Creating COMPLETE CAD Model of M42: It Cannot be Done Alone!

[bmwman91]

I have always wanted to find a complete CAD model of the M42, but surely any that exist are somewhere in the bowells of BMW's design databases, and probably in a format that is no longer commonly used these days.  Even if the models were importable, it would probably be impossible to interact cleanly with them (IIRC CAD stuff back then was mainly wireframe, as opposed to the solid feature-based stuff we use now).  So, with that said, is anyone interested in getting some team-work going?

The complete modeling of the M42 is not going to be done in a week.  I am a busy guy with work and my attempts at maintaining a normal social life, but I DO have free time that I like to devote to hobbies.  I think it would be awesome to build a model of the M42, with all the parts.

Obviously there are some pretty intricate castings in there with draft angles and all that jazz.  The modeling should be like 99% accurate for the critical moving parts, but those are all cast/machined and are easier to model than, say, the outside of the block.  Stuff like that can be like 80% accurate.  Cosmetics are secondary to capturing everything's functionality and getting a good idea of the amount of space things take (so if one wanted to mess with turbo manifold designs and turbo kit fitments it could be of use).

So, here is the teamwork part.  I do not have a spare motor to take apart and measure.  I know some of you guys DO.  Yeah, I am sure you know what is coming next...
Yes, making this a group effort with our combined free time and parts we can do this (I think)!  So, who is up to help out.  It would probably be best if it were divided up and each person was given a certain set of parts to be responsible for.  Before I try to delegate anything, here is a breakdown of the areas I would split the motor up into:

- Engine Block (1 person)
- Crank/Rods/Main Bearing Caps (1 - 2 people)
- Pistons/Rings/Thrust Pin (1 person)
- Oil Pans/Dipstick (1 person)
- Timing case & attached parts [idler sprocket, tensioner rails, crank sprocket/woodruff key, cam sprockets] (1 - 2 people)
- Cylinder Head [head ONLY] (1 person)
- Valvetrain Parts [inc. cam trays] (1 - 2 people)
- Valve Cover (1 person)
- Intake Manifolds & Fuel Rail/Injectors (1 - 2 people)
- Throttle Body, boot & AFM (1 person)
- Water Pump/T-Stat/TS Housing (1 person)
- Exhaust Manifold (1 person)
- Alternator (1 person)
- PS Pump (1 person)
- AC System (not sure I want to do this as lots of people remove it)
- Engine Mount Spars/Mounts (1 person)
- ICV & Vacuum System (1 person)
- Pullies (1 person)
- Crank & Cam position sensors (1 person)

Yes, this is a massive undertaking.  Yes, there is a likelihood that it might not get too far.  I would still like to try anyway though.  Let's start with who has what, and if there is anyone else in here that does CAD modeling let me know.  Anyway, that is my little idea for the moment.  I guess we will see how muh free time we all have (or don't)!

[D. Clay]

You are totally obsessed and completely insane. I would love to help you on your way to confinement for an indefinate period. I once did a complete TransAm chassis in AutoCad12. It took 6 months of all my spare time. This was on a 486 machine that took 3 minutes to "hide" and about 10-12 to render. I know nothing about the new CAD stuff but can read a tape.
Penske has all of their cars including the NASCAR sedans in CAD down to the nuts, bolts, and washers.  They can take components from one car and put them into another and all kinds of stuff like that.  I'm subscribing to the thread.

[bmwman91]

Sounds neat.  Working at Cisco they have all of their chassis stuff down to the rivet/nut/1pF capacitor/whatever.  Everything has a PN and it is really easy to test fit prettymuch anything in CAD.  Now, whether or not the manufacturer actually builds stuff within the allotted tolerances is another story sometimes...but CAD is good stuff.

[Euro Nation]

I can do solidworks but not CAD.

[16vcoffin]

Man this is gunna be sweet.

[bmwman91]

SolidWorks is good.  If things can be exported to a format where the features can be preserved then it is all good.  It is hard to find a program that will recover them all properly though.  You may be of use anyway though lol.

[Deutschbag]

Wow that sounds like a sweet ass project. I used to work with AutoCad 2000 in high school, but that was archtectural drafting and it's been quite a long time since I've worked on anything so I'm pretty sure I wouldn't be of any help. I see you are a fifth element fan though

[bmwman91]

Haha nice.  I was not sure if anyone would ever pick up on the user title.  Everyone was like..."what's a 'goot'"?

[Jimmy Lewis]

haha I am interested as i sit in my architectural drawing class. Ive had 3 years of CAD and I could help with some of the less complex peices.

[akorcovelos]

Sounds like a good idea, I use Solidworks 2006 for a living. SW is actualy better than ACAD for mechanical design. It can produce a 3 view drawing with a isometric view included using the 3D part file, so it's MUCH more productive for mechanical parts and assemblies. I can donate some time to do some modeling, but the only M42 I have gets me to work everyday, So I can't really tare it down for extended amounts of time. I would also recomend that any part measureing should use something more accurate than a standard tape. These cars are built to very tight tolerances, especialy the motors. When I do machine design at work we design within thousandths (.xxx) and thats considered loose tolerances compaired to engin design.
I would love to have a complete assembly of the M42 in SW, that would make any work MUCH easier.

[bmwman91]

Agreed, ACAD is not a hot item for anything like this.  Maybe ACAD Inventor.

I primarily use IronCAD, which most have never heard of.  It is about the easiest program to use for doing modeling and assembly all in one.  I always found SW to be a little clunky in that regard.  I also really like SDRC I-DEAS, but that is only available at work.  I have Pro-E there as well, but cannot say that I have been all that impressed either.

[bmwman91]

OK I want to make some parts.  I want to start with modeling the pistons/rings/thrust rods and connecting rods/bearings/caps/bolts.

Someone please take pictures from 3 angles (top/front/right) and hook me up with some dimensions.  You could also ship them to me (95115) and I would pay the shipping id you do not have calipers.  A tape measure is not going to work here lol.

[an318is]

Hello all,

I havent posted much but this cought my eye. I am currently about to start this exact task. I have a M42 in pieces in my garage to make measurements from. For the really high tollerence stuff i have acces to a 3D digitizer i was planning on using. I was actually planning to do most the work in Catia as a learning experience. I do have Solidworks aswell though and im currently most proficient at using that. What program would people prefer?

[bmwman91]

Either of those is fine.  Heck if you have access to a digitizer, you can definitely be of use.  Although I DO want to be as accurate as possible, the items with really tight tolerances can be spec'd off of an engine specification manual.  The most important parts are the working internals.  I was just planning on trying to get a good approximation of the block and such as it is such a complex bit, but again, if you have a digitizer then we could do pretty well.

If we are all exchanging parts, I think we will have to use the STEP format.  It sucks because you lose all feature control, but at least it is universal.  If you are comfy with SW that is fine.  I have SW2007 and given a little patience, I could be as good with it as I am on IronCAD and SDRC I-DEAS.

[jmeyer318is]

I just noticed this thread.  I would love help if needed.  That is something I've wanted to do for a while, but haven't gotten around to it yet. The only problem is that my M42 is currently assembled.  I use Solid Edge mostly at work, but I also have access to Solid Works and CATIA.