Project: M30 335i Touring (Maybe now an S38)

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steve_k
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Sun Aug 05, 2018 7:41 pm

excellent thread, will be keeping my eye out for this round the county.
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lellis
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Sat Feb 23, 2019 6:47 pm

Well, this has been a long time since I have updated this, mainly down to as always, not much progress..

Unfortunately for my e30, I've been getting a bit too into these switches and for a while now it has been pretty full on.

However, that means I have finally started selling these new units, they're able to monitor oil or coolant temp to a much more accurate level compared to the cluster gauges.

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It has taken me over 4 months of testing and prototyping to get to this point, but I am very happy with the final product.

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Message me if you're interested :banana:

Back to the project, I haven't really been in the mood to finish this any time soon recently. Mainly due to the huge amount of tasks left to do, it becomes so much where you don't even know where to start and feel like doing one part won't exactly help the process.

But I bit the bullet and decided to send my big engine parts off for vapour blasting.

Putting my touring to good use.

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Then, here are some comparison pictures.

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So all was going well, until I found this:

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One step forward, two steps back. Have passed it on to a specialist who will give me their verdict next week.

Great.
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lellis
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Sat Feb 23, 2019 7:19 pm

Till I find out the news on my block, I've decided to start painting engine parts. Mainly to stop be from throwing everything in the bin and locking myself in my room for an eternity.

So only photo I have of the rocker cover when I got the engine is this

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First, I spent a couple evenings wire wheeling, de-greasing and paint stripping the cover.

Next was to remove the AFM mounts, this is because I'm using a flipped inlet manifold so they won't be needed.

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Then I filled the rest and sanded it all done, ready for primer.

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Primered

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Then used VHT wrinkle paint,

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And I am SO happy with how these bits came out! I still have to shave off the BMW part but I will let it set for a couple of days.

Also did my mates TDS rocker

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Turns out I have this car in my garage too? Can't remember it being here..

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E30 335i Touring - In Progress..
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lellis
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Thu Mar 14, 2019 8:00 pm

Right, I may have made a slight investment..

My M30 block was still with the engine specialists and they weren't crazy happy with the condition of it. I was advised to start looking for another block, just in case it doesn't work out for them.

So, I noticed an S38 for sale. Obviously I had a quick look at it, had a dream over it then got back to searching. I couldn't find anything for sale M30 related that I was looking for, whether it be too far away or just astronomically priced..

So I had another look at the S38, passed it on to my friends, and they didn't exactly say no. A couple days go by and I bite the bullet and contact the current owner, I have a long chat about it and he says that the bottom end started to knock so he removed the engine and replaced it, it has been dry stored for 4 years and he pretty much forgot about it.. He explained that he can't guarantee the condition of the bottom end but the sale was for the top end, it just came as a complete item.

Luckily he was only an hour away from me so I decided to go have a 'look' at it.

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I wasn't able to really check any of the internals, but I knew that if it wasn't salvageable, I could make my money back in parts.

Soooo I put a deposit down for it, to collect in a couple of days.

It was a pretty tight fit in a Ford Connect..

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It was a long night but we had to see what it would be like when it's in place

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I forgot how big these engines are.

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Now it is time for me to strip it down and see if I can actual save it, I am really not fussed about how long it will take.

Is there anyone out there with an s38 swapped e30? I can't seem to find many in the UK, would be great to talk to someone about them.
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SeanOB
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Fri Mar 15, 2019 9:46 am

8) ooooh that is cool. I hope the S38 is salvageable!
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Steve
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Fri Mar 15, 2019 9:58 am

Yup, very cool, fingers crossed for the engine.
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lellis
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Fri Mar 15, 2019 1:52 pm

Steve wrote:
Fri Mar 15, 2019 9:58 am
Yup, very cool, fingers crossed for the engine.
SeanOB wrote:
Fri Mar 15, 2019 9:46 am
8) ooooh that is cool. I hope the S38 is salvageable!
I'm trying to keep my calm and not get too excited just yet.

Will be stripping it down early next week, so I'll either post the outcome on here or make a for sale post haha!

Thanks for the comments 8)
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TurtleDesignTech
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Fri Mar 15, 2019 3:14 pm

SeanOB wrote:
Fri Mar 15, 2019 9:46 am
8) ooooh that is cool. I hope the S38 is salvageable!
Me too. Could turn out quite epic!
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lellis
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Wed Mar 20, 2019 12:46 pm

Quick update;

Started on the strip down the other night to assess the cam and crankshaft situation.
Seems like one of the middle conrod caps had actually come off whilst driving, it has beaten up the journal quite bad but nothing toooo crazy (I hope).
All the other main and conrod journals are good with no apparent wear, so it can't have been oil starvation as first thought.
Seems to be a slight bit of pitting on one of the cam lobes, this will need to be looked at too.

My question is, if repairable, would it be possible for me to just grind down the one damaged journal and fit the thicker bearing, or due to the balance of the crank will I have to have them all ground?

I need to get a micrometer to check the dia of the journal first anyway, hoping to get the head off tonight to inspect the block, head and cylinder walls too. Will update the thread with pictures soon..

Help from anyone with experience on this would be greatly appreciated.
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lellis
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Mon Apr 01, 2019 10:14 am

Is there anyone out there who has worked on s38's who can give me some guidance with the strip down of it?

