the gearbox cross member while mines on back order. cheers dude, without it we could complete the headers next week.

Bought some more stuff today

Having searched high and low for a atleast dual 2 1/4 input that wasn't made from playdoh .. I opted for something else

Remus e60 550i single 3.5 inch input and dual 2.25 output.

This thing is huge











So I will have a second 2 into 1 collector at the end of the 2.25 stainless dual pipes.


Also a first pic of the MSS50 Siemens DME.



New Walbro 500hp external fuel pump and mounting kit. I had the option to go to a bosch 044 but it really would have been over kill @ 700hp.




Also a shot of a MSS50 map dump Im mucking around with



Hopefully have another cool update for wedensday all going to plan .. but you will have to wait and see

cheers

Exhaust update:

Guess what bitches ... it fits!!!!111one

So some pretty major work has been done to get the z3 2.8 turn rack (from the 4.0 standard rack) everything ended up being 'tweaked'.

You can also see the new runner pipes from the collectors. After some advice from Gavin the runner size was kept to 2 inch to retain the b32 torque. Going 2.25 inch will get you more peak, however the pipes have been calculated to handle 400 HP nicely as it is. Which is bang on the money we reckon for the range this engine will be operating in.














The 550i e60 exhaust rewelded to clear the M-Coupe diff








Like a glove


Thats all for now. The complete system should be done Friday afternoon as with the Oil cooler.

This is an older post of images of how the underneath was built .. more for you guys who haven't seen it. Yes it will be dropped down, I have a bit of panel work to do after the engine is all in. As you can see the wheels come out past the gaurds a wee bit.

Brakes at 332mm Wilwood SL-6's and M-coupe 315mm rears.
M-coupe rear end, half shafts, diff, trainling arms
GC / koni / Eibach / GC camber plates all round
e30m3 front struts

cheers fellas

MK II 1.3 golf brake booster update:

Back from Percision Autowerks, treated and double coated with a factory satin hard shell finish with the added feature of having chemical resistance to common engine bay fluids

Before and after



More close ups ...






All rust was removed from every nook and cranny

Another update today:

Unbolted the whole front subframe and shock assembly / engine and gear box to finally install the clutch. Turned out the first time we attempted (at 1am in the morning I might add) we bumped the alignment tool and just couldnt get the input shaft into the spigot bearing on the crank. Today was pretty challenging as well, took us 5 goes and 3 practice runs before we could get it in and the gearbox fully on with torqued and loctite'd pressure plate bolts.

anyways .. some cool shots of the engine and suspension.

A video of us dropping it out.

http://www.youtube.com/watch?v=GFuU--mMPRU

Prep work.




and out she comes





gearbox / clutch mounting time..




All a bit of a tight fit in the bell housing. But its finally in!


Took the time to tidy up a few other things while the engine was out

Put the new copper nuts for the extractors on and torqued them.



Also modified the s50 water pipes while we had a chance... as it sits in behind the engine between the firewall .. there is much room to move, but we have sussed it now


Finshed off now not hitting the number 6 pipe and now allows the heat shield to be put back on. Which is a wise move as a rubber hose sits on that pipe.


Also modified the steering rack so it has 3-4mm clearance from the sump .. as I said before this whole thing has been very very tight.



Thats all .. we are now on the home run! .. next just bolting all the misc stuff to the engine and hanging the radiator etc etc. re-hang the exhaust that we took off earlier in the week .. will photo it when its back on for ya'll to see.
and then itssssssssssss.. wiring time! Will re-align the DME <-> EWS and we should be ready for the first test fire in the next week or so ...

[Teaser]

Wheel design revealed ... Going in tomorrow for their two week surgery.

18x8.5 and 9.5 are going to be this.

Polished lip, gun metal silver centers, black chrome bolts (see second photoshop image below), reverse face for extra toughness and red cap centers (on order)


reverse face vs non reverse.

Long day today..

Worked on trying to get the rest of the exhaust hung but unfortunitly over looked the legnth of the linkage into the gearbox. So have decided the best way is to sort this is to weld a short link rod onto this rod so the gearbox end fits perfectly.
This held up the drive shaft which I've managed to swap the hanger bearing on.

