My 320ise S62.

[turk]

Prop is looking good. I need to grab their details off of u as I have 2 which need to be made.

[GermanGorilla]

Hi,

Yes E36 325 TD Propshaft is good
for the 5 Speed Getrag and the
6 speed.

No good for S65 or S85 as they have
a larger and deeper Gearbox Spigot output flange
that can not be swapped due to the
clearance required for the gearbox remote
selector.

Regards,

The Gorilla.

[davethegoat]

Thanks again Germangorilla. That's handy to know.

I went to fit my prop today, but the centre bearing I was sent is incorrect.
I've got another one coming out to me in plenty of time for it to stop raining... This drought really sucks donkey plums. I might turn the car upside down and turn it into a boat!

[davethegoat]

Well well, the sun finally came out, so I got on with a couple of bits and pieces (at last!).

The correct centre bearing turned up today, so I test fitted the prop. I had a bit of a jiggle about with the engine and gearbox mounts, elongated a few holes, and now have the engine and 'box within a millimetre or three of being in line. :


Over the last couple of days, I've been on the verge of ordering some silicone elbows, 45 degree aluminium tube and some other odds and sods to make up an induction kit. I've looked at squeezing the standard airboxes in before, but thought (for some reason ) that they wouldn't fit.
Anyhow, with a bit of chopping about, it looks like they will. :


I had to cut down the maf holding pipe a little to get the right side in and even with the left side. I think with a bit of tidying up, they should look ok! :


There's a funnel which protrudes horizontally into the airbox lids which I'll cut down to accept 90 degree elbows. I'll pop K&N filters on the end of those. Standard panel filters would have been mega convienient, but seeing as the front corners of the airbox and lids are now missing, They wouldn't seal awefully well! (unless I can find similarly sized filters with the corners "missing") :


You might have spotted that I've also made a mount for the oil filter. I'll get some pics up when it's finished.

Cheers! Dave.

[turk]

looking good! What are the inside of the air boxes looking like? Cramped?

[glenn]

looking good dave

did you remove the engine? or was it already removed for you?

[davethegoat]

I've only had to remove the front outer corners of the lids (which were square) and airbox Turk, so they're not actually too cramped! I'll get a pic or two tomorrow (if it's not pi$$ing down) with more detail.

Cheers Glenn. The engine was already removed, but I got a few bits and pieces thrown in with the deal.

[davethegoat]

Here are a couple of pics of the airboxes Turk.
The one one the right is (obviously) uncut here:


Another:


From the top:


I also took a little off the bottom of them too after I took these..

Bonnet closure was a little worse than tight where the MAF pipe routes over the top rad hose, so I cut the MAF holder part out and cut a disc out of the round part of the piece of diguarded airbox.:


Here it is bonded in place:


I spent a bit of time playing about with the old panel filter which came with the airboxes. I never planned on using this filter, which turned out to be a good thing as I miscalculated measuring it up by somewhere close to half a mile!


I'd like to use cut down standard type panel filters as they flow pretty well and are cheap, but I'll more than likely end up with a pair of K&N's as they'll cope better with the $h!te weather better.

I'll knock up some fitting brackets when I get a chance.

Cheers! D.

[Jonsku]

Looking good. you're going to "plastic-weld" the intake boxes also?

Yes E36 325 TD Propshaft is good
for the 5 Speed Getrag and the
6 speed.

Ummm.. 5-speed and 6-speed gearboxes have different diameter flanges on the gearbox side, so there is no way that propshaft would fit with both of them. With 5-speeder it is ok, but the 6-speeder has the larger "hardy-scheibe".

[turk]

Whenever I have done 6 speed conversions (on 6 pots) I use an e46 auto front prop, fits perfectly with e30 rear end.

Looking good Dave. Looking like we are nearly ready to fire the turd up

Has an exhaust appeared yet

[GermanGorilla]

Hi,

Quote-

''Ummm.. 5-speed and 6-speed gearboxes have different diameter flanges on the gearbox side, so there is no way that propshaft would fit with both of them. With 5-speeder it is ok, but the 6-speeder has the larger "hardy-scheibe".

