S62 Project - Denmark

[Duckmann]

Hello everybody.

I bought this half finished project from a good friend last year. I'm still a long way from the goal, but it is going the right way, thanks to Glenn.

Some picures of the thing:


















After I bought the car I got the ECU reflashed, bought a new EVO steering wheel, fittet the bonet so it could close, with ~1cm clearance on both sides of the engine.

Comming up is the wiring and the completion of the new exhaust manifold.

[turk]

Looks Like a great Project!!!

What brake setup are you using?

[Duckmann]

The front is XYZ, but I dont remember the size.

The car has a E36 wheelhub in the rear, so its 5 slottet. Still havnt made up my mind for the rear brakes. Any sugestions?

[turk]

What about servo / Pedal box?

Porsche rears could work nicely. If you use a Pedal box you can adjust the bias bar to give you more front braking.

I can see there are copper hoses coming through the servo hole. im guessing its a pedal box

[davethegoat]

Subscribed.

Is there an oil filter housing tucked away somewhere in there?

Dave.

[turk]

I defo think the v10 oil filter housing is the way forward!

under mounted. Wonder what the hose id is on the v10? wouldn't want a drop in pressure.

[davethegoat]

I've found another solution. I'll drop you a PM rather than have Duckmann's thread spear off topic Turk.

[Duckmann]

Wasn't planing on using a pedal box. I've bought a modified 540 mastercylinder, I'll snap a photo or two when its mounted .

Havn't figured out what to do with the oil filter housing yet.

[Duckmann]

Some photos of the manifolds:

[davethegoat]

Reagarding the oil filter(s), if I do another S62 conversion, I'll use something like this, placed on the right hand side of the block (where the air coditioning pump used to be) I haven't looked into what filters would work as yet.



Coincidentally, my S62 will have the exhausts started on next week hopefully.

Cheers. Dave.

[Duckmann]

Looks interresting . And very nice project you have there Dave Mine seems like a walk in the park in comparison, hehe.

[davethegoat]

Thanks Duckmann.

Yours looks like there's still a fair bit of work to do. Let me know if it's a walk in the park, I'll deliver another one to you!

Did you make the manifolds yourself?

Cheers. Dave.

[Duckmann]

Haha, maybe "a walk in the park" is a overstatement ;). No, my good friend is doing it for me, just as the rest of the welding on the car.

Whats the time frame for your project?, if there is such a thing

[davethegoat]

It's handy to have a good friend like that.

I just looked on my thread. My first post was in late January, but I'd been working on it for a couple of weeks here and there already IIRC... It's now nearly August!
I've been held up with not having a workshop and not having a summer, but I under-estimated how much time and money it would cost. Anyway, mine should be running in a few weeks, then I will be able to get on with suspension etc. As I'm very sure you're aware, there's also a hell of a lot of time spent on the internet reserching/hunting for parts.

Looking forward to seeing yours taking shape!

If there's anything I can help with, or any pictures that you need, give me a shout.

Cheers. Dave.

[turk]

I like your manifolds!

[Duckmann]

Hehe Dave, projects like this always takes x 2 the estimated time

Looks interesting with the oil filter solution, got some more info?

Got the engine out today, removed the loom so that turk can do his magic Welded the 2 EGR pipes.





Found out that the previous owner grinded a bit of the steering, so I dicided to move the enigine ~10mm forward and but a 10mm spacer under the crossmember so there is enough room for the bolt. It will also give me some more clearance for the loom when the engine is going back in.

[Duckmann]

Some new stuff for the exhaust arrived today:

[turk]

We need an update Duckmann!!!

[Duckmann]

I know, but I have just startet in a new job, which requires a lot of travel . The plan is that the new clutch and loom will get installen this weekend, before i leave for London.

When I get back the first thing to do is make the fuelpump modification.

I'll update ASAP

[Duckmann]

Finally!

Made a mod on the two heater pipes because I wanted more space between the engine and firewall. Installed the new clucth and the new oil console from a X5 on the engine block.

Som pictures:













Also test fittet the new engine loom, and everything looks fine

[turk]

Finally!

Also test fittet the new engine loom, and everything looks fine

GOOD GOOD!!! Did you find somewhere to hide the throttle potentiometer yet?

[Duckmann]

No not yet, I hope to reinstall the engine this weekend and then I'll find a place to mount it

[senna]

Finally!

Made a mod on the two heater pipes because I wanted more space between the engine and firewall. Installed the new clucth and the new oil console from a X5 on the engine block.

Som pictures:













Also test fittet the new engine loom, and everything looks fine

What did you do to the loom?
I used it as standard

[Duckmann]

The loom was modified by turk / Ergen so it works with the E30 standard wiring, and made it posible to use a fly by wire system for the gas pedal.

Sorry for the missing updates, but I'm not in Denmark at the time.

[Duckmann]

Installed the engine today. Moved the engine 2-3 cm forward to make space for the water hose connection. Made a new bracket for the transmission, the old one was kind of crap .

My good friend found a place for the throttle potentiometer, pictures is on its way!

[Duckmann]

Forgot to borrow a "clutch centering device" (english plz) from a friend, so we made our own ;)

[Duckmann]

Decided to mount the throttle potentiometer above the brake pedal, so made a bracket to do this. Still needs some work, and a rod end ball joint to be complete.

[Duckmann]

I thought I bought a "bolt on" brake master kit, but no, had to do a bit of modification to make it fit.

Cut of 4cm, otherwise the hood couldn't close.

[Duckmann]

And now I'm back where I startet, engine out



Fuel pump is on its way, and so is the FPR.

Stay tuned, and happy new year !!!

[Duckmann]

Made a new bracket for the transmission:







Much better than the old one, which only supported 3 out of 4 screws.

[Duckmann]

Dropped the engine in again. Hopefully it wont get out again before I have heard it run!





Yes, the hood can close, not much space, but ~8mm when I have had some fun with a hammer on the hood



At last, back at my own garage, time to do the 5lug front conversion and figure out what to do with the rear brakes.

Maybe I'll ditch the rims, they are to wide in the rear, and the cops in Denmark don't like if the rim or tire pokes out of the wheelbase

[Duckmann]

Clearance looks fine so far, still in the progross of making the manifold.



Needed some room for the two silencers, so I made room

[Jonsku]

Looking good, and fine new idea with the brake booster linkage!

[davethegoat]

Regarding the rear 5 lug conversion... I used 120d rear hubs, which share the same bearing size as the stock E30 hubs. I also used 120d discs, which are 300mm. From memory, I'm very sure that E30 M3 discs are very similar in depth to the 120d discs.

Cheers!

Edited to say:
My 120d discs are 300mm diameter, 20mm thick, 66.5mm deep, vented.
E30 M3 discs are 282mm diameter, 12mm thick, 65mm deep, solid.