S54'd e30 (FLORIDA)

[turk]

Somewhere, in top secret location, Not far from Portsmouth and just off jnc 11 of the M27, I have begun building my ultimate E30...

I found a 56000 mile Lhd Beauty of a car! 2nd owner from new , Aircon and auto (sadly)... It was imported from florida in 1997 and is proper yank spec'd. Hence the name "florida"

Anyhow, I went and got myself a nice S54 out of a 2003 E46 M3 coupe!

The shopping list grew and grew... and finally im at the stage where I have started putting it all together

SO, briefly this is the story so far:

The S54 is very similar to the s50 swap in that a lot of the same components are used, Ie M535i mounts, clio servo, M50 sump, pump, pick up, and dipstick, etc etc etc...

I have decided to use a 6 speed gearbox from an E60 diesel, so hopefully strong enough to cope with this beast. I will also be retrofitting the aircon and heated seats Quick, Warm, And Cool!
The Ecu is Oem, It has been reflashed by Genius, I call him "Mr X" and this will allow the ecu to no longer will look for canbus network, Wheel speed sensors, traction control etc and will therefore not go into limp mode. I will still need to use the fly by wire throttle, but thats no issue, and the front to o2 sensors. The car will feature a genuine working @sport@ button, just like the Z4M. and will supply switchable maps.

Also will change the interior to all black, with e46 m3 heated leather seats.

SOOOO, The Old 2.7 ETA engine had to come out. (for sale btw )



S54 has an oil return pipe and the thread happens to be EXACTLY the same size as the m50 pan drain plug, so in it goes (love bm's)



M3 pump out, m50 IN!




Vac motorsport sump baffle


M50 sump


Nice new clutch disc to match the box, Will try and use the m3 flywheel and pressure plate and see if It works




Selector is defo too long... Needs to be chopped and changed and possible twisted...



Auto pedals out and converted to manual
Fly by wire throttle fits perfectly on the e30 accelerator mount



Some heated seat switches that will hopefully work


Clio servo and audi master cylinder, Might have to play around with the plenum to create enough clearance, if the combo doesnt work well i will swap to a ford transit connect servo and MC... we shall see...


M535i mounts (cheers Glenn ;) ) Hopefully will allow the engine to sit at the right angle.


I have also fitted all new wishbones, track rod ends and drop links etc etc

I have an 8 bar max capacity fuel pump to fit and the original e46 pressure regulator as the m3 needs 5 bar pressure.

If u see anything done wrong that may be a cause of my death in the future please let me know

Hopefully More next weekend...
Hope u enjoy the project...

[glenn]

good luck

[turk]

Cheers fella

[DanThe]

Nice, I like the baffle plate, how much are they all in?

Just so you know my M52 destroyed a pair of those engine mounts, S54 will be quite a bit heavier!

[turk]

It was $200 plus about 40 postage, but then theres the hidden import duty tax of £34, so not cheap... knwoing what i do now I would probably dare to make one up myself... but that chance has flown by

Essential for a hard accellerating car in my opinion, esp with the front heavy m50 sumps...

in regards to the mounts, they are mainly there for testing purposes, one i can verify the angle etc is all correct I will look for an upgraded set..

Any suggestions?

In regards to the e46 bex u used Dan, do u think u could have gotten away without making a spiggot bearing carier if u have used the e46 flywheel & pressure plate too???

Can wait to hear is fire

[turk]

Here is the start of my custom gear knob. Not only am I teaching myself to use a lathe but I'm creating a sliding top which will reveal my genuine sport button at least if my patience lasts long enough. I will press a ball bearing into the sliding mechanism to keep the cap in place to prevent accidental "sport'age" in the wet.

[e21Jason]

Uprated engine mounts

http://www.akgmotorsport.com/catalog/ca ... M50%20Swap

Jason

[Dave_M3]

Brilliant!!! Hope the project goes well for you now

I was just about to mention the engine mounts but looks like Dan and Jason have already chimmed in and given their advice.
I'm using AKG mounts for mine too.

I'm not sure what I'll do with the throttle as I'll probably be using a pedal box as mine is a competition car so will be interested to see how the fly by wire turns out


Baffle is a very nice piece of work but agreed its one of those things when it arrives on your doorstep that you think you could have made it yourself
If you want to send us all on some dimensions, I'm sure you could get alittle comission to make it alittle less painful


Is it a secondhand oil-pump your using?
I'd strongly recommend a new one even if they are expensive...

A friend of mine that I did an S50b32 conversion on stuck with a secondhand one from a breakers and its rattling alittle... Not what you want when the engine is all in and sump down nice and tightly on the subframe
I'm going to try use the E46 sump on my car just so I can avoid the 300 quid for the pump and the scavenger pump will be good for drifting.