I spent a long night last week trying to get the head off to inspect the whole engine however we came across an issue.

As it has a kind of two head system, we started by removing all the bolts holding the top head to the lower one, but we could not remove it. We did leave the cams in place, and i'm wondering if that by leaving them in place, due to the valves being at an angle, you cannot simply lift the head off without removing the cams and shims etc.

Is this right? any help would be greatly appreciated.
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BMW_E30vert
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Wed May 22, 2019 5:47 pm

Any update with this? Really interesting read, you have probably worked this out already but cams will have to come out to remove head.

I’m going to be rebuilding a s38b38 this summer so have been researching a lot lately here are some helpful links if still needed-

https://www.bmwtechinfo.com/repair/main/741en/index.htm

http://www.mwrench.com/Whitepapers/torqspec.pdf
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lellis
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Wed May 22, 2019 8:54 pm

BMW_E30vert wrote:
Wed May 22, 2019 5:47 pm
Any update with this? Really interesting read, you have probably worked this out already but cams will have to come out to remove head.

I’m going to be rebuilding a s38b38 this summer so have been researching a lot lately here are some helpful links if still needed-

https://www.bmwtechinfo.com/repair/main/741en/index.htm

http://www.mwrench.com/Whitepapers/torqspec.pdf
I was planning to update my thread this evening hah! what a coincidence.

Thank you for the links! The engine is now fully stripped, it has some issues though..
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lellis
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Wed May 22, 2019 9:08 pm

Been a while yes, there has been progress but i've hit another issue.

I got some assistance from an s38 guru about the strip down, and got it fully stripped for inspection.

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Got the head off after a lot of head scratching.

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So as explained before, I suspected the conrod cap came off on piston 4 when it was running. And i'm even more certain now, the piston is broken on the edges from the valves hitting it, but no damage to the cylinder bore and the valves so far don't look too bad.

All the other bearings are in pretty good condition, there is some scores on the other bores, probably due to pieces of the conrod bearing and piston..

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With everything in the house now (two stripped engines and many e30 bits in my spare room is not how I expected it to be used) more photos to come
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lellis
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Wed May 22, 2019 9:16 pm

Annoyingly, the engine is in pretty good condition apart from these 'slight' issues.

The plan was to either go for it if it's worth it, or sell it off. But can I really let an s38 go after all the stuff i've watched on them? Definitely not, s**t.

I got some pictures of the damage to the crank

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I've spoken to three different companies now about attempting to fix the crank, to either weld it up, metal spray or grind down and custom bearing being made.

Every one hasn't been tooooo optimistic about it, but it's not like the crank is readily available (within price range), so I really need to get it fixed. The main issue is that they're saying it will be case hardened, so this has to be undone for welding then re hardened.. Big job

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Hard to look at it as the rest of it is in such good condition!

P l e a s e, if anyone has any experience with getting cranks repaired, know someone who does it, or knows a better solution, message me!!

For now, I've had a 'break' from the engine, and have concentrated on getting my engine bay built, photos to come.
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lellis
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Wed May 22, 2019 9:36 pm

So whilst getting through my procrastination period, I've started back on my engine bay. Depending on how much of this thread you've read, I'm going for a smoothed/shaved/tucked bay, not everyone's taste, but it is for me.

After an absolute fiasco with my welder, I got it going again and got started, I had a free weekend and a mate spare.

I started by finishing off/cleaning up the side which is already tacked in. Fully welded it in, filled in a few holes and ground it all 'smooth'.

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My ebay dremel bits died on me pretty quick, so it's not fully ready yet. They're on their way.

Started work on the other side

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A lot of CAD (cardboard aided design) went down to get this in. Tacked in place

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Luckily, my friend restores train coaches everyday, so when it came to making a piece to replace the rust, he took his skills (aged 22, but uses imperial??? Weird) and produced this piece out of one piece. Unreal.

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Got it tacked in place

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Then I started to weld it in place, then ran out of gas for my MIG. So that finished off the weekend, but I'm really happy with the progress.

I gave it a coat of primer and locked it all back up.

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The next day, I decided to do some more grinding and actually pulled the car out the garage for the first time this year.. I forgot what it looked like

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That's all for now, kinda cool actually breaking the mental barrier and making progress on what seems a never ending project.
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steve_k
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Wed May 22, 2019 10:14 pm

Aside from the engine drama it looks to be coming along nicely.

As for the crank, might be worth having a word with byron (maggspower) on here see if he can give you any advice.

Can't hurt to try.
if it's got t*ts or wheels it's bound to be trouble...............prove me wrong.
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lellis
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Wed May 22, 2019 10:49 pm

steve_k wrote:
Wed May 22, 2019 10:14 pm
Aside from the engine drama it looks to be coming along nicely.

As for the crank, might be worth having a word with byron (maggspower) on here see if he can give you any advice.

Can't hurt to try.
Thanks! I'll send over a pm tomorrow to him.

Wish there were more people in the UK working on s38's, I also haven't found anyone with an s38 swapped e30 in the uk yet!! I have so many questions to ask haha
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Acaciastrain360
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Thu May 23, 2019 12:39 pm

I have one!!








Not really, sweet thread though :)
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