JRW'S 91 318is turbo build

[colin86325]

Do you mean the thrust journal on the crank?
You can almost count on the thrust face being destroyed nearly 100% of the time with these engines.

[jrw21]

Do you mean the thrust journal on the crank?
You can almost count on the thrust face being destroyed nearly 100% of the time with these engines.

Yep, I stopped by today to check it out. It was definitely shot there was a huge indentation.

Dropped off the 83.5mm crank, he is going to spin the crank and see about removing the impulse sending wheel. We talked a bit about shaving the wiseco's 1mm. He is going to work on it and get back to me on his recommendation. Also, while I was there I was quoted my bill $1,500.. Little bit higher than I was expecting but not by enough to warrant not having them build it. This includes: cleaning the block/head paint, milling head/block, boring out the block, balancing the entire rotating assembly, 5 angle valve job, and assembly among other things.

[jrw21]

Picked up a zf 310 today! Was really hoping on finding a zf 320 but all I could find were ones with high miles. I found this 310 with only 62k miles with a bunch of updates I couldn't pass up paid a bit of a premium but I think it will be worth it:

BMW Clutch Release Bearing Guide Tube
BMW Manual Trans Input Shaft Seal    
BMW Manual Trans Output Shaft Seal    
Red Line D4 ATF    
BMW Transmission Detent Repair Kit (ZF S5D320Z)    
BMW Clutch Pivot Fork    
BMW Clutch Release Arm Spring    
BMW Clutch Release Throw Out Bearing    
RallyRoad Stainless Clutch Pivot Pin

Also picked up an e36 driveshaft for parts

[jrw21]

Small updates. Stopped by the machine shop today to check on progress:


Block bored honed and cleaned. Will be test assembled tomorrow to check clearance. So, tonight I was digging around my shop organizing parts and came across an 81mm crank. Forgot I had it! I can't believe I forgot I had this crank I pulled it from a 95 engine that had hydro locked. The crank blew a rod/piston right out of the side of the block. Would you guys think it would be safe/worth using it knowing that it threw a rod out of the side of the block?

[wazzu70]

If the bearing surfaces are good I dont see a lot that could go wrong with it. Have the machine shop spin it to make sure its balanced and straight.

[jrw21]

Talked to the engine builder today. He had already started test assembly with the 83.5mm crank. He spun up the 83.5mm crank with and without the impulse sending wheel and determined that it would be best to leave it on as he would have to alter the crank too much for his comfort level to get it rebalanced. He then added he put the impulse wheel back on and locked it in good with locktite.

I mentioned that I had come across another 81mm crank and he told me in his opinion I should stick to the stroker crank even if it is cast. So, I will be sticking with the 83.5mm crank. He also measured the crown thickness of the wisecos and came up with .285" wiseco spec for turbo applications is between .220 and .250 so he said I will perfectly fine hacking off 1mm (.0394") as I would be at .2456" crown thickness which is at the top of wiseco's threshold.

So, that's basically the final bottom end right there. Calculating out to be right about 9.5:1 compression and 1,963cc displacement.

[jrw21]

Started removing the undercoating using a 40grit 3m flap wheel on a 4.5 grinder. It was working well but after grinding this small area the shop was filled with dust so much as I couldn't see anymore. So, will have to wait on this until the weather breaks and I can move this outside. Cut he spare tire well out with a plasma cutter as I will be installing a RCI 12 gallon Fuel cell back there.



Also, received a shipment today. Z3 2.8 turn steering rack! Just needs cleaned up a bit but this should be fun!

[Slowered318]

If I ever build another e30, the rotisserie is the first place it's going. You should beef up the jack points behind the front wheels and flatten the floor pan, mechanics can't resist using those regardless how flimsy they are.

What are you going to do with the spare tire area?

[jrw21]

What are you going to do with the spare tire area?

I will be installing a fuel cell back there this one:

[Slowered318]

Oh, I was thinking you were going to mount the turbo and intercooler back there or possibly the radiator?

[jrw21]

Tore down the sub frame and suspension parts. Much bigger task and time consumer than I anticipated. The rotors were frozen, hubs were frozen, and bearings were broken. I would say this overhaul was LONG overdue. After hours with pullers and pressing I managed to break it all down. I purchased reinforcement pieces from Garagistic. I was going to cut my own but they have some nice pieces at great prices so I purchased a kit from them.

I Purchased their front sub frame reinforcement and sway bar reinforcement and made my own diff reinforcement. I would encourage anyone who has the opportunity to at least reinforce there front sub motor mount area.. Mine was bent way out of shape.  The only reason I noticed is when I went to weld in the reinforcement pieces and they wouldn't fit. At first I thought I received bad pieces however I found a hairline crack on my sub frame and then realized it was bent. Several good blows later with a ball peen hammer got it back in shape. I welded the motor mount reinforcer on the top part of the subframe on purpose in case anybody is wondering. I was running the m5 motor mounts prior to tear down which position the motor a touch higher than stock so welding the reinforcer on top "should" get me back to approximately the same height with m42 poly bushings. Here they are with all the pieces welded in.  Now they are off to get blasted and powder coated!

[jrw21]

The expansion tank hose entry into the cabin before and after:

 

[jrw21]

Slowly making progress on the fuel system..doesn't look like much but stay tuned...:

[Hsiao]

I want't to build my turbo m42 engine,but i have some question.Can you give me a help?

What's crankshaft you use?m44 or m42(this is my first question)

Thx

[jrw21]

I was hoping to get the fuel system mocked up this weekend however FedEx and Amazon failed to deliver all the parts in time. So basically all I did was weld flanges to the aluminum fuel cell for mounting. Tomorrow I plan to cut the aluminum for the other side of the fuel cell. That area will be used to mount the prefilter, pump, and post filter. Also drill and tap the mounting scews fuel cell and system mount. For the fuel filler I am hoping to fab up a filler using the stock fuel filler assembly, hence the hole cutout near the fuel cell.