As its an '03 engine, I'd suggest replacing the bearings just in case unless your absolutely certain they were done already in the re-call.



You've the same lathe as me too by the looks of it!!!

[Rav335uk]

Here is the start of my custom gear knob. Not only am I teaching myself to use a lathe but I'm creating a sliding top which will reveal my genuine sport button at least if my patience lasts long enough. I will press a ball bearing into the sliding mechanism to keep the cap in place to prevent accidental "sport'age" in the wet.

Ejector seat like Jame Bond would be a better idea Turk

[turk]

I wish it was my lathe. I'm just borrowing a friends after work. I'd say I'm about half way there on making the knob alot of measuring to do yet tho.

The sump baffle really pussed me off when it arrived. It's so simple. Plus it kept fouling the pickup so I had to bend and reshape a lot of it. Vac blamed the different variety of sumps available of the e34. But hey it in now. One day I will take some measurement and see about making eke.

The pump is second hand and I aknow exactly what u mean but aylt the moment. Just don't have the cash. Will be driving gingerly to make sure everything is working fr quite a while. If it makes any noise it will cme out and new in.

I had bm chck the file on my car and the said that this car never needed the recall. And they assure me if it wasn't called then it would be fen. So I'm fairly happy with that.

[turk]

More of my knob

[E30BeemerLad]

Nice work dude, I admire you getting stuck into a project like this.

Not sure if it's just the angle of the pic, but that accelerator pedal looks very close to the brake. I think there is a minimum distance needed for MOT

[turk]

Nice work dude, I admire you getting stuck into a project like this.

Thanx Dude!!!!

In regards to the pedal Its the pic angle... I noticed that when i posted the pix... the pedals are in the axact same place as standard as they use the same mounts etc Thanx bmw for being lazy enough not to change anything!

[UweM3]

Turk, what brand is the clutch disk you are going to use? From the pictures it looks like a solid centre?

[turk]

It's a BMW e60 diesel one to match the gearbox splines. Tried to find a hi performance one but couldn't for that box.

[turk]

Does anyone know how to move the servo over to clear the plenum? Bearing in mind its Lhd and the servo fork goes straight onto the pedal.

I know its possible on rhd by simply extending the bar that links the pedal to the servo pivot bar...

If not who can heat weld my plenum to accommodate my servo???

Cherz

[Gunni]

You should be able to see any competent TIG welder or qualified welder.

Just browse around your local area

[JoeDiese]

How much room do you need to clear the plenum on an s54?

Most folks (for the amount of room needed for LHD s5x swaps) just slot the holes for the servo on the firewall/bulkhead and move the servo half an inch over, and the servo pushrod takes up the change in angle alright...

[Kos]

i will be amazed if this works properly

[UweM3]

How much room do you need to clear the plenum on an s54?

Most folks (for the amount of room needed for LHD s5x swaps) just slot the holes for the servo on the firewall/bulkhead and move the servo half an inch over, and the servo pushrod takes up the change in angle alright...

I would not push onto the servo in an angle. If you move the servo over, you need to modify the pedal. It's possible, just another job.

And for TIG weldeing the plenum, isn't it PLASTIC ?? (part of the weight saving compared to and S50)

[UweM3]

It's a BMW e60 diesel one to match the gearbox splines. Tried to find a hi performance one but couldn't for that box.

I am thinking about the OEM clutch disk for a while now and I am still undecided if I use the fixed hub S50 clutch or a E34 M3 with sprung centre.

I want to use a TTV flywheel and I am a little bit worried if the solid clutch disk will not be a bit to unforgiving without the dual mass flywheel

[turk]

The plenum will need to be heat welded. Specific to plastic. Defo not mig :0

[Dave_M3]

It's a BMW e60 diesel one to match the gearbox splines. Tried to find a hi performance one but couldn't for that box.

I am thinking about the OEM clutch disk for a while now and I am still undecided if I use the fixed hub S50 clutch or a E34 M3 with sprung centre.

I want to use a TTV flywheel and I am a little bit worried if the solid clutch disk will not be a bit to unforgiving without the dual mass flywheel

Use the E34 clutch Uwe. The solid disc clutch will tear the gearbox apart in no time and until then you'll think you'll have a bottom end in bits with the vibration and death rattle from it.

I tried it with a E46 M3 clutch and solid single mass flywheel when I fitted the 6 speed to my iS and could only bear driving it about a 100ft before I went back to the drawing board.

I'm going to use one of the 240mm billet flywheels next time and find some sprung E46 M3 clutch from somewhere as the M5 one won't fit the input shaft of the E46 box.

[glenn]

the plenum is made of PA 6, which is polyamide....basicly its nylon.
i heat welded mine myself.
use a good output soldering iron ,and use some thin strips of pa6.
weld it in a simular way to gas welding, make sure the two joining surfaces are fluid, before trying to add the 'filler' strips.

