Rotrex M42 Build - 285bhp little update

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e30_Turbo
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Mon Dec 29, 2008 10:12 pm

Most of the companies I do work for are off till next week, so kinda twiddling thumbs today, will take some work in with me tomorrow winkeye

Was hopeing to keep the finish as it is, maybe even a polish if the machine is working, should be easy enough to do any finish, that crackle paint looks good too, I'll just wait to see how many scratches I have too polish out! Too many and I'm joining you. :cool:
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appletree
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Tue Dec 30, 2008 6:42 pm

More progress today on the plenum, got a big hole saw and cut two 55mm holes in the base plate.

The little bit i left at the side of the holes is for a M8 bolt to thread in to the back of the plate of the plenum from the back.
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Then joind them up with the slitting disc in the grinder.

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the view with the plate cut out, the bolts on the inside will be bolted on first before the plenum bolts over the job lot and lock tighted in place, i might even use longer bolts and even up some nylocks on the bits that poke out.

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Next clamped all the way round with mole grips ready to drill the holes and keep everything aligned :D :D

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Holes drilled and a slight downward pointing bend welded on to the plenum, not that neat as when i weled the two joining halfs of the plenum togeather and must have slightly miss judged how big a half was as its ended up at just over 3".

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All trimmed on the edge of the stainless and ally sheet, just need to make a gasket.

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Bolted it on to the car which ment i could weld up a boost pipe for the IC to TB leg of the pipework just need to work out were i want to put the dump valve. :D

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need to make up the plate that the TB will bolt to next, got a peice of 10mm stainless flat bar which i will be able to cut out and then grind/polish it to match it to the plenum and the TB as there very slightly different sizes probly 3" and 2 3/4" or maybe even less :cool:

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M42 Supercharged 285bhp + M3 6speed box
Jon_Bmw
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Tue Dec 30, 2008 6:44 pm

Looks wicked as ever Matt.

Good job you don't have ABS. :)
appletree
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Tue Dec 30, 2008 7:05 pm

not sure i'll be saying that when its up and running :drive: :clin:
Last edited by appletree on Tue Dec 30, 2008 8:09 pm, edited 1 time in total.
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
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hoshy
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Tue Dec 30, 2008 7:35 pm

Loving that dude!
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papercutout
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Tue Dec 30, 2008 10:23 pm

Looks fantastic, I'm still watching this project in anticipation of the finished product! Its going to be even better than before, and it was great then!
Turbo-Brown
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Tue Dec 30, 2008 10:54 pm

He heeee, that really does look fantastic!

Actually I though your last kit looked fookin' awesome too!

Oh dear, I fear I might have to go back and re-make some stuff just to keep up! :D
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www.air-in.co.uk free M20 exhaust and inlet flange
appletree
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Tue Dec 30, 2008 11:07 pm

LOL


If you do i will :tongue: :notworthy:
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
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DieselMeister
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Wed Dec 31, 2008 11:00 am

Simply awesome :thumb:
"Pass me the wheel before you hurt yourself, mate."
Phill172
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Wed Dec 31, 2008 6:14 pm

Looking fantastic, can i use the same rad as you on the 2.5? Saves so much hassle having the expansion tank on the side!

that setup really is a work of art

i need to be able to tig :cry:
appletree
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Wed Dec 31, 2008 7:20 pm

Think it would mount ok as it uses the same mounts but i dont know if it would hold the pressure or hold enough water??? Spose the issue is really the surface area available to disipate the heat.
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
appletree
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Fri Jan 02, 2009 9:07 pm

turned this up this morning, ready to be welded on to the boost pipe to mount the dump valve.

As i bought the dump valve with the 38mm fitting kit i made a new stub out of 1 1/2" dairy pipe and machined a grove for the grub screws to lock in to :D

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Filed the bottom to make it but up to the boost pipe :D

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Hole sawd the middle out and then welded the pipe on.

