My Rotrex build going for 300bhp+

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Ruger

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My Rotrex build going for 300bhp+
« Reply #30 on: January 09, 2009, 10:47:35 AM »
Love it!!!!!!!!!!!!!!!

Big fan of your fab work. Good luck with the rest of the build it seems a great project

rob_e30

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My Rotrex build going for 300bhp+
« Reply #31 on: January 10, 2009, 11:17:53 AM »
We really need one of these for the race car...

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My Rotrex build going for 300bhp+
« Reply #32 on: January 11, 2009, 03:11:46 AM »
Have you see the 666 fabrication ally one? quite expensive but it does look alot better than mine and its bound to be loads lighter.

http://store.666fabrication.com/m42-short-runner-intake-manifo.html


O/T rob could you give me the part number of the rubber bits that plug on to the spark plug and he coil on the coil on plug adaptors you use??

Ive bought 8 new ones from a rangerover V8 (BMW engine) with the same bremi part number for the coils and tha same bmw part number but i'm  not sure the "pencil" bit is the same as the BMW one you use.

Cheers, matt

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« Reply #33 on: February 22, 2009, 10:27:18 AM »
Bit more progress over the last two weeks or so firstly i finished off making the tesioner, ive used an E36 m43 idler pully which also donated its crank pully to make the charger pully so its should be rated at the same sort of rpm/power.





Trail fitted the inlet manifold today and worked out were the FPR will fit, fingers crossed it wont be need after its mapped and it will run fine on the 3bar reg but it gives me the option to play about if needed.



Made this plate to bolt up to old air box mounts so that i can mount the supercharger oil resivour of it, it right next to the charger so the pipe length to the supercharger oil pump is kept to a minimum which is good.




Made a plate to mount on the old throttle pot bolt holes with the large plug and now fitted the newer smaller throttle pot with the now normal plug on it.


Nothing realy major but i decided to paint the charger bracket silver just to stop it going rusty and looking crap. need to sort out the wiring for the oil temp and pressure sensors to now i can get there. :D


Somthing that i was never realy happy was the old oil resivour i fitted from the suzuki swift, it did a job but mountd off the strut brace it looked naff and the pipes were in the way.

Found my old origonal one cleaned it and refitted it and replaced the low fluid  level  switch, always nice to know youve got brakes :D



Mark, that inlet looks great in the other pics you sent, keep emailing you back but 3 days later i get a Email not sent warning! god knows why. Any more news on it by the way?

Would a 540 throttle be any good to you? its around 82mm, fits over a 3" pipe anyway with alittle to spare.

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« Reply #34 on: February 22, 2009, 10:30:07 AM »
Just done a little more, got my injectors back from being cleaned at Emerald and fitted them to the inlet manifold.

They were £30 and are from a rover 620i but they are also fitted to other rover trubos like the 220.

Cleaning From emerald with new lilters, tips and o-rings was £15 each
 
For any one intrested there 440cc at 3bar or 460 at 4bar fuel pressure.

Part numbers on the injectors are
MJY100460
D3184GB
0646





Few bay shots for you Rich.





Little more progress, got the bracket for the resivour mounted on the plate i made, used some rubber mounts to holed the plate to the airbox mounts so that i can pick up on the other stud to make a flexible mount for the inlet pipe so it can rock with the engine.



Also got these hose tails fitted today, the inlet is now fitted all sealed up and ready to go! :D



TB pics for you, it mahooosive! think the palte bit could be machined down easy to make it more managable. its actualy two Tb's one normaly open and one normaly closed, is one the traction control? you dont need both for it to work, its a 540 one ya E39

what size trumpets do you need?









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« Reply #35 on: February 22, 2009, 10:33:47 AM »
Ignor the throttle pics they were for a freind whos doing turbo 325inlet.

Well another good bit done to the project, been realy busy at work but mangaed to get a few bits done.

After all my questions on the m20 clutch swop ive managed to get someware at last.

thanks chris w, town325i and odbod especialy.

Heres a few pic of the m20 b23 flywheel compared to the m40 one which most uk IS's seam to come with. bit of a weight differance.




Only 1mm differane from the crank face to the back of the flywheel, nothing to worry about.

Had to use a m30 starter in the end an mahine the back of the pinion gear down where the spring sit.

you can see where i had to turn the shamfer back on to the back of the pinion, also had to put the groove back in were the spring clip clamps to holed the spring on the shaft. :D





Now i can run an m20 b25 clutch which should take the torque.
i just have to use the e21 323 release bearing whih was £70! £20 cheaper than the sach clutch kit that came with a 325 release bearing which unfortuanly is the wrong size which is why i need the e21 one

The thing is that the m20 has all the weight near the centre of the wheel which helps more than the weight loss its self. :D

