Tatty Old Bodged Racecar (2015-10-15) - Season End - 7th :(

[Altrezia]

Hey guys.

I guess I should probably put a thread on here as I've been using you lot as a info and parts resource for all of the project so far! ;)

(I had started this thread on another non-bmw forum, hence a few catch-up posts)

7th November 2013:

So; I've bought a race car which has previously raced in the Production BMW Championship (http://www.pbmwc.co.uk), and plan to take it racing in 2014. It's tatty and needs quite a bit of work before it'll be ready, but I think it should be a laugh, and it was pretty cheap.

The car has a relatively recent (mileage wise) rebuild at X-Sport, but everything else looks tired and shot.

So; I have three things in my plan..

1. Mot the car
2. Trackday trackday trackday.
3. Race it

Feel free to ignore the thread if it's not your thing.


I've got a todo list too:

--
General Todo
--
Gearbox exhaust mount?
Paint rear valance
Buy & Replace suspension
Replace exhaust
Buy new race wheels
Wiper Motor Clean
-- Gearbox mounts
-- Engine mounts
-- Stickers? (work related + more?)
-- Fuel stickers on dash (safe, full and minimum)
-- Fill with fuel (to full line!)
-- Door pulls
-- Fit mirror glass
-- Fit race wheels
-- Raise suspension 5mm? (if still crap on race wheels)
-- 2 wheels in boot (for rolling road)
-- Number plate mounts
-- Lap timer bracket
-- Fit mirror glass
-- New race tyres
-- Replace Gearbox
-- Fit rear discs
-- New road tyres (to solve rubbing - didn't solve)
-- Blower Motor Replace
-- Replace Propshaft Center Bearing
-- Indicators (water ingress - front bumper? - take apart and re-seal)
-- Knocking (Propshaft / Rubber doughnut)
-- Paint interior
-- Fix oil leak on front of engine
-- Replace dipstick (current one is not a 320 one)
-- Raise steering wheel (new spacers) ??
-- Raise seat a touch at rear
-- Side trim (rear quarters)
-- Email SD about rollcage
-- Replace / improve gearstick surround thing


--
For Race 1
--
-- Short shift kit
-- Replace safety bonnet stickers
-- Remove pass seat (and weigh - 12kg)
-- Fix safety pulls
-- Cut away bonnet
-- Rubber doughnut (check first)
-- Replace mirror glass
-- Weigh car & get it to min weight
-- Fit 12v socket
-- Fit steering wheel spacer & wheel height
-- 2014 Sticker Pack / vinyls / Black cross sticker
-- Sticker on dash
-- Seat adjustment
-- Resistor on cut-off (for ECU)
-- Rear exhaust mount
-- WD40 Rear Shocks - Free up adjusters.
-- Check brakes (again).
-- Re-adjust harnesses
-- Fit Injectors
-- Fit new hub-cups and caps
-- Fire Extinguisher checkup (Sent to service centre on 26/02)
-- Rear demister screen
-- Replace bleed nipples on front calipers
-- Raise steering wheel (different mounts)
-- Raise rear of seat
-- Speedo drive
-- Rear diff
-- Stalling issue (TPS or Air Leak?)
-- Solve the long-brake pedal (bar thing)
-- Rear bearing(s)
-- Front hub/bearing(s)
-- Weld up rust holes in pass front foot well
-- Video camera wiring (regs mention it)
-- Fit new rollcage padding around driver area
-- Battery in Lap Timer
-- Rear grinding / rubbing noise
-- Front towing eye/mount ()
-- Fit wide rear view mirror
-- Fit high level rear brake light
-- Check battery in lap timer
-- Ensure fitting of timing sensor is OK
-- Check fitting of lap timer thing
-- Fit standard airbox


--
For MOT
--
-- Adjust tracking
-- Fit brakes
-- Fit new headlight bulb
-- Investigate front suspension knock
-- Replace crossmember
-- Replace control arms
-- Fit steering rack
-- Weld boot floor
-- Replace missing wheel bolt
-- Replace downpipe nuts for proper ones
-- Replace gear knob
-- Fit horn
-- Exhaust leak (manifold to downpipe)
-- Move seat forward (Raise seat?) (yes I'm short, shut up)
-- Fit 2nd seat (for test/trackdays)
-- Fit new tyres / wheels
-- Fit number plates
-- Remove numbers
-- Sticky rear brakes

[Altrezia]

8th November 2013

This is how the car arrived on Nov 7th 2013:











As you can see it's tatty, covered in dents, and needs a fair bit to get it 'nice'.