The 5 speed dog leg Getrag I have fitted to
my E30 M3 uses the E46 M3 'Doughnut'
that was originally fitted to the 6 Speed [E46 M3]
and then to the Drenth Sequnetial before I reverted
back to the 5 Speed Getrag.

The E92 M3 [S65] uses a larger Doughnut.

Regards,

The Gorilla.

[davethegoat]

I was going to enclose the airbox and lids, and use modified panel filters Jonsku, but I was a little concerned with what effect driving in the rain would have on the (paper) filters. I thought about running some flexi pipe down below the airboxes (via a hole in the panel which they sit above), but space is a little too tight and it would have involved more work.
I might well leave the front of the airboxes open, perhaps with some mesh to stop small dogs, children and such finding there way inside. I'll take a few pics when I get the filters etc. I'd appreciate some feedback/ideas.

I wish an exhaust would simply "appear" Turk! Half of me is really looking forward to getting stuck in, the other half is bloody dreading it! I should be ordering the bits and bobs that I'll need to make one next week.

Anywho, today I spent some time making up some airbox brackets. This one for the left hand, rear mount:


This one for the left hand, front mount:


I've finished the right hand, rear mount this evening, so just the one more mount to make (thank ****! ) Making stuff like this takes (me) bloody ages!

Here they are fitted:




Cheers! Dave.

[Andy325i]

Where have I been for last 6 months????

AWESOME AWESOME project! About to sit down and get reading

Keep it coming!

Andy

[davethegoat]

Thanks Andy!

Comments like yours really help with enthusiasm. I've now been topped up enough to get the last airbox bracket sorted!

Cheers! Dave.

[GermanGorilla]

Hi,

When I had the E39 M5 different
Car same engine the std Intake was
changed for Carbon Dynamics Air
Boxes set down low, each side.

With these fitted the engine was constanlty
going into limp mode and more strangely
the Exhaust Cam sensors were always
throwing a fault

Code: Select all

 which again would
mean Limp mode.

These were then changed for a Intake 
set up from the States from a company
called ''BeastPower'' and it did not change
much.

Then the ITS was Piggy backed but still not
much change.

In the End went back to the std Boxes\Filtres
and the car was fine again.
Well as fine as E39 M5 can be.

I was going to then go Alpha N type arrangement
but that would have made the Warranty Void.

Point of all this waffle is that the S62 likes 
its air unfettled, so if your retaining the dual MAF's
then its something to consider.

Regards,

The Gorilla.

[davethegoat]

I've heard of a few problems to do with the standard M5's induction being modified GermanGorilla, including (as no doubt you know) the MAFs sending the ECU false temp readings due to them getting warmed from the outside.
Hopefully I'll avoid the worst of the problems. Mine will be running Alpha N.
I worked on trucks years ago. A customer once asked me what warranty came with the work I'd just done on his truck. I told him "5,000 miles or 5 minutes, whatever comes first" It took a few seconds for the penny to drop.
Seeing as I'm underwriting my warranty, I've decided that it won't be invalidated.

Did you get any meaningful power gains BTW? K&N claim 20bhp gains on their S85 induction kit IIRC. Sounds like you went through a hell of a lot of grief and expense to make your car run worse! How these companies sell products which work so badly is beyond me!

[turk]

AlphaN is defo the way forward! I cant wait to get this beast to fire. Hopefully it'll push me to get off my arse and crack on.

Welding is looking pucker as usual too ;)

[GermanGorilla]

Hi,

In the real world if you gain a
few ponies with any Intake mod
your doing well.

AlphaN or a Bastardised version is
def the way go.

Another thing that helps on the S62 is
a lower Water temp Stat, so that it
opens much lower say 60 deg, and then
stays open.

Stops fluctuations in water temps which with
the alloy blocks etc via their water jackets
is much, much better.