Bought these off ebay last week, Supertech valves with a nitrid coating. there designed for boosted aplications and are solid rather than the sodium filled so there shouldnt be any trouble with them when they start to work hard and get hot in my set up :D

coatinghttp://www.nolimitmotorsport.com/supertech/valvetrain.html




Also bought the retainers, seats and dual springs that the guy was selling. pics to follow

Only problem i can see is that the supertech valves are 1mm thinner on the stem than the standard ones so i will have to get some guides/seals to suit. any ideas?

manjambles

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« Reply #36 on: February 22, 2009, 10:30:03 PM »
im excited to hear how this comes out, i was intrested in a super charger kit also.   i just dont know what to do when it comes to the ecu, do u run a standalown

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« Reply #37 on: February 28, 2009, 02:59:22 AM »
Got some progress on the flywheel swop, got another engine and gear box bolted up upside down and bolted all the flywheel assembly on to it with the modified starter, connected a set of jump leads up and and it burst in to "life"/ turned over :D

No i know it all works i can get it properly bolted up.

i had to turn it upside down as there was no way of sitting it on the floor with the sump still on.

The head was already off when i got the engine off kedge and someones glued the sump plug up so its still pritty full of oil to.





Bit rough but it proved a point :D

Got it running to day, the first vid, running with the trottle set up wrong.

[youtube]http://www.youtube.com/v/DziUacOQJPM[/youtube]

This is later tonight once it had been idling for a bit and the enigne was up to temp, still got a  3000rpm limit for the first 60miles to run the charger in.

First i forgot to reset the throttle limits so the ecu thought the throttle was open but it was shut so it was over fueling, anyway heres the vid of it running properly. need to tidy the bay up now i know it all works ok.

[youtube]http://www.youtube.com/v/GCW9VSA4EpA[/youtube]

bearsbmw

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My Rotrex build going for 300bhp+
« Reply #38 on: February 28, 2009, 03:11:04 PM »
Be intrested in purchasing a intake off you if you ever decide you wan't to fab more ... PM me if you decide to do some ... thanks!

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E30 single head lights (all in one)
« Reply #39 on: April 12, 2009, 02:46:21 AM »
Breakthrough with the lights!!!

It would appear that the kind people at BMW made the bracket for the smiley light just then right size for the new head lights ive got to fit streight in to!!

I'll let the pics do the talking but this seams like its now going to be a case of a few self tapper in to the bmw frame from the frame of my new lights and a loom plug :D






Only thing i need to check is how far back they sit behind the grill but i'am sure its going to be pritty close!



Time for a small up date.

Got the lights finaly working after a small problem, copied the diagram with the relay from rix313s thread to turn the dip feed off when the main beam came on so as  not to burn the bulb out.

Worked fine with the lights on but it ment that because the mains were relying one feed from the dips to supply the mains when the main feed switched the relay if you didnt have the lights on you would couldnt flash any one, say at junctions or what ever.

so spoke to rich to see if he's managed to work out away round it which he had, running the mains off the switch of the relay (main feed> relay coil> lights> earth)

It worked but on my lights anyway it made them dim, probly the coil acting like resistor. So anyway i linked the main feed to the coil to the + for the light and meaning you could flash some one but if you had the dips on you wouldnt be able to turn them off.

nearly there, the main was feeding back through the relay and keeping the main on so.... i disconnected the pin from number 87 on the relay so when the relay switched from the main feed it turned the dips off but didnt  turn anything else on as the mains feed was  linked to the main beem light directly, hope that makes sence :D  :D

So heres the finished look.





Also got the car booked in to go and get remapped at emerald on the 3rd of april to get a rough map to run the new engine in when its built up :D  should also get a good feel for how its going to go when its done :D

To get the car running and drivable i fitted this copper dip stick tube to make it all work but wasnt relay happy with it.






So borrowed some pipe benders from work to day and bent an origonal dip stick to fit :D  just need re painting.




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« Reply #40 on: April 12, 2009, 02:47:20 AM »
As some of you may know i bought some M42 supertech valves, retainers and springs off E-bay from a guy in ireland from an unfinished project.







These are solid and made of better suited material than the bmw ones for my boosted application.

However, when i got them and measured them the stems were only 6mm not the usual 7mm on and e30 m42,  e30 is the important bit here, emailed supertech ot ask how i was supposed to fit then and made out i'd just got them from one of there dealers.

Turns out then never new the m42 was in a E30 and these valves were made for the e36 m42 which had 6mm valves from  mid 92 onwards up till the m44 came along. however they did offer to make me a set of new guides so they would fit my e30 7mm head for £8 each plus Vat + shipping

Pure luck would have it i bought a  e36 m42 head off kedge last year with a job lot of m42 bits he was selling and the guides look to me good in this so ive have sent this off to be re cut to suit the new valves.

the other problem is that the stem seals are also 6mm and these are also harder to get hold of although ive now been able to get hold of some, and the guides are NLA just so you know.

Before the head went off i stripped it and steam cleaned it, heres the pics.





And whats all this got to do with todays up date?