[Altrezia]

9th November 2013

Today I had a few minutes spare so I removed all of the wheels and tyres from the inside, and gave the car a quick look over. I noticed a few extra things to fix, but hopefully nothing too bad.


A 'few' spare wheels and knackered tyres..



Found a big crack/hole in the boot





Engine bay


Need to replace this hose/pipe with a proper BMW air-box for the regulations

[Altrezia]

10th November 2013

Spent a bit of time looking at the car today; finally without rain pouring down.

Things I've done:
Moved seat
Fitted 2nd seat
Removed numbers sticker

The rust/crack worries me a bit and I think it's a bit beyond my crappy newbie welding, so I suspect I'll pay the MOT chap to sort that for me.

Also the boot floor is all bent up - but I don't suppose it matters too much in the grand scheme of things. I'll have the car Geo'd before I take it on track to make sure everything is pointing the right way.

Some pics from today:




















Bent/rusty bits..











Someone likes it, though..


a

[Altrezia]

12th November 2013

Not much to report - removed the tape off the headlights.
Fitted the standard airbox (for the PBMW regs).
Also ordered an exhaust gasket from BMW, which should be there to pick up on Thursday.

[Altrezia]

12th November 2013

Spent a bit more time on the car today. I removed the crappy gear stick, removed the nasty window button mount thing, and wanted to tidy up some wiring.

So far I've re-cable tied a lot of cables, moved some around so they're less tight, and stopped a few things rattling. I've P-clipped some cables in place, as they were just hanging loose in the driver's foot-well which I wasn't a fan of.

I've also added some door pulls so I can close the door without trapping my fat fingers in the frame, and made a new button mount with a new horn push, too.
I re-mounted the lap timer on a stereo blanking plate, rather than using the on-board 'computer' it used to be on (which I've moved elsewhere).

Oh, and I found out what was up with the horn - a broken wire and the horn itself was broken. I've ordered a new horn unit, and fixed the wiring (by adding a button elsewhere, as I don't have a steering wheel horn push anyway).

Still looks pikey, but I prefer it to how it was.

Waiting on a new gear knob to arrive, and I think some grip-tape stuff will tidy the floor up a bit?









a

[Altrezia]

17th November 2013

I picked up a set of 15" BBS wheels (Thanks Paul!) yesterday, and the tires will hopefully get the car through the MOT.

Today I whipped the front wheels off and fitted the new ones.

I then fitted the new downpipe gasket. I found that two out of the four nuts were totally shot and that's probably why it wasn't sealing properly - I had to use a couple of spare nuts I had in the garage for now, and I'll order some proper copper ones when I get a moment. That said, the gasket was knackered too.

I then took the rear wheels off, removed the drums, checked everything over and gave it a wobble and clean, sanded the insides of the drumbs and then put it back together - no more binding rear brakes.

I also fitted the number plates.

I noticed that the steering rack has some play in it, so I'll look for a replacement. Also found that one of the wheel bolts is rounded.

[Altrezia]

That's up to date for now. Also many thanks to Trev who has been a real help in finding me bits and giving great advice.

[SHeap]

Making some very quick progress with this, fingers crossed for the MOT.

I'm currently trying to do the same thing, take a track car and get it back on the road.

Where about in Hampshire are you?

[Altrezia]

Thanks mate.

I am up near Basingstoke. You?
Do you have a project thread? Reading them is the best way to get inspired!

