E30guydownunder's Track car build.

[e30guydownunder]

Sorry if its a bit hard to follow, the quotes in my posts have come through from the oiginal forum

[e30guydownunder]

Just ran out of gas! And its 5:30, so thats progress haulted till tomorrow. Just uploading some pictures now.

Wait for it

Wait for it

BAM something is missing:



Yep thats right, engine mounts!
I didn't quite get to finish the gusseting on the passenger side mount:



And I'm giving up on squeezing the turbo down the side. Everything works better with a top mount so what ever:




The finished Drivers side mount:





Should support the thing no matter how much power its making!
Cheers folks, now to work out what I'm going to do with myself for a few hours with no welder :crazy

[e30guydownunder]

anyhow, an update is due! I've finally shaken the multiple hangovers and scrapped together some time in the shed. This is all post an adventure to the wreckers where i picked up two perhaps suitable radiators (one with fans/shrouds etc) and a set of HKS springs and adjuster out of a jazz (mostly got these for the adjusters but you never know). Anyway, the price? It was good

So today I've finished off the cooler mount I began and about 90% completed the lower mounts for the radiator, just need to find my other OEM gearbox mount and paint em up. Then a couple of mounts on top for the radiator and the intercooler and bob's your uncle.

The view from the front:



And the back (note ou cn see the lower radiator mount in the works):



First person to guess the origin of the radiator gets a prize. In the mean time check this out for luck of the draw:



Thats a late M20 radiator hose and its damn near perfect. NICE. The radiator is roughly double the volume of the M42 one so should do the trick. And having copper tanks we can modify the lower hose connection to suit our application and will also be adding a couple of extra ports (for temp senders and turbo outlets etc). I'll also be using one of the fans/shrouds off the other radiator and with some mounts this should be more than enough to keep the car cool in the pits.

I've mouted the radiator level with the bottom edge of the chassis, so low as possible for CofG but still protected

Have also got some thoughts in the works for the remote oil filter in the form of the oil filter canister off an M30, including thermostat and oil cooler take off points (free).

Turbo manifold is probably 70% complete. Some final welding of runners to do and then facing the flanges.

Hope everyone had a Merry Christmas (I sure did) and have a Happy New Year.

[e30guydownunder]

Time for an update

Been taking it easy, back at work now and funnily enough i sorta got a bit enthuiastic...great timing.

Anyway I got a nice lil package today. Some turbo bits:









Still waiting for all my Couplers to get here:

Another slow weekend, but solid progress non the less. I mounted my thermo fan on the radiator. Dad helped me out with a solid start on the radiator/intercooler shroud. Thats coming up real nice and will do the trick (There are some rolled ribs in the top section of the shroud, didn't come out in the picture). Also had a play with the intercooler pipe.



I also made a solid start on the relocation of the oil filter. Just need to weld the bracket to the chassis. The blanking plate needs to be drilled and tapped for the inlet/outlet ports yet, and I need to work out where the oil temp/pressure and turbo feed are going to go. Now thats left with the oil filter/cooler is the lines (which are pretty much sorted for a good price ) and then the take off plate on the block.

[e30guydownunder]

Just a lil update from the pst couple of days.

Got my Take off plate nearly 100%. Just need to fit the top port a bit better and then weld the reducing bush in.





And here is the start I have made on me custom sump. I recon it will come out fairly well, time will tell.



(Yes that back plate is recycled steel, free material WIN)

[e30guydownunder]

Figured I'd put up another update. have been slowly tinkering away at things.

The oil pan as it is in situe. I have since added mounts for the windage tray and will be bending up the pan tomorrow hopefully.



I finished up the oil system over the weekend. Here is the take-off plate, including all fittings and lines:



Then the M30 oil filter housing, blanking plate, various fittings and takeoff ports. I haven't added the tee for the turbo oil feed and pressure sender yet and the port for the temp sender needs to be tapped the correct dimensions...need a temp sender also.



From there the oil cooler lines run over the top of the intercooler pipe (yet to be finallised, suitable alloy pipe and bends are in the mail) down thru the sheet metal, which will have a rubber edge in the final product and down to the oil cooler. For these I was able to remove the standard crimped on lines and reuse the barbed fittings in my push-loc line and then threw on some crimp on clamps just to be sure to be sure. The BMW fittings were a little looser than the push-loc hose ends, hence the double clmping. Doesn't look too ugly and considering I only had to buy the hose clamps (~$30) worked out rather affordable!



