Twin Seq. Dry sumping for beginners :D

[NK]

A friend of mine took 330i's corresponding forged pistons and con-rods plus the crank. He machined the 325 block to fit these things, and replaced his camshaft with the 525e camshaft.

Then fitted a T61 turbo and Dicktator Fuel management system!

The Car is just damn fcuken fast, i really can't explain that, but he doesn't want to do it on mine, right now his is the most powerful in Botswana.
He is a mechanic and am not!

I am trying to find something more deadly than his!

[Gunni]

525e camshaft?

[Turbo-Brown]

Sounds impressive! Wonder what gains he could make with different ignition timing


Got one of those jobs I've been really putting off done today. Modded the block to accept the M52B28 crank. I've got a VANOS crank so the webs are all over the place and foul a couple of things. Easily sorted, although grinding things in the block isn't synonymous with the clenliness you'd like to have around your crank!

Here's our block, an M20B20 which I think had done about 150k or so, can't really remember!




The crank sitting in the block, unable to turn due to obstructions at the crank case breather and jackshaft rear bearing.




The solution at the crank case breather having ground away enough material to give about 1mm clearance:




And the same kind of thing at the jackshaft rear bearing. Need to remove a fair amount of material here to gain clearance: (sorry, the photo doesn't really show anything!!




And here are the tools I used to do the job: An electric drill, a pair of goggles, ear defenders, a little grind stone mouned on a long M8 bolt, and a cutting disc from an angle grinder again mounted on an M8 bolt.

The little stone was used on the breather, the cutting disc was used to tackle the jackshaft bearing:




Here's a random pic of the flywheel on the crank:




Will call the machine shop during the week and see if I can't get my bits booked in. Need to get the manifold skimmed flat too!


Lastly, here's a couple of pics of the exhaust downpipe. First time I've put it together off the car! Doesn't it look strange, the route it takes?!

Oh well, it fits and that's the main thing

[JazzMan]

That flywheel looks nice. Not masses of changes needed to make that crank fit, that's good

[Gunni]

And that´s even the hard 2.8 crank to install.

[Turbo-Brown]

Think the work itself took about 40mins, the rest of the time was spend finding grindstones and bolts, washers and the like to actually shift the material

I was under the impression that the non-VANOS crank would drop straight in, is that right?

Really I just jumped at this crank as it was dead cheap!

[Gunni]

That´s what has been posted in this forum section so far by the others that have done a 2.8

[Phill172]

alex sent you a pm a while ago about picking up the exhaust. Havent heard anything. Sorry its been so long! Give me a buzz or something. Thanks mate

[Turbo-Brown]

Oh, sorry dude probably thought I'd answer it later and forgot!

Sorry about that mate!

Not around next weekend, but can do the one after if that's alright.

[Andy335Touring]

Can you tell me where you get your C/F supplies from please ?

I wouldn't mind making a few bits, how do you drill C/F and get a nice clean hole or a hole that won't weaken the area around the hole ?

[Turbo-Brown]

Yeah, it all comes from these guys, who I'd whole-heartedly recommend as their service is superb!

http://www.ecfibreglasssupplies.co.uk/store/

Haven't had to drill any cf yet, only saw and sand it.

With the sawing, the key is to put absolutely no pressure on the blade at all, make sure it's sharp, and keep it moving fast. I'd guess that increasing the rake angle on your drills and running them good and fast with minimal pressure would give neat holes.

Just been in out to start fitting the ali hinge and lock carriers to the reinforcement bits of the boot. I don't really wanna rely on rivnuts straight into the laminate or anything like that as I reckon having large load spreaders is the way to ensure the laminate doesn't get damaged in daily use.

[Phill172]

No worries mate! Can i do the whole speech of I left it so late to pick up so I can have a sneaky gander at your new one!

Been reading the thread again....and wooow! Make me c/f goodies!
Its looking awesome

[Andy335Touring]

Cheers Alex

[Turbo-Brown]

Okay, the block and exhaust manifold have gone to the machine shop!

I'd forgotten just how heavy the blocks are when you're shifting them about on your own, and it seems that in 1993, BMW hadn't reached the idea of lowering the lip into the boot of their cars, so you have to lift an engine block (or your shopping) right up to get it in the boot

Also made the new gear lever today. I liked the old one I made, but it was a bit light weight and the sun used to reflect off it into your eyes, so this one's made from solid stainless steel instead of ali, and has a brushed finish instead of polished.....well, that's one reason it has a brushed finish anyway.

Unfortunately the batteries in the camera died before it was finished so there's only a pic of the component parts. Gonna wait until I know the angle of the gearbox before welding the bit on under the ball joint as someone mentioned that the angle of the lever is different with the 525tds 'box compared with the 325i one and I really don't want the lever to be on at some strange angle!

[Phill172]

Sorry alex dont mean to hijack your post, come up sometime this weekend to collect the exhaust?
send me a pm or something and well sort it out, thanks!

PPC, heroic magazine

[Turbo-Brown]

Hey Phil, Sorry dude, I'm in Amsterdam with work from tomorrow.

Can do the weekend after though

[Speedtouch]

Work eh?

[Turbo-Brown]

[Phill172]

haha, if only my work would go to the 'dam, sure buddy, no worries, give me a shout when you back! Have a good one!