Make sure set the O2 [Lam] sensors a
little further back than stock so that they get a better
reading as the scavange on the exhaust
gases will be a little cooler and give a
more accurate reading.

You Guys really are doing the walk when most
just talk.

Really interesting couple of projects [Turks]

Regards,

The Gorilla.

[turk]

Another thing that helps on the S62 is
a lower Water temp Stat, so that it
opens much lower say 60 deg, and then
stays open.

Stops fluctuations in water temps which with
the alloy blocks etc via their water jackets
is much, much better.

The Gorilla.

Have u got any links or known brands? I nearly did this on the s54 but everyone advised against it and for life of me I cannot remember why!

Thanks for liking our projects btw, and for the help ;)

[GermanGorilla]

Hi,

Should have also added that on the
Lid to the S62 Airbox [plenum]
a Guy on the M5 Board many moons ago
had the inside of the lid lined with a
very thin 'alloy' film.

It made a difference in that it solved all
the issues he was having regarding incorrect
temps etc, so much so that he then removed
all the plastic intake trumpets and had the whole
airbox lined on the inside with this very thin
alloy film.

Some copied, and some even did the inside
of the intake tubes which then gave much more constant
and accurate Temp readings.

Something else to think about.

Heat in the smaller engine bay will be an enemy.

Not expensive, more time consuming, but
well worth doing and does not spoil anything
visually.

Regards,

The Gorilla.

[Jonsku]

Hi,

Quote-

''Ummm.. 5-speed and 6-speed gearboxes have different diameter flanges on the gearbox side, so there is no way that propshaft would fit with both of them. With 5-speeder it is ok, but the 6-speeder has the larger "hardy-scheibe".

The 5 speed dog leg Getrag I have fitted to
my E30 M3 uses the E46 M3 'Doughnut'
that was originally fitted to the 6 Speed [E46 M3]
and then to the Drenth Sequnetial before I reverted
back to the 5 Speed Getrag.

The E92 M3 [S65] uses a larger Doughnut.

Regards,

The Gorilla.

Yes, the 5-speeders use the 96/12mm donut, whereas M60 V8 6-speeders use the 105/14 donut.
Some diesels use 110/12 donut (found also with some M62:s), which may be same as in the new M-cars.

Lots of different "donuts", get mixed up quickly

[GermanGorilla]

Hi,

Used the Tropical Stat on both my S54's
have done so for many years.

Do not Know if BMW still sell the ''Tropical''
Stat for the M62/S62 but that is what you
want.

Its the Stat they fit in warmer climates.

Turner Motorsport sell the S54 ones, but they are also
available via BMW.

http://www.turnermotorsport.com/BMW-E46 ... stats.aspx

Why would anybody unless living in Iceland
advise against a Tropical Stat on a performance
engine ?

Regards,

The Gorilla.

[turk]

something to do with the engine running rich if I remember rightly. Surely this will not be an issue if we use AlphaN?

I will ask next time im in Bmw. My branch are very used to my odd requests now I formed a great bond with the manager when i took him out in the s54'd e30 and nearly made him sh*t himself

Building bridges eh....

[GermanGorilla]

Hi,

Jonsku- my error, you were talking
about V8 Gearboxes, V8 Thread,
and for whatever reason I was going
on about my experincies with 6 Pot
Gearboxes.

Regards,

The Gorilla.

[glenn]

Some diesels use 110/12 donut (found also with some M62:s), which may be same as in the new M-cars.

both the e60 m5 / e9x m3 use a 110/12 doughnut.
i couldn't find it listed for any other bmw?

both the gearbox and prop flanges have recessed bolt holes, then the doughnut has protruding metal inserts that locate into the flanges.
so i dont think any other doughnut would work with the s85/s65

[davethegoat]

Thanks for the compliment Turk!