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Polished up with the dump valve ftted :D

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Next machiuned out the stainless plate to weld to the manifold for the throttle to mount on to, as the throttle was just alittle bit smaller than the 3" bore of the manifold, hopefully it will make it flow well :D

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Welded the plate on along with a small plate to work as a mount for the throttle cable to pull against just need to round off the plate and polish it up :D

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Also welded this plate on to work as the pressure/vacume take off for all the various sensors.

Dump valve
FPR
IVC
MAP sensor
Temp sensor
Boost gauge
an some more i forgot....

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Here it is all bolted up and polished, still think i'm going to crackle black it.

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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
shalmaneser
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Fri Jan 02, 2009 10:33 pm

Woah! Awesome fabrication there!

Bet she'll go like the proverbial, nice smooth bends, you've clearly given a lot of thought to airflow, great to see such attention to detail!

Good luck - hope she goes as good as she looks!
vinni
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Fri Jan 02, 2009 10:51 pm

Looking good, keep up the good work :cool:
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cliffybabe
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Sat Jan 03, 2009 12:08 am

looks wicked dude :cool:
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Considering Selling the Cabby, looks like its gonna go
rix313
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Sat Jan 03, 2009 9:30 pm

@Matt: re previous discussion, my radiator is a Nissen's rad
magpie
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Fri Jan 09, 2009 4:55 am

brilliant work,,,nice to see it all on the m42,,this will fly. 8)
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m52 b30 stroker 6-speed 318is Galvanizer
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+ a yard full of scrap turds :)
rix313
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Sun Jan 11, 2009 1:13 pm

Matt quick question.

When you put the new engine in that you bought, what did you do with the old one?
GrindCulture
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Sun Jan 11, 2009 1:41 pm

:eek: I only wish I had your fabrication skills, this will be one hell of a car when it's done! My hat is well and truely off to you sir!
Not in E30s any more :(
appletree
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Sun Jan 11, 2009 1:55 pm

Thanks grindculture is it you with the same name on the m42 club? id guess it is :D

Dont under stand rix, this is the origonal engine that the car has always had. i bought a spare one to mock it up on last time and that is now getting built up for this one lower comp and forged.

What do you need? ive got 4 heads and 3 blocks ( 3 complete engines + the one in the car) :mad: :mad:
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
rix313
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Sun Jan 11, 2009 5:23 pm

Oh right I thought you built it up on the new one then dropped it all in didn't realise you did that.

I'm after a good new engine.
GrindCulture
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Sun Jan 11, 2009 5:25 pm

appletree wrote:Thanks grindculture is it you with the same name on the m42 club? id guess it is :D
Yeah I'm on there every now and again getting my fix and pretending I know what I'm on about :P
Not in E30s any more :(
e30_Turbo
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Sat Jan 17, 2009 5:22 pm

Getting there:

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Managed to tack most of it, will finish it tomorrow and mark out the plates top and bottom, made the airline take off plate too, learned a few things doing that! slow and steady drills the holes without burning drill bits, cutting fluid helps too, still my pillar drill is the nuts! :D
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appletree
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Sat Jan 17, 2009 5:33 pm

thats going to look the dogs bollox when its done, its quite long isnt it guess its going to get to just past your old dump valve take off judging by the pic in your sig. :cool:

And its got to flow better than the 90 bend in the current set up, cant wiat to see it finished :D
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
appletree
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Tue Feb 03, 2009 8:56 pm

Bit more progress over the last two weeks or so firstly i finished off making the tesioner, ive used an E36 m43 idler pully which also donated its crank pully to make the charger pully so its should be rated at the same sort of rpm/power.

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Trail fitted the inlet manifold today and worked out were the FPR will fit, fingers crossed it wont be need after its mapped and it will run fine on the 3bar reg but it gives me the option to play about if needed.

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Made this plate to bolt up to old air box mounts so that i can mount the supercharger oil resivour of it, it right next to the charger so the pipe length to the supercharger oil pump is kept to a minimum which is good.

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Made a plate to mount on the old throttle pot bolt holes with the large plug and now fitted the newer smaller throttle pot with the now normal plug on it.
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Nothing realy major but i decided to paint the charger bracket silver just to stop it going rusty and looking crap. need to sort out the wiring for the oil temp and pressure sensors to now i can get there. :D
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Somthing that i was never realy happy was the old oil resivour i fitted from the suzuki swift, it did a job but mountd off the strut brace it looked naff and the pipes were in the way.

