M30 throttle bodies

[buster]

I used an angle grinder to move the hole over,then silocone sealed it when i bolted it back,after re- drilling that is.
For the lever see pic below ,



Just matched the thicknes of the lever and made an extension for it, put weld preps on both sides ( 45 degree chamfer to a point) and welded it on,then re-drilled the end.

[gareth]

looking sweet toby!

what about using one of those wierd hydraulic servo jobies to avoid clearance issues? (i have absolutely no idea how these work by the way but i've seen them on some larger bmw's)

incidentally, what's that thing sitting in the battery tray?

[Andy335Touring]

incidentally, what's that thing sitting in the battery tray?

oil filter housing

[gareth]

ahaaa! not a clever remote mounted thingy of some sort then!

[ric325i]

as always a good read! will be buying the mag tomorrow.

but i could keep up before...now this is going even more MENTLE!!!!!

good work.

P.s i enjoyed the fight before. made me laugh lots.

toby_unna no LSD for ya sorry.

[Toby_Unna]

Cheers Glenn/Buster, i'll do that.

today's problems: thermostat housing's main radiator outlet stub hits TB number 1; FPR also hits thermo housing severely.

using an adapter from a power boost kit in place of the FPR which is more compact and means i can use the adjustable one Ant sorted out. meanwhile i've cut off the offending stub from the thermo housing in order to set it at a different angle - time to pay for more atig welding

Gareth, not messing about with the E28 booster system, too many pipes and connections and stuff. you also happen to need a PAS pump, and i'm buggered if i can be bothered to install one of those too

[gareth]

low tech (no pas) and high tech (trottle bodied brainy turbo install) meet in one unsuspecting 316i!!!

incidentally, how heavy is the steering if you have a M30 and no pas?

[Toby_Unna]

parking: reasonably heavy but managable
driving: lovely

the extra weight just doesn't make that much difference anywhere unless you're on a racetrack - contrary to what some might have you believe

[Andy335Touring]

Sorry dude, looks like it's turning in to quite an involved/PITA kind of job, i wish i'd have known before then i could have warned you

[Toby_Unna]

lol... would be no fun if it was all plain sailing

involved is the right word. i wonder how many pages this thread will end up with

[Andy335Touring]

I just hope he can TIG weld that stat housing stub as they are normally very manky ?

[Demlotcrew]

the extra weight just doesn't make that much difference anywhere unless you're on a racetrack - contrary to what some might have you believe

Thats just so not true!

Andrew

[Toby_Unna]

yawn...

anyway, back on topic

Glenn/Buster, what did you do with the two left-hand servo mount studs? is the servo moved so far over that they no longer go through the black mount bracket inside the car?





This is the extent of clearance issues between 'stat housing, FPR and TB number 1. I'm going to cut the offending stub back further so as to lose the third tapping in the top, then hopefully get a stub welded in at a better angle. Aluminium looks fairly decent underneath the grime. Have sourced an adapter from an old FSE power boost valve kit that should sort the FPR issue.

Meanwhile on a more productive note I've shortened the throttle spindle and made brackets to hold my TPS as close to TB 1 as possible. that's one less thing to worry about then

[glenn]

yawn...

anyway, back on topic

Glenn/Buster, what did you do with the two left-hand servo mount studs? is the servo moved so far over that they no longer go through the black mount bracket inside the car?

with dips V12, i cut out half the bulkhead, because i needed to re-position the hydraulic booster.
the nearside inlet manifold was the deciding factor that everything else had to fit around. so once the booster's position was decided, i then made the bracket inside the car fit it's original mountings and fit the new position for the booster

[buster]

yawn...

anyway, back on topic

Glenn/Buster, what did you do with the two left-hand servo mount studs? is the servo moved so far over that they no longer go through the black mount bracket inside the car?

The 2 left hand side bolts on mine fastened up to the left of that vertical rib.
I welded a piece of 1" wide flat to the side of it and drilled through it and the bulkhead,and bolted through them both.

Let me know if you need that thermostat housing machining in any way.Pop it in the post and i'll do it for you.
What does that rear stub supply water to anyway ?

[Toby_Unna]

um, the top radiator hose , fairly critical really!

cheers for the offer, that's very decent of you. i've cut it back sufficiently now, just need to get hold of a suitable aluminium tube section and get it tig'd on which will hopefully be possible.

good info re the servo, i think i'll try to do mine exactly as you've done.

throttle bracket done today, one small step closer

[buster]

so if that one is for the top hose,what is the larger one for infront of it ?