[Turbo-Brown]

Minor update....I've ordered a cam by way of some retail therapy.

It's a catcam 1300533.

Gotta pull my finger out and look into what material to make rocker pads from!

[Phill172]

Hey Alex sorry to hijack the thread again, not sure if my pm side of things is working.......

Wondering if i can pick up the exhaust today/tongiht/tomorow/tomorow evening?

Let me know!

[Andy335Touring]

Are you making your own rockers then ?

[Turbo-Brown]

Phil, I'll send you a PM with my moby number if that's alright dude? I'm currently car-less (despite owning four fecking cars!) as my latest aquisition loses all it's coolant for some reason!

I'm planning on making some rockers if I can source some material to make the follower end from. It's gotta be machinable and then hardenable.

[gareth]

how hard do you need alex? we use stainless steel 431 at work for making loadcells. fairly cheap martensitic stainless which when heated to cherry red then quenched (big blowtorch will do) will harden to around 40-44 rockwell C. very strong too, UTS around 1250N/mm². similar to a grade 12.9 bolt may not be quite hard enough though...

if you need anything hardess tested for a comparison, i have a harness tester at work and will happily make dents in things for you

[Turbo-Brown]

Oh that'd be awesome Gareth, could I send you an old rocker arm for testing?

It's just the follower pad I need testing, seem to recall reading that it's chill-cast iron....but I've no idea how hard that'd be!

Don't suppose anybody knows if cast iron is hardenable do they?

[gareth]

course you can matey, i'll pm you my address.

[Turbo-Brown]

Cheers dude, will probably be taking a head apart next weekend so I'll pop a rocker in the post then if that's cool?

Have had a bit of a weekend of finishing things off (and taking pics with the phone as I forgot my camera!)

Had a quick trial fit of the plenum before comitting it to carbon fibre. All looks to be well clearancewise, the bonnet even shuts believe it or not! Have decided to bond the outlet trumpets, IACV spigot and dump valve outlet on after the bulk of the plenum has been formed.






Also finished the dump valve off properly. It doesn't look any different than it did a few months ago, but now it has a spring and a spring guide inside, a piston ring (which actually seals! ) and a little pipe connection on top




Spent about four hours today making a pulley for the vac pump. The original pulley was tiny which is presumably as the pump came from a diesel engine which didn't rev very high. I'm aiming for about 7k with this engine (maybe 7500rpm actually) so I reckoned a bigger pulley was gonna be needed.






Lastly, I've been making a gauge pod for the oil pressure, boost pressure and AFR gauges during the evenings. Just needs a trimp over on the right hand side to fit the E30's binacle, holes for the gauges, a sand back and laquer and it's done

[appletree]

Good work on the pully! looks like you've done a good job

O/T do you know if BMW ally castings (inlet) are easy to weld to by anychance???

[Turbo-Brown]

I've no idea Matt, I've only welded cast ali once and that was the end tank of an intercooler.

[shalmaneser]

I've posted before, and once again have no guidance or advise, other than to say that this is such a fricking sweet project and I wish you all the best!

Makes my monday logging onto this and finding out what you've been doing over the weekend while I've been drinking beer and falling over!:roll:

[Turbo-Brown]

He hee, cheers dude! Much appreciated

Right, not gonna have much chance to get anything done this weekend, but my Dad and I are planning (finally!) to build a bench to put the milling machine on this Sunday

Hopefully this'll mean I can easliy get on with the throttle body linkage, brake caliper brackets and the like. With any luck, I'll be able to machine the exhaust manifold flange flat.

Picked up the adaptors which fit the E36 front hubs onto the E30 legs so I'll do my best to get some piccies of the setup too

Should be able to pick up the block from the machine shop next week apparently so I can start to build the engine up too. Really looking forward to doing that!

[jaistanley]

E36 hubs onto E30 legs? Sounds interesting. Do you mean the spacer type thingy's that allow an E36 wheel bearing and hub to go onto an E30 stub axle? Have you machined them for E30M3 offset or for E36 offset?

The other way (if you can find the parts cheap) is get hold of e36 M3 evo hubs, TCA's and struts. I have deducted after ages of specs trawling that the Evo hubs are the only ones to use.. The normal E36 hubs have a different KPI.

I've seen E36 struts shortened and a thread machined to accept E30 dampers, they were quite cool.

[march109]

Jai - allready spoken to brown about the hubs the offset is waaay off, are you on e30tech? theres more info there at: http://e30tech.com/forum/showthread.php?t=48607

[Turbo-Brown]

Must admit I'd not really looked at the offset of the hub flange as I always planned to just adjust the offset of the wheels themselves.

Didn't get a chance to play with the new hub adaptors this today unfortunately, but I did buy a car to replace the piece of shit touring I bought which has suddenly developed a blown head gasket (I'm now the proud owner of a sewing machine (Honda Civic 1.8VTi ) ) and having done that, went to my folks' house to build this:



with my Dad. It's been a long time coming this bench, and we need to remove the shelf above it so that the drill press and mill can be moved back a bit and bolted down, but having a mill means I can easily machine the manifold flanges flat, make brake caliper brackets, gear linkage parts, the throttle linkage....basically all the things I've not wanted to do using cobbled together attachments for the lathe

[Phill172]

just had to