When i sorted the stem seals it was only a tenner more for a Victor rymes ( eom) head gasket set than bmw wanted for just 16 stem seals and i thought that the other gaskets would probly come in handy at some point, like today, so i orderd one.

I orederd the gasket set thursday and was told it would be here today for me to pickup from parkside bmw.

So woke up early on my day off and started to do the timeing case gasket which has leaked ever since i got the car but has started to get worse of late, thought i'd be able to get to the gasket without taking the thermostat housing off but snapped one of the heads off the case bolts in the removal process and it turns out i wouldn't have been able to change the gasket anyway with the housing on.



so a simple job turns in to a major one, draind the coolent and removed the housing, removed the timing case cover which wasnt realy down to the gasket and was sitting proud of the rest of the head at the top( the holes are slotted so it does move during installation) this means the cam cover/gasket was sitting on a small step, removed the snapped bolt stud with mole grips.


It is actuly quite clean in there although the phones flash has made it look abit more orangey than it is.


next stuffed half a roll of kitchen paper down the timing case hole to stop sh1t going down when i cleaned the gasket surfaces (yes i made sure i got it all out again :D ) also borrowed the hoover to catch the crap thas had got in the little gaps.

You can see from the cleaned timing case were the oil had soaked in to the crap on the cover and stopped it from corroding
theres a diagnol line from between the top and 2nd hole on the left hand side to the bottom hole on the right hand side



So with everything cleaned ready to be re assembled rang parkside, no gasket set, ECP/GSF have no 6mm stem seal gasket sets in stock at any store. so its been reordered from some were else for tomorrow.

Moral of the story, never ever do a "small job" when you know you need your car the next day, or when its going 100miles to get remapped on friday, i should no better :mad:

Also got this made at the weekend for my run down to emerald as the cars abit hard to drive as you cant use light throttle openings to much or the AFR leans out, its ok on WOT though winkeye






Well, went down to see Dave Walker yesterday and got the car remapped with the new charger on.

Set off from mine at 12 and got to his for 3ish, i can say that a 3hour 100mile drive in a a car that you cant realy use part throttle on stuck behind lorries on the A17 isn't much fun!

I had to keep dropping back, using half throttle then knock it out of gear and coast for a bit to keep the AFRs from going lean.

The journey back was alot smoother apart from a large foam fire extinguisher i had on the back seat went off whilest exiting a roundabout, the hose  was pointing forward and sent foam on to the back of the seats, dash, windscreen and me, then filled up the back seat foot well so i had to stop and clear some of it out, you can just see what i scraped off my arm on to the floor in this pic, luckily it seamed to disolve ok with out damaging anything. :D  Sh1t me up abit :lol:



Anyway, heres the results so far, Asked dave to map it up till it made 8psi boost as i didnt what to go much more than what it was running before still on the standard internals.

BHP - Red
Tourque - Blue
AFR - Green
Boost - Purple



And heres the new plot against the first set up.

Supercharger setup #1 - 205bhp@6521rpm  178ftlb@4310rpm
Supercharger setup #2 - 187bhp@5301rpm  185ftlb@5301rpm



As you can see from the graph the new setup is going to be a much more topend power build and feels as if just starting to get in to its stride past 4.5krpm which is what i missed so much with the Eaton blower making the car much more low down torquey car.

Just looking at the curves and putting a rule next to them if it carries on rising like it appears to be at 6500rpm i think i should be seeing something like 13-14psi boost and 260ish BHP, which int bad but i was hopeing for a little more, so might have to fit a smaller pully at some point although i cant find much info on how the rotrex boost changes as they become more effiecent higher in the RPM.

I also had the pleasure of seeing/hearing the RX7 with the LS? engine in it Dave writes about in his "Walkers World" section in PPC 7ltr 700bhp  V8 :drool:  :wan:

What a car that thing is, dave took it for a spin and said you can almost feel the chassis twisting under the power

JBGbimmer

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My Rotrex build going for 300bhp+
« Reply #41 on: April 20, 2009, 09:54:39 PM »
love this thread, subscribing right after i post this. im just wondering what you are running as far as a computer because i dont think there are too many tuning shops around me for e30s so i would probably have to self tune, which i dont trust myself on too much :(. and what did you ended up doing to lower the compression. im really new to e30s, i dont even own one yet but im trying to pick one up within the next month, and i love the rotrex! :D

visionracingdevelopments

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« Reply #42 on: April 22, 2009, 03:41:38 PM »
I thought the same as you RE tuning but its so easy on these they're fab cars. There are loads or tuners about if you dont feel up to it too.
http://www.visionracingdevelopments.co.uk

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« Reply #43 on: April 24, 2009, 01:41:14 AM »
I'am running an Emerald ECU, mapped by dave walker at Emerald

http://www.emeraldm3d.com/

nickmpower

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« Reply #44 on: October 09, 2009, 12:07:27 AM »
is there a reason you didnt put the supercharger where ac used to be?