Found my old origonal one cleaned it and refitted it and replaced the low fluid level switch, always nice to know youve got brakes :D
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Mark, that inlet looks great in the other pics you sent, keep emailing you back but 3 days later i get a Email not sent warning! god knows why. Any more news on it by the way?

Would a 540 throttle be any good to you? its around 82mm, fits over a 3" pipe anyway with alittle to spare.
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
rix313
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Tue Feb 03, 2009 9:03 pm

I was wondering when the next installment would be looks awsome. Got any of the whole engine bay with it how it is atm?

I've hit my brick wall atm rattled on how the S/C is going to go.

You should recieve the slab of ali tomorrow mate :)
appletree
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Tue Feb 03, 2009 9:49 pm

Cheers, might get chance to do it tomorrow as ive got the afternoon off, or at least get some of it done.

i'll get a bay shot next time its altogeather although its in bits at the moment as i'm siliconing all up with my new gaskets.

just got the dip stick and the oil cooler to get in place then its near enough ready for a test run, engine only though as the lights and stuff need doing before it can go on the road. :D
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
appletree
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Tue Feb 03, 2009 10:03 pm

Just done a little more, got my injectors back from being cleaned at Emerald and fitted them to the inlet manifold.

They were £30 and are from a rover 620i but they are also fitted to other rover trubos like the 220.

Cleaning From emerald with new lilters, tips and o-rings was £15 each

For any one intrested there 440cc at 3bar or 460 at 4bar fuel pressure.

Part numbers on the injectors are
MJY100460
D3184GB
0646

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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
rix313
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Tue Feb 03, 2009 10:24 pm

460 cc blimeymight as well use a pipe lol

You cooling the engine oil?
appletree
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Tue Feb 03, 2009 10:35 pm

Not yet.

A can of carlsberg a minute! :cry:
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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
e30_Turbo
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Wed Feb 04, 2009 8:13 pm

Looking good!

Inlets stuck in progress, have been advised I must have a radius on the inlets in the manifold, so I've looked into flaring the runners, no go, so spoke to a machinest who quoted me 50 for 6 mild steel radius tops that will slide over the runners a give me what I need. My only other option is to start again with ali tube and a 20mm thick plate and have the runners radius edge milled in but I find ali is quite aweful to work with, I need more tools!

That TB sounds ideal, 540 you say?
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appletree
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Wed Feb 04, 2009 8:32 pm

ya, i'll get some pics for you. :D
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M42 Supercharged 285bhp + M3 6speed box
appletree
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Wed Feb 04, 2009 9:32 pm

Few bay shots for you Rich.

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Little more progress, got the bracket for the resivour mounted on the plate i made, used some rubber mounts to holed the plate to the airbox mounts so that i can pick up on the other stud to make a flexible mount for the inlet pipe so it can rock with the engine.

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Also got these hose tails fitted today, the inlet is now fitted all sealed up and ready to go! :D

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TB pics for you, it mahooosive! think the palte bit could be machined down easy to make it more managable. its actualy two Tb's one normaly open and one normaly closed, is one the traction control? you dont need both for it to work, its a 540 one ya E39

what size trumpets do you need?


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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
appletree
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Wed Feb 04, 2009 9:42 pm

Mark i can get these from work, there very nearly a trumpet shape and would weld streight on to stainless pipe, they come in 1/2" sizes but you could just open them up abit if your runners are a different.

Might be worth a punt. :D

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You should never underestimate the predictability of stupidity

M42 Supercharged 285bhp + M3 6speed box
e30_Turbo
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Wed Feb 04, 2009 9:50 pm

I'd say that was pretty big too, that bend will be awkward to make work, the other looks nice and small, will need to see where the outlet sits in the engine bay before making a decision.

I need trumpets for the 50mm pipe you sent me, was told it wouldn't flare very well.
Last edited by e30_Turbo on Wed Feb 04, 2009 9:53 pm, edited 1 time in total.
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