-al

[SHeap]

Not too far then. I'm based in Camberley but the cars in Portsmouth for the time being.

I do indeed, it's in the members ride section (link: http://www.e30zone.net/modules.php?name ... c&t=245050 )

Not much on my thread at the moment as had the car less then a week and not spent any time on it, hoping to spend the weekend working on it though so lots of pics/updates then

Aye members rides are always good for ideas and inspiration, also good at emptying your wallet!

[emdog]

What do you race this in?

[Altrezia]

Production BMW Championship - www.pbmwc.co.uk

[Altrezia]

(Apologies in advance for the following post - it contains graphic photos of awful welding)

Spent today fixing the rusty crack in the boot.

I also replaced the temporary downpipe nuts for the proper ones that I bought online.

Nicky helped out with the car today and started removing the stickers. She got about half way, and there is still loads to remove, but we'll jump on that shortly.


So, the welding. I'm awful at this, but I think I've done a good enough job to get by.

Here is a link to the crack from inside the boot, and from the outside.


First, I cut out the rotten bit, and some of the surrounding area. There was actually a surprising amount of rust, and the crack/bent bits went quite far.





I then added some metal to the edge of the middle bit, as I had to remove a bit of rot from it.



I then made a template for the main hole



And (badly) welded some metal in place



I then popped the bit of metal from under the towing eye back on





Quick view from the inside - you can also see the bit I added to the vertical edge.



I then threw a can of hammerite at it. I couldn't be bothered to tidy it up that much after doing the welding, as it's probably only going to get punted again, and the whole car is rough. That's my excuse for laziness anyway.











Meanwhile as I mentioned, Nicky was removing stickers, and here's a quick snap of the car so far.





I've got a steering rack coming soon, and once I've ordered the tie rod arms, that's the next job.

[B7]

The rack should be with you tomorrow mate. Along with the headlight closing panels and wheel bolts.

Coming along well. That air intake pipe was legendary! I bet it's quieter now!

[SHeap]

Coming along nicely, looking forward to the next update

[Altrezia]

I have now removed most of the stickers. I have left two that I quite like in place - a PBMWC roundel and a small BARC one. I've also not touched the bonnet yet as I'm not sure what I'm doing with that.

After removing the remaining stickers, I set about removing the left over glue, and the dirty outlines. I started by rubbing the whole car with white spirit which seemed to do the job although it took ages - I tested it on a small area first as I didnt know how it'd affect the paint. It didn't do an awful lot really. It took about 2 hours to rub the glue off.

After that, I gave the car a once over with the polishing machine, and then gave it a wash.

The passenger side is totally fubar - and it looks even worse now it's not got stickers on. Is it possible to replace a whole rear quarter I wonder?

Also noticed an interesting clonk from the rear suspension which I need to check out.

Anyway, some pics of the car as it currently stands:

(it looks much better in photos than it does in real life)























-a

[Altrezia]

Two jobs done today

Firstly, I fitted the wide angle rear view mirror.



I might change this later as I'm not too happy with it, but it'll do for now.

Then I fitted the extra high level brake light.





I think the sticky pads will probably fail at some point as they seem to be crap, but I'll think of something better when that happens.

(and yes, I need to do a better job of cleaning the glass after the stickers were removed!)

I also tried to fit the plastic covers that go behind the headlights, but they weren't playing ball as the car has had a racing-knock on the nearside corner and it's bent the inner wing so much that it won't fit the plastic. Fun, as it's a regulation defined requirement..

[Altrezia]

Urgh.

I've replaced the steering rack and tie rods now, but what a pain of a job - at least it's a pain doing it in the rain on a driveway anyway.

Looks like my subframe has seen better days and I suspect I'll have to replace it for the MOT. Great news.

Everything else under teh car (except the actual shell) seems to be horrid and rusty, so I may have to do a full refresh sooner than I had hoped.

At least my steering clonk has gone.

