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Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 16 Apr 2016, 15:41
by Miuge
Recently I've machined and bought some new stuff.
Current engine mounts were kind of temporary, never welded them complete, because turbo and supercharger locations were only approximate.
I wanted a lower design to clear the turbo intake pipe.
The design, steel sleeve with delrin bushing:
This was something I could machine by myself :rolleyes:
Obviously I had to mockup alternator location before making intake/charge air piping, but the old one had seen it's best days. Instead of refurbishing and machining new pulleys for the old one I bought a new, smaller, modern alternator:
This spring and summer will probably be busy time with the project, more parts is already on the way
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 04 May 2016, 22:08
by Miuge
Some new bits acquired, Toyota MR2 electric power steering pump. Remain to be seen if it's even working, connectors had damaged badly during shipping...
Today's job was to make another front fender, it was easy one, I used the same cardboard templates which I made for the driver's side:
Extra pic:
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 15 May 2016, 10:00
by Miuge
This will be a frustrating and time-consuming job
1 out of 4 corners in progress, after spraying a paint layer I noticed one spot needed to be cut open and hammered down.
Finally got all the parts for the control arms, roll-center/bump steer -adapter fits perfectly
Also few lengths of aluminium tubing appeared this week, need to build up
something of those
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 19 May 2016, 22:21
by Miuge
Earlier this week I bought few liters of paint, should be plenty for mock-ups and molds. I picked the same hue which might be the final color, we'll see...
At this point the fender starts to look like something, but still a lot to do. A couple of bigger dents showed up after the first gray paint layer.
But... this will probably do, picture taken this evening. I'm afraid something goes wrong when I start to mess up with fiberglass
I think I should take the camera more often with me, mobile pics look crap besides these..
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 20 May 2016, 21:43
by Miuge
Paint paint.. Color looks perfect to me, just the way I wanted it to be, nothing too fancy. Paintwork ok for molding:
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 20 May 2016, 23:35
by rockker
Really awesome
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 26 May 2016, 21:38
by Miuge
Thanks!
After the front fender was done I moved to the rear end to see if I could conjure it up to "mold ready". Massive filler layer hid under the paint. Round corner will be made into the mold, I find it easier than forming the metal mockup.
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 28 May 2016, 16:45
by TreLingon
Nice job !!
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 01 Jun 2016, 21:02
by Miuge
Thank you
I'll have to wait for wheels and tires to check if it's good to continue the fender or start again.. I don't know what I've measured or left unnoticed, but my latest measurements kind of worried me
Anyway.. postman brought me some goods; Davies Craig electric water pump and controller, now I can get rid of belt driven pump and thermostat housing, keep things simple
Package also contained very compact cabin heater and a 16in radiator fan:
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 10 Jun 2016, 14:49
by Miuge
Tires arrived yesterday..
All I can say that's a lot of rubber! Although they look massive it will fit inside the fender strictly:
To avoid ruining them in the first practices I ordered E46 MK60 ABS/DSC unit, but only ABS will be used. I've seen people using MK60 standalone systems earlier, but the price of the complete harness was far out of my budget. Lately I started to sort out ABS system again and found out it could be done by myself maybe.
If anyone has a complete wiring diagram or MK60 ABS unit pin layout, please send me a message! All the info I've come across is kind of dispersed..
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 15 Jun 2016, 21:17
by Miuge
Here's the Mk60 ABS unit. This thing is mini size compared to E30 pump + ecu!
I'm probably going to mount it in passenger's footwell, easy to route piping and electrics. Cabin heater will be bolted somehow over the IC:
ABS unit sits nice behind the aluminium foot rest:
http://i187.photobucket.com/albums/x281 ... tseub5.jpg" onclick="window.open(this.href);return false;
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 23 Jun 2016, 19:10
by Miuge
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 04 Aug 2016, 21:15
by BmwClubFinland
Hienolta näyttää!!
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 06 Aug 2016, 11:30
by Miuge
Kiitän!
Summer vacation is over... back to work and back to build the project.
I supposed to fabricate intake manifold right after the exhaust was done, but I ended up doing something else. Now I felt like doing aluminium parts. Previously I did aluminium charge pipes for my friends E21 turbo and welding felt pretty easy, maybe because of the thicker material or gained experience
Anyway...
Got to start from somewhere, cut hole for IC to throttle body -pipe:
Making plenum backplate:
Our hydraulic press channel:
Now with integrated trumpets:
Next on to do -list are the runners, there's no too much space and I think I have to do some minor compromises.
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 06 Aug 2016, 11:34
by Miuge
One day I tried how things fit in those RF wheels, 15mm spacer is minimum to clear the caliper but with 7" inner barrel it's pretty close to damper. So maybe a 6.5" barrel would be a better choice.
As someone might ask, here's the complete list of the parts:
-E36 M3 spindles
-E46 M3 OEM rotors with aluminum hub
-Brembo ZL/ZR18 calipers
-MagnusRacingTeam control arms with roll-center/bump steer adapters
-K-sport circuit dampers with custom valving and spring rates for my car
If anyone else is interested in similar front control arm kit, I've got a few extra sets in stock.
U.S. buyers please contact
dylan@neuemotorsports.com he's making a pre-order.
Scandinavian buyers please contact
info@motornord.se
If located elsewhere, please contact us
magnusracingteam@gmail.com
"These control arms are made for E30 chassis to accept and correct the front end geometry using E36 or E36-M spindles.
E36-series spindles are often used to get 5-lug bolt pattern, but they also have better variety of brakes and coilovers than E30-series. Spindle itself has better geometry for racing as it is closer to E30 M3 variants.
The most notable advantages are correct wheel location and roll-center/bump steer correction which are decayed when substantially lowering the car. On the side the adapter plate also makes the steering ratio quicker. Kit only has about half the weight of orginal cast control arms.
The kit offers a chance to adjust the front end the way you want it; width, caster and anti-dive properties are all adjustable.
This is pure motorsports from the E30 DTM era."
Re: BMW E30 Street/TimeAttack (exhaust manifold and aero)
Posted: 10 Aug 2016, 21:21
by Miuge
...story of the intake manifold continues:
Tuned length 330mm:
Re: BMW E30 Street/TimeAttack (intake manifold fabrication)
Posted: 14 Aug 2016, 09:27
by Miuge
Next thing was to make the airbox/plenum part. Space was limited but the volume will be near 9 liters when finished. I think there's no ultimate formula for calculating ideal volume, but 2-3 times the engine displacement should do when seeking at maximum power.
Started with two long radius elbows and a piece of straight tube:
Tried to fabricate a smooth air inlet transition piece, this should distribute air better than just an elbow welded to the bottom:
