JRW'S 91 318is turbo build

[jrw21]

Haven't posted in awhile just wanted to say I'm still alive!

New firewall plate for the z3 rack:




Aluminum top fabrication, fastened on with 3m panel bonding adhesive and lots of rivets. Short strand fiberglass and evercoat filler to smooth the edges:








More body work:

[wazzu70]

Looking fantastic!

I found when I did the steering rack swap I had to remove a lot more firewall material than the "how to" articles showed. Looks like you found the same thing

[jrw21]

What flywheel and clutch setup did you end up using with your zf? I was planning on running the m20 flywheel and clutch setup but can't seem to source a decent one. Started drooling over the UUC kits and am tempted to pull the trigger just not sure on fitment. The site says for the m20 kit they use the m5 clutch with their light weight flywheel. I imagine I would still need the 323 throw out/release bearing.

[wazzu70]

I used an F1 flywheel and clutch from ebay.

What transmission do you have? G240 from the E30 I suppose. In that case I would go with the M20 flywheel and clutch. M20 flywheels should be all over the place. I dont think you actually need the 323i tob either. Dont worry about a ltw M20 flywheel, I had a stock one modified for $75 at a machine shop to copy the 323i flywheel. I don't think thats even necessary either as the M20 flywheel alone is light enough.

[jrw21]

I have a zf310 that I will be using.

[jrw21]

Talked with UUC and pulled the trigger on their lightweight flywheel and m5 clutch kit. Since using the zf they suggested the e36 package with 325i slave. Should be here next week. Can't wait to get it on and put this engine back in!!

[wazzu70]

That will be a really nice kit for you. Since you are using the E36 trans any kit for the E36 cars will work great. The UUC kit has been around a long time and has good reviews!

[jrw21]

Got the kit installed and transmission mated. This kit is really nice fits together with the zf310 and m42 like it was oem. The extra grabbing power of the 240mm clutch will be perfect!

had to make a tool to get the crank bolt torqued to 244ft/lbs spec:






New pilot bearing installed:

[jrw21]

[keflaman]

Looking good!

[nuvolarossa]

this build is a pleasure to watch.
I know that turbo, a bit old school but works great on this engine.
IIRC I had (years ago, not anymore) 7-8 psi at 2800 rpm on a m44, internal wg too. Not too bad, but I had the .48 turbine housing 
Maybe you'll want a bigger one now that engine is fully built.
A little scared about the 86.5 bore, how much wall left between pistons? usually that bore is used on high revving N/A, but if correctly tuned and built it will not be a problem.

[jrw21]

Thanks. Yeah, the turbo is old school. The tubine housing and wheel have been upgraded to flow a bit more. Down the road after I get this thing dialed in I will look into getting a decent matched turbo with ball bearings etc. I'm hoping The .63 turbine housing with the 84 trim wheel will start building decent boost around that same rpm. What was your max boost and respective rpm?

Compressor:
46mm Inducer
60mm Exducer
Trim 60

Turbine:
56mm Inducer
61mm Exducer
Tim 84

To me it looks like there is enough meet between the walls to be ok.

[TheArchitect]

wow amazing build. can't wait to see the rest.

[jrw21]

Engine is back in its home! The shocker was the oem m42 transmission brace was a direct fit. I was certain I would have needed to fab up a special bracket. I made a new oil drain for the turbo, much better routing and location. It was a very tight fit to squeeze behind the crank sensor.

[Darky]

Neat, where is your oil pickup going for turbo?

That will vibrate a lot though with those mounts.