[turk]

the plenum is made of PA 6, which is polyamide....basicly its nylon.
i heat welded mine myself.
use a good output soldering iron ,and use some thin strips of pa6.
weld it in a simular way to gas welding, make sure the two joining surfaces are fluid, before trying to add the 'filler' strips.

I might have to pop round Glenn and beg for some help on this one...

good to know it can be done

[adit]

good luck with it all Ad

Also will change the interior to all black

oh yes, that reminds me, how are the door cards?

may pop round at the weekend for a nosey

[turk]

No worries mate ;) bring ur car clothes tho, it aint no spectator sport

[Dave_M3]

Fook that... pedal box and CF airbox FTW


If you fook it up, I have a spare standard plenum or two for you anyway

[UweM3]

It's a BMW e60 diesel one to match the gearbox splines. Tried to find a hi performance one but couldn't for that box.

I am thinking about the OEM clutch disk for a while now and I am still undecided if I use the fixed hub S50 clutch or a E34 M3 with sprung centre.

I want to use a TTV flywheel and I am a little bit worried if the solid clutch disk will not be a bit to unforgiving without the dual mass flywheel

Use the E34 clutch Uwe. The solid disc clutch will tear the gearbox apart in no time and until then you'll think you'll have a bottom end in bits with the vibration and death rattle from it.

I tried it with a E46 M3 clutch and solid single mass flywheel when I fitted the 6 speed to my iS and could only bear driving it about a 100ft before I went back to the drawing board.

I'm going to use one of the 240mm billet flywheels next time and find some sprung E46 M3 clutch from somewhere as the M5 one won't fit the input shaft of the E46 box.

Thanks for your info. Exactly what I was worried about. But having said that, all "race" clutches are solid. i.e. Tilton twin disk.

But I am going to play save and fit a sprung hub disk

[turk]

Fook that... pedal box and CF airbox FTW


If you fook it up, I have two spare standard plenums for you anyway

nice one

[Dave_M3]

I am thinking about the OEM clutch disk for a while now and I am still undecided if I use the fixed hub S50 clutch or a E34 M3 with sprung centre.

I want to use a TTV flywheel and I am a little bit worried if the solid clutch disk will not be a bit to unforgiving without the dual mass flywheel

Use the E34 clutch Uwe. The solid disc clutch will tear the gearbox apart in no time and until then you'll think you'll have a bottom end in bits with the vibration and death rattle from it.

I tried it with a E46 M3 clutch and solid single mass flywheel when I fitted the 6 speed to my iS and could only bear driving it about a 100ft before I went back to the drawing board.

I'm going to use one of the 240mm billet flywheels next time and find some sprung E46 M3 clutch from somewhere as the M5 one won't fit the input shaft of the E46 box.

Thanks for your info. Exactly what I was worried about. But having said that, all "race" clutches are solid. i.e. Tilton twin disk.

But I am going to play save and fit a sprung hub disk

Yeah, but they are also usually paired with race gearboxes!

Never again would I use a solid clutch on a single mass flywheel anyway.

The noise from it was truly horrendous and the gearbox only had 28K on it with new MTF-LT2 or 3 (whichever it is now) fluid in it.


OK, it might be alittle better on an S50 as the M42 would have alittle more vibration due to being a 4 pot but it wouldn't have been enough to make a difference to how bad it was.


I've hear of fellas trying to use them for drifting too in nissan yokes and they broke a gearbox at every event until they saw sense.

[tomson]

Interesting thread, I'm subscribing

Good luck, looks good so far

Have you not thought about converting to RHD ? ? ?

[turk]

Interesting thread, I'm subscribing

Good luck, looks good so far

Have you not thought about converting to RHD ? ? ?

Nope, took me ages to find a Lhd in such good condition. I've always wanted a left hooker as I grew up on lhd and actually prefer it... everyone thinks im wierd but hey, each to their own hey...

might get the engine test fitted this weekend

Watch this space

[UweM3]

Interesting thread, I'm subscribing

Good luck, looks good so far

Have you not thought about converting to RHD ? ? ?

Nope, took me ages to find a Lhd in such good condition. I've always wanted a left hooker as I grew up on lhd and actually prefer it... everyone thinks im wierd but hey, each to their own hey...

might get the engine test fitted this weekend

Watch this space

+1

I prefer LHD for my track car.
RHD is better for daily driving in the UK. I drove my LHD for a few years in UK and was getting fed up with climbing over seats to pull the car park ticket.

[turk]

Popped the engine in today without the gearbox to do some measuring and checking etc etc.

I am waiting on a flywheel to match the box and starter and once I have them It will be in there permanently.

and this is what is looks like