Thanks GermanGorilla. I've put a few race bikes together in the past . On all of them (where rules permit), I've lined the outside of the airboxes with chrome type tape to attempt to keep airbox temps down a little. I've also used a kind of heat blanket, though on the bikes, it's a lot easier to properly insulate the airbox by attaching it to the frame spars etc...
Although I'm 99% sure using the tape (which I still have some of) on the inside of the airbox would be no problem, that 1% of me is imagining the lot of it peeling off and dissapearing down the inlet trumpets!
I guess there a couple of other options that I can think of off the top of my head. 1. Paint the plenum and lid white. 2. Polish the plenum and lid. (Mine has an aluminium lid). I'm not keen on either though to be honest!
Some great info on the stats and lamda sensors too! And of course, thanks for the compliment!

Today, these turned up:


So I cut the end of this:


then cut 20mm from the end of the elbow, and fitted it, the cut off trumpet, and an adapter to the airbox lid:


There's enough room in there for a 150mm long air filter, which should do the trick.

I also finished the remaining airbox bracket today. Which was nice.

[turk]

LIKE!

[davethegoat]

For some reason, that made me laugh Turk!
I've got all the details of the parts I used if you want to go the same way when the time comes.

BTW, when did K&N filters become so sodding expensive??!
If there's an alternative with decent filtration/flow, I'd be interested in knowing about it.

[GermanGorilla]

Hi,

Try 'ITG' filtres, very good product
and do a very good range.

Always used them when requiring
'Sock' or 'Cowl' type filtres.

Not that expensive either.

Regards,

The Gorilla.

[Jonsku]

Looking good, first start soon?

Some diesels use 110/12 donut (found also with some M62:s), which may be same as in the new M-cars.

both the e60 m5 / e9x m3 use a 110/12 doughnut.
i couldn't find it listed for any other bmw?

For some reason 110/12 is listed also with M57. I Just changed new one for my 330d touring and it had 14mm bolts, so maybe it's just an ETK error?

http://bmwfans.info/parts/catalog/E46/T ... vel_joint/

[davethegoat]

I looked at the ITG site GermanGorrila, but they don't make a filter spot on the correct size for my airboxes, where as K&N do... It looks like I'll have to pay up!

I'll wait 'till the engine at least a set of headers before first start Jonsku.. Engines running without any exhausts sound as rough as hell IMHO!

I mounted the power steering reservoir yesterday:


Today I found this:


So I stuck some of it to this:


Another:


Hopefully it should keep the plenum a little cooler. (Cheers GermanGorilla! )
I'm not sure whether to tape up to the bottom of the plenum lid. I might experiment to see how bad it looks tomorrow!

I can't decide whether to use an E30 M3 header tank, and a standard looking master cylinder reservoir for a kind of OE look (which would kind of suit the stock airboxes), or whether to fit an alloy header tank, and seperate master cylinder reservoirs... What do you reckon guys?

Cheers! D.

[GermanGorilla]

Hi,

E.mail ITG and ask for a price
on Custom Filtres to the sizes you
require.

Also ad that you do not really want to
go the K&N route.

You may be surprised.

Plenum looks ''Cool'', [sorry'].

Regards,

The Gorilla.

[davethegoat]

Plenum looks ''Cool'', [sorry'].

Ha! Nicely done!

I'd be interested to know why you're not a fan of K&N's...

Cheers.

[davethegoat]

I found a squatter in my car yesterday.. :


In other news... I collected this from the welder today:


I'd also taken the radiator there too, to get the overflow pipe re-positioned from the rear of the rad (where the pipe would have had to run through the inlet tube) to the side:


I also routed the power steering pipes. I cut the standard E39 return pipe in half and used a joiner, and used the standard E30 feed. It took longer than you'd think to get them all routed properly! :




Just need to pop a few jubilee clips and a P clip on them now.

I ended up using the E30 reservoir with vertical take off pipes. The black one is the E39 one:


There's not exactly a mile of clearance between the alternator and chassis:


I'm pretty sure it won't be a problem, but I might look into whether there's a smaller alternator which'll fit, just incase.

That's about it for now!
Cheers. Dave.

[glenn]

that alternator clearance looks about right to me dave