I also knocked up a joiner piece for the intake. This joins the air filter and the flexible hose I will be using to feed the turbo. There is heaps of room in front of the wheel so i positioned the filter to allow me room for my brake ducting hoses (which will be added at a later date, Ignore the piece of pipe infront of the air filter that is a piece of scrap that got in the photo!).

[e30guydownunder]

Alrighty nothing has been happening and heres why:

As for an update from today. Well I have made most of the sump section of the oil pan. but I made the wing too long, it just hits the control arm, here is a picture. If you look closely you will notice the standrd windage tray is mounted also:



Stupid mistake really. Shoulda had the arm in there for mocking up purposes. Its not that big a deal to fix just a pain in the ass.

By this stage I was already starting to loose motivation and interest. So I took a step back and had a look at what was left. The majority of the mechanical stuff is bowled over. Theres the sump with is about 50% done, the intake mods and then the radiator outlet modification. Then a bunch of lil shit and its done. Except I hven't even started the brake master cylinder relocation (in the form of a custom pedal box with twin master cylinders etc). And then it dawned on me...the electrics! I want a full from scratch custom engine loom and dash wiring, integrated with the standard chassis loom etc. This wasn't going to happen in the time left. The decision was to get the engine rebuilt and stick it in and go from there....then this happened:

Well I was getting tired of this no updating BS. So thought I'd shake it up this weekend. Enter my weakness/mental disorder:



Yup another engine has landed! This one came complete with a gearbox and M3 clutch. 240mm diameter and rated to 350bhp or something. So thats my clutch issue sorted. Thanks go out to Ruger for the hookup.

But that wasn't enough. So today I washed it down as can be seen above. And Im going to have ripped the timing case apart and the sumps off and resealed them up before it goes into the race car.

Further to this I figured I would get crazy on my spare E36 Rack. I present to you the fabled leak free BMW Steering Rack.



I followed this miata guide (the two racks are very similar in design)...Click



Just need to plug the In/Out lines from the PS pump and the job is done. Very simple procedure and at last I will enjoy BMW ownership without a PS fluid puddle acumulating under the car (even my looped rack in the race car with powersteering fluid in it, leaks!)

So that about sums up the weekends happenings. I'm shooting to change the drivetrain by the end of this coming weekend as after that I will be back at uni.

And there ya go...I now have 4 M42's between 2 cars. Probably the oddest piece of info is between all the engines I only have 1 E30 head, but have onl purchased 1 E36 specific engine. The joys of bastardisation done by others!

[e30guydownunder]

Went for a lil drive

Here's some pictures of the beasty in action. I'm behind the camera not the wheel Me and Dad had a great day punting the car around the short track (1.0km)  and at the end of it all weren't going too slowly either. We were both down under 47 second laps which is reportly the mark to beat. I had a best of 46.6 after the broken swaybar link fiasco, which initially cost me about a second. a 45 second lap is apparently very impressive for 100hp





















And just to give you guys who don't live over this side of the pond some perspective this is a of the track:



And an S2K Doing similar sort of lap times to me.

[youtube]
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http://www.youtube.com/watch?v=57bjytuV6oc

[e30guydownunder]

In light of the recent drive I got all excited again and am looking to make progress with the turbo as well as driving the car. Heres a minor update:

Pedal Box arrived...VERY HAPPY!







$350 AUD shipped! Freaking steal



While we're going here is a picture of how the insides have finished up:







Currently the car is laid up while I find some funds for a new set of tyres aand make some suspension mods. First on the agenda is fixing the Front Swar bar links:







It only gets worse with more bump. I'm close to a solution however.

[littleboyblues]

Anything new? Been reading your stuff on this forum and the Austalian one and you always have good things to say. Respect!

[e30guydownunder]

not heaps lately. i have a thread i update and talk shit in more regualrly on r3v. but not alot has happened on the turbo front, being busy fiddling with a new road car and uni. im still aiming to be boosted by the end of the year though

http://r3vlimited.com/board/showthread.php?t=156425

[e30guydownunder]

Thought I might update you guys aye this is going to be a dirty copy and paste, but gives you a quick run down on the last month or so.


I've been cracking on the brake master cylinder / inlet manifold clashing problems straight up. Once I get that done, focus can turn to making the other shit work. Whats the point finishing the engine install if I don't have any brakes???

Here is what we started with, nice tidy and business like. Let the shit FLY!



First Problem, c*rather nice people*s don't design their shit to fit in an E30:



So I'm back at the beginning but with a handful of master cylinders and a balance bar. So lets make our own shit.