Got everything else done like re-installing the heater pipes / new painted booster and master cylinder and plenium.
Also installed the alloy race radiator.



too long .. time to modify





Welded oil cooler lines for AN fittings.



and the engine




Starter motor wiring.




Installed the fan belt.



Plenium installed





Installed the radiator and new mounts.





Installed the e36 pipes



Stock sensor position in the Fluidyne radiator







Money ...




Thats all for now...

Update:

Fuel Pump - Walbro 255lph '500hp' external to keep up with the 5bar pressure requirements

It took some time as I run a pre-facelift which run an external low volume-high pressure pump and a intank high volume-low pressure pump system. This is different to the facelift single intank pump with baffles in the tank.
We removed the fuel dampner (little bell looking think) as I dont think it will be up to the task of as you say 5bar fuel delivery, It will also provide for some nice vaccum backfires ;). We also removed the rear regulator (pre face lift thing) as the s50 has one up on the engine.

I had to run two fuel lines the one from the tank to the fuel pump was larger diameter and the one from the pump to the main fuel line was smaller. The oem pre-face lift configuration about explains why.

BMW were very clever with this system as it means that the pre facelift was setup for cornering and nil fuel starvation from the get go. Weight saving, costings and the potential for more parts to go wrong in the fuel delivery systrem saw BMW change this to the single intank system.

If the internal high volume low pressure pump can't (it should be able to) keep up with the new pump at sustained high RPM, I will look at installing a swirl pot system instead. But thats for a later date. We worked out pretty quick that there are no published Pre-face lift s50b32 euro builds out there. (im sure they exist just not in our part of the world)



here is it finished

So another long day but we got a lot done. In fact we got more than a lot done! .. We think by the end of tomorrow we will be powering up and aligning the DME <-> EWS2 .. which means (if the oil lines and fan is completed by monday) we will be firing it up on weds night.

Anyways, picked up the new modified steering coloum. Countersunk allen head screw caps .. hot






And a machined and shorten linkage connector rods which now mates the DTM shifter and ZF nicely.






Which now brings us to drive shaft installation .. I know this is pretty boring for most of you, but again as usual nothing was as it seems and with out modification. e30 m3 grp-a driftshaft thanks to conrod, we spent about 2 hours getting the diff end bolts pressed in *rolls eyes* and pre-loading the hanger bearing. Thanks to ray for all his help and the guibo bolts which turned out to be e39 ones! m12 10.9 @ 115 NM torque thank you very much :wacko:









The cover was then added, after an intense 30min session with industrial grade degreaser and a water blaster.

before




after




Then came the exhaust which I have actually had for weeks, I just took it off before I could photo it .. anyways here is the new pride and joy, light weight stainless 2inch (to retain torque) to the 3 inch collector at the rear to the e60 550i muffler.




















And a completed shot from underneath rear and front

Part 2 of today

So feeling pretty stoked we got everything done underneath we started on the wiring and I modified the radiator supports to hold the radiator better.

I love the hellbm parts bin .. with out it I would of never of found half the solutions I would have to this date for small little annouying problems.






Next was the throttle cable, we tried the e30 one but as thought it was just two short.. so went for a nicer e36 one instead



and my cheesy first time pressing the throttle video, with the legacy e30 cable



Right after that excitment, on with more and more wiring. stunning messy engine bay picutures, however you can see the new covers and how they will give this engine bay a truely factory look when completed.











Here are some random images I thought may be mildy interesting of the workshop the car is in..

Tune rocking out on our local rock station, notice the taped down tuner so bad people dont go change it something bad. (Im being PC here all right! )


Whats this ... another M-Coupe which is being decided on its future. Its sitting in our little car bay where the e30 sat for over half a year ..



Have you ever played lego as a kid, well this is the adult version and one of 5 or so around the shop. We'd be lost with out it and I can thank it for many a cut finger. I have a love hate relationship with it now.



Some other headers I have



New parts storage









And this is what sits under neath it when the e30 s50 is sleeping






Anyways .. another big update tomorrow ...

In the mean time, some photos of incoming parts.