I also picked up a pair of doors, a front valance and a bonnet as they came up not too far away in the right colour. Will fit them at some point soon if the rain ever stops.







a

[SHeap]

Keep up the good work

[B7]

I bet that feels better now?

I've got a solid cross member here if you need one. No pressure, it'll still be here after xmas. That one looks very crusty!!!!

[G-Bear]

Hello Al... Nice little project there..

I wouldn't beat yourself up about the welding... snotty but solid. I went on a short evening course course for welding a year ago.. apart from fixing a exhaust bracket I'm yet to try welding any bodywork..

I funnily enough I fitted a steering rack on my back in the rain this summer.. was on a slight hill so had surface runoff soaking in around my shoulders and back, with constant drips from the front valance soaking into my pants.. nice..

Looking forward to some updates... really want to have a track car now..

Replied to your PM too.

[miniblob]

This looks like a great little project!!!

Also loving the mini & the lotus - shame I'm not a fan of red cars!!!!

[Altrezia]

I am not a fan of red cars either - it's just bad luck that seems to make me buy them.

[G-Bear]

I am not a fan of red cars either...

Neither am I.. but an E30 two door (especially with shadow lines) seems to work in my eyes...

[Altrezia]

Been buying a few bits - new control arms (lemforder) and drop links. Also a 2nd hand crossmember to replace my rusty one. The first bits have arrived and hopefully the crossmember will arrive on Monday so I can get cracking.

Found a bit more rust too - inside the front floors on top of where the jacking points are, so not sure what to do about that really, might just leave it to the MOT guy!

Anyway, the real reason for the post - I can't decide - red bonnet or the chequered one??

[G-Bear]

I'd say the red.. Biased I'm sure. But I reckon the checkereds look a bit too mad max..

[Altrezia]

I attacked the subframe crossmember thing today. I swapped the crossmember with a 2nd hand one bought from Mick (Magpie) and I also bought some new Lemforder control arms and some new drop links too.

Easy enough job really, with no major issues to report - other than one of my trolley jacks failing whilst holding the engine up without any engine mounts, letting it fall down annoyingly low.

Anyway, a few pictures. Please forgive the blurry ones at the end, it got dark!

Old subframe and control arms out


Lots of bits missing!


New bits bolted in




Old bits for the bin


And back on it's wheels!






I guess the next job is to fit some new headlights and bulbs and then MOT the car and see what it fails on.

[rix313]

Looks like an alright little car that mate, it'll do the job! be good feeling when ya finish doing the bits to bring it up to standard and get out there driving

[Altrezia]

2013-12-30

Spent a few minutes doing a few small jobs, and took a quick pic:





2014-01-04

This evening I decided I needed to get away from work for a few hours, and decided to fit the new front valance (which is the right colour), a front splitter (which I had to cable-tie together..) and the red bonnet. The old bonnet was fun, but I wanted to make the car my own.

Took a few hours and I'm not too happy with the way the bonnet lines up at the front, but the car has been through so many bumps in it's racing career that it needs more than a little fettling anyway. It'll do for now. I used the old bonnet as a template for the holes, and I guess it must be more bent than I thought! Ha ha.

Also, I need to stick some MSA stickers on the bonnet for the cut off and fire pulls.

Few snaps in the dark:







a

[Altrezia]

Just been told I can't race with that splitter so I'll find a regular 320i one. Fun

[Altrezia]

I swapped the throttle cable today, and ran the car up to temp to see if everything is running and working OK.

The throttle cable made a huge difference. Before changing it I greased up the old one to see if that would improve it - no. The new one is lovely and light - great!

The car seems to run a bit funky - it hunts all over the place and eventually stalled. I'll have to work that out.

I took a few snaps afterwards too to see it in the daylight. I really need to adjust that bonnet a bit - not happy with it!

[Altrezia]

Quick update with the correct front splitter and towing 'eye' thing, and repositioned (a bit) bonnet..

[bmwsean]

looking good! looks loads better withe the red bonnet

[G-Bear]

Like the red toe strap..