I have finalised on a pedal ratio of 5.85:1. This is slightly less aggressive than the pedal box I bought (5.3:1) and much better than the factory pedal setup would have been (4.8:1), but that is on a booster system. I have done this because the pedal box I bought came with mammoth cylinders. 2 x 7/8's and a 1". I am going to give the 2 x 7/8 a go and hopefully it works out half decent with the standard calipers.

Having said all that I am working towards a brake upgrade that will include fixed calipers atleast on the front of some unknown origin. Lots of stuff to do before then!

Some more Pictures.

It's a bit hard to get a decent picture without the masters mounted:


 
birds eye view of the setup:





custom hand finished bell crank (non of this laser profiled shit), not finished yet:



As far as I got with the master cylinder mount plate

[/QUOTE]



Just finished fabbing the pedal box up! Now to paint it, install it and hose it all up.







In this picture you can see the weld off to the side where I have plug welded a 6mm High Tensile Bolt in as a sort of drive pin. Just so there is something mechanical connecting the two pieces, not just weld. Also I will be buying new bearings, of course.







[/QUOTE]


Brakes are mounted in the car, I have plumbed them up, but haven't filled with fluid and bleed them yet as I have been mucho busy focusing on other shit, like tidying up the yard.

But anyway I have been doing other stuff since the brakes.

Spent a good 4-5 hours stuffing around getting the pieces for the sump finallised. Then we got it all tacked up for the final time!





Brother has some new found TIG skills and with our recently acquired bottle of Argon the TIG has been working overtime. Welding of the sump is about 50% complete.



Well I still haven't bleed the brakes! But I have got all the parts on the inlet dummied up. Just waiting for the correct silicon joiner before welding it all together. Also made up a TPS mount for the new TPS on the M30 throttle.



I have also started to modify the fuel rail. Normally the fuel reg pipe goes down the inside (ghey) so I have removed the fuel reg and will be welding on fittings either end for the supply / returns and then running a different fuel reg (probably a Subaru one as I have heaps of them)



I got out my spare E30 alternator mount and looks like this is going to work better than the E36 one. Because of the way I made the take-off plate for the oil system I need to space it off the block, but this won't be a big deal

[e30guydownunder]

Work continues. A day off work is just the time to get some shit bowled over. My radiator showed up during the week. A Nissan S14 no less. $200 ebay special, twin core blah blah, looks pretty fantastic for $200 shipped! Going to get a set of AU fans to go on it, a very simple conversion according to Nissan Buddies.



So now that I got that I can get cracking on mounting the thing. Take some old broken swaybar links???



BAM, you got yourself some lower radiator mounts, had to make it go around the radiator drain too:







I pressed the rubber bushes out while welding and drilled the centres to suit the radiator. Pretty stoked with how it turned out.

I made some top mounts for the radiator as well (that incorporate the intercooler mounts), but no pictures. So thats everything sitting in there nice and pretty.



The standard top hose works perfectly! Clears the new intake pipe very nicely indeed.



The 135 silicone bend showed up. Clears the radiator nicely. Might have to rejig to position of the oil filter / hoses, but nothing major:



And that was today. Had a quick look at the lower radiator hose and will get cracking on the sway bar mounts.



And now another update

I managed to drag my ass outta bed about 12....the wedding reception was perhaps a bit bigger than anticipated, but hey can't say no to free beer! All good as I got plenty done yesterday.

I threw a few of the other bits in to get a feel for how it is all coming together. Going well if you ask me!





Got the fans in and mounted, upper (standard 318 ) and lower (hacked up M20) radiator hoses finished, upper radiator and intercooler mounts done, all the intercooler pipes dummied up and threw the BOV in for an idea on required real estate. The accusump just out of shot, about where it will go.

A view from the front can see all the coolers air filter and other shit.



The intake pipe was a tight fit on the fan shroud



I modified it with a bit of heat and hammer The 10mm intake spacer coming will help add a bit of extra clearence also



Alternator in and spaced out. Going have to knock a bit off the spacers to get some more clearence on the chassis rail. Got plenty of clearence over the oil lines anyway.



The new fans and alternator position are occupying where I previously had the oil filter setup. So i have moved to to behind to headlight. making it nice and serviceable from below also. The hoses will work out ok too, with the turbo oil feed and stuff all pointing the right direction



And from under neath



While were down there, here is the lower radiator plumbing / electric water pump (i'm yet to make a mount, but it's in there!)



And a shot of the turbo pipes, fans and lower radiator hose all nice and tightly packaged in there

[e30guydownunder]

Postman stopped by with a few things today:



Boost Valve courtesy Rz