[Demlotcrew]

Water pump

Andrew

[Toby_Unna]

few latest pics...

brake servo moved around 2cm to the left to give more clearance to the plenum. didn't really trust my welding to extend the servo actuator arm, so i opted to move the entire bracket across, there's enough adjustment in the cross bar.




extended mounting on bracket



made up some plating to fill the cut out in the plenum, ready for welding now...





hopefully this won't interfere too badly with the flow to cylinder 6. there's good clearance all round the servo, should be sufficient to cope with engine movement under load.

made a throttle cable bracket





also got hold of the fpr adaptor from an fse power boost valve kit, which fits into the m5 fuel rail and misses the m30 thermostat housing by about 1mm. game on

[gareth]

[Andy335Touring]

Very !!!

[buster]

top bananna toby ! Keep them updates coming.

[DRIFTBOY]

Yeah, this is inspirational!

Goes to show that there is no such thing as "Doesn't fit!".

Good work Toby, loving this car more everytime I read about it!

Makes my 335i look really gay!

[gareth]

Makes my 335i look really gay!

ant isn't far from us..... may have to pay him a visit!

[Toby_Unna]

cheers all, support much appreciated as fitting these is being rather more involved than expected

FPR adapter



plenum finished up today and gone off to be welded.

[maxfield]

Awesome! can't believe i missed this thread.

[Andy335Touring]

So, just the 'stat housing stub to sort out now ?

[Toby_Unna]

i wish!

yup, that stub is the biggest problem. i'm intending to get a long pipe section added, at a downward angle, with a squeeze in it to miss the no1 TB. there's bugger all room, even the bloody TPS is bang in the way, and bringing it up and over will hit the bonnet and be impossible to bleed of air. however i'm concerned that having this long stub welded on will mean it's impossible to assemble the stat housing and TBs to the head

other things:

mount and set up external FPR
find places for the rest of the coolant pipes to run (need to remake most of them)
port out the TB mouths and adapter plate
source an e28 m30 oil filter housing (i'd accept a non-oil cooler 525i/528i one for now, it would fit ok)
sort out the dipstick (which is currently bent out of the way!)
sort out a balanced pressure signal between TBs to run MS MAP etc
plug all breather tappings in plenum
modify adapter plate to accept flush mount head bolts
fit injectors fuel hoses etc
sort out brake servo line
refit brake res and run new fluid right through because it was spitting with rain when i removed it and i guess there's some water in there
put new oil and coolant in

i want to cry now!

[DRIFTBOY]

Yeah, but just think about when it is done!

Do you have any idea what sort of power you could end up with?

Good luck though!

[Toby_Unna]

Martin,

it'll certainly look nice

however i reckon power gains won't be much to get excited about - a NA engine with a hot cam would love these, but with the turbo there's much less need for a free flowing inlet. throttle response might perk up a bit hopefully, but it probably won't sound that different either as the turbo does a good job of muffling the induction noise

i guess i'll end up fitting the setup to a non-turbo e30 m30 one day

it's doing over 300bhp at the wheels on 7psi. with this adjustable regulator attached and more fuel available it might do going on for 400 at 1 bar (or blow to bits trying)

[DRIFTBOY]

Over 300bhp at the wheels!

All you need now is a nice big nitrous oxide kit!

Every time I read about your car I get the turbo itch!

Maybe one day!

[mybmw6]

That is looking mighty fine! I like the symetry in the engine bay very classy! Great work!

[Demlotcrew]

I want more pics

Andrew

[Andyboy]

With regard to the top hose problem; what you COULD do is completely blank up that back one that's partially obscured by the TB's, remove the 'stat completely and convert to an M10 or S14 style remote thermostat. I think you'd have to remove the stat housing, bore it out and then weld up the reamost stub that the top rad hoses fits to. The top rad hose can be shortened at the radiator end by an inch or two and fitted to the front stub.

This will require a lot of thought - it might just be easier to cut and modify the existing thermostat housing to make the troublesome rear stub come up at a different angle. The M88 engines used a totally different system with external water jackets and didn't have that big lumpy thermostat housing there. Another solution could be to space the TB's away from the head more but you'd have a spacer plate like a railway sleeper.

A tricky one.

[Toby_Unna]

might be an idea Andy.

couple more pics...

welded plenum







adjustable fuel reg - cheers Ant



need an E28 525i/528i/m535i oil filter housing badly