Simota 89mm neck and 130mm air filter .. anything bigger I don’t think will fit. Thing I like about these filters is they withstand engine heat and have a life time guarantee. This one will sit inside a cold air box once its fabricated up. (and anodised black ;) )



and a close up of the new centers for the new wheels

They really do look 3d, the red isn’t a bright red its more a ruby colour which is awesome!

More 'parts' so to speak...

245/40zR18 rears




And the ever important fluids.

They don't seem to stock redline 10w60 in this country *rolls eyes*

So Castrol 10w60 edge sport it is.

Gear box is a secret blend of 11 herbs and spices .. for gearbox chatter (from the lighten flywheel) nahhhh its just Redline 75W140 ns and MT-90 added to taste.

Some coolant

Some Castrol Dot4

and the saraficial lamb in yellow (4 liters of $40 engine flush oil before the good stuff goes in)

Still working on the wiring at the moment. We now have the starter motor working on the actual 'starter' key position and not ignition. It was to do with the starter circuit pin out differences on the loom adapter for face lift vs pre-face lift. I have a pre-face lift obviously a quickish re-route in the fuse box sorted the start problem out. However we are still not getting 12 volts down pin 15 or pin 16 down the diagnostic port. pins 14,15 and 16 should have 12volts running through them. We again are checking the dfferences in the pre-face lift loom. Confirmed this on Ray's M-Coupe.
Anyways so not startup glory today so instead I took a trip down to see how the new wheels are getting on.
They have finished the barrels and are just working on the inners., black bolts still to come but ill save that for when they are mounted on the wheels.
With out further ado, Arrow wheels work their magic
This is the bit they used to drill the PDC and the caps they press into the holes.

Welded and in the middle of being milled.

new wholes ready for caps to be pressed in

A new colour they have made up for me, Ill name it hybrid gunmetal Tested on one of their spare centers to show me what it will look like and give me approval for the go ahead. Note its tastefully darker than the standard silver (in the back ground)

Barrel win. Polished lips




enjoy..

Update.
More wiring (12 hours of it) and connecting up of misc stuff like booster air lines etc.
What a day yesterday was.
EWS is a steap learning curve, We started out but checking the loom and electrical diagrams for the e30 and e36. by about lunch time we had found that the pin 15 voltage problem actually wasn't a problem at all. Its just that the e30 doesnt have an EGS/IKE/etc to put 12 volts down the line back to the diagnostic port. So we jumpered it across from another ECU pinout.
The pin is only used to tell the diagnostic equipment that the ECU and modules is present and accounted for.
With that problem out of the way and confirmed, we could suddenly take reading from the ECU. YAY!
however we were having issues addressing the EWS. So back to the diagrams.
I noticed while I was looking that the EWS unit we had only had 'EWS' written on it. I asked ray to check his 2000 M-Coupe and it had EWS III written on it. AHA! we had an EWS I unit, crap.
SO out we went to search for an EWS II + key. again turned out to be a bit of a mission. We had worked out they (EWS II) were only produced between 95 and 97 so finding something was going to be hard. We searched all 5 series and 3 series cars and finally found one in a 318ti.
Awesome, so here we go again. (the sun was going down at this point)
Plugged in the EWS II and got a different bunch of error messages saying the EWS unit couldn't find the key. YAY! at least the GT1 computer had found the EWS module.
Brendon had read somewhere that you need to make sure the key is in the right position, so he adjusted it, we cleared the fault codes and tried again.
Success!
Cool so were not had a working system ready to code.
Brendon and I complete n00bs with progmanSSS ray made a 8:30pm on a saturday phone call to the dealer and he explained the start proceedure.
Reading all instructions and linking up extra batteries for constant current while programming, we set off to code.
message: you need atleast 13 volts to performing coding
Crap! .. time to bring in a running vehicle and jumper cables.
right now we had 13 volts.
We could now code. We tried and tried and tried but go stuck at the need part number for replacement module screen. so at 10:30pm we decided to call in a night.
We are going to look at using my carsoft software as its not so anal about part numbers etc etc and has a simple function to just align DME -> EWS. So will give that a go.
Once the EWS is aligned the car sould just start.

Awesome work dude

Stunning project, awesome