BMW E30 Street/TimeAttack (DTM style control arms)

[TreLingon]

Really nice... Sick project !!!!

[OPKNSE]

You are a very god car builder and fabricator! I'm very impressed!
/ Viktor E

[Miuge]

Thanks TreLingon och Viktor! I try my best to fulfill my criterion, nice to see it meets with others taste too

Lately I was browsing the interwebs looking for a throttle body to get the intake finished. No reason to go massive size flap so I wanted one to fit my alu elbows. I found a 80mm TB and same shop was selling v-band flanges suitable for the upcoming exhaust system, incidentally I found an oil filter relocation kit with thermostat, I think the blue color won't stay though...

[Miuge]

One busy month behind, but not with the car.. Some progress with cylinder head and intake manifold.

Along with some other laser cutting parts I finally ordered an adapter plate for the gearbox. I've machined a centering tool to align everything perfectly before marking the holes.


Earlier when starting to make the intake, I was talking about one minor compromise..
There was no enough room for the supercharger or atleast it would have been very difficult to mount it with all the piping etc, so I decided to get rid of it.

Now it's only this baby taking care of the boost production Custom 1.10A/R exhaust housing is on it's way.

[Miuge]

Yesterday I visited at the garage measuring and listing the bits needed to mount the new parts.
First note; my centering tool was slightly too big to fit crank bearing slot, need to machine max. tenth of a millimeter off:


Adapter plate test fit:


Found a pic how the intake manifold matches the port:


And as you can see in the earlier pictures cylinder head was full of dirt, dust and metal chips so I gave it a little wash:

[Miuge]

I ordered the turbine housing with typical BW marmon flange as it was the cheapest option, I was quite sure I can turn it into a 3.5in V-band:


Like this:


Gearbox adapter flange is now ready with threads and holes, I'll try to find some time to mount gearbox rear end into the chassis this weekend.

For the engine I found EV14 injectors which will allow me to finish the intake manifold (fabricating injector weld bungs, fuel rail and it's mounts). Injectors will be fed by two 380lph fuel pumps.

IGN-1A coils will ignite the mixture hopefully

[Miuge]

Ok I've forgot to post few updates, but here's one video clip

[Miuge]

Here's more comprehensive update of what's done and what not:

S369 turbo seems to fill up the space effectively, in fact my earlier S467 was equipped with a rare small comp cover which is smaller in diameter...


I got my injectors and made couple of weld bungs which turned out too short after drilling the holes




Pile of ignition coils:


I was thinking to order a laser cutted rack for coils, so I made a "coarse" 3D mockup one evening:


Primarily I focused on drivetrain, gearbox adapter plate needed a few holes, apparently I had cutted my cardboard mockup along the wrong line and there was not enough material for one hole, but it was easily fixed with a welder:


Before I was able to make a cross member I hung gearbox from the inside, also I've forgot to take pictures of the cross member and mounts in the chassis:


The gear shifter episode:
Got to start from somewhere, this is what felt a good location:


And how it turned out:

[Luen]

Just love all work you put in this e30!

[Miuge]

Thanks

I got my new longer injector weld bungs and welded the plenum chamber together. Injectors are Bosch 210lb with 15mm extensions with filters.
I also got 2x 380LPH fuel pumps which will feed E85 through the 7micron inline filter.


One day I scanned the oil pump back plate and made a 3D model, a blank will be most likely water jet cut, then machined:

[Miuge]

Holidays... Good time for the project!

Apparently it was time to finish the new engine mounts, now with delrin bushing:


You might remember I just did one gearbox cross member, but surprisingly I wasn't happy with the outcome so I did a new one:
[/QUOTE]

E60 M5 driveshaft needed to be shortened 400mm, I hope my welds will hold:




While fabricating the drivetrain I wanted to revise rear axle carrier mounting one more time. I machined a couple of delrin bushings and formed some sheet metal pieces to get this appearance:




Prototype of a M30 ignition coil rack was finished too:

[Miuge]

I've seen lot's of discussion about damper/crank hub related problems in M30 engine builds lately. I found out some Finnish builders have used ATI 2JZ damper in their builds (both M20 and S38), but I wanted to have some facts before heading to buy one. That made me contact ATI directly, luckily I did, because they didn't recommend using 2JZ damper, probably because it's low weight/inertia (for M30). Their recommendation was bigger 7" damper for a SBC so I started to search one..
One very slightly used item showed up on eBay so I had to buy it

I'll have to fabricate a new crank hub and trigger wheel to make it fit, a good thing that's a serpentine damper so I can directly drive my alternator belt with it:


Some time ago I had to acquire couple of aluminum chunks to fabricate some engine flanges, the first one was oil pickup plate I made by hand. Still need to add AN10 fittings to draw the oil line to remote oil filter sandwich plate.

[Miuge]

Yesterday I spent few hours thinking about the damper solution, first I gathered critical dimensions of the orginal damper, crank and hub, then I moved on designing new parts.
Chevy hub is much sturdier than M30 hub, but changing the crank front seal to a next ID size I could grow the wall thickness


Everything seems to fit rather well, trigger wheel could be located behind the damper which means orginal sensor location could be used, also belt line remains pretty much the same as orginal of course the v-belt pulleys should be changed..

[Miuge]

I made two more flanges, one for water in and another for water out, I'll weld 40mm bends to both flanges. No more need for that big thermostat housing because EWP


Earlier I acquired boxful of silicone hoses for coolant and charge pipes from size range 16mm to 100mm:

[Miuge]

Now that I got my ATI shell assembly I was able to get accurate dimensions for the model, then just turn on the printer and this it what I got:


I also made a 3-piece trigger wheel as my printer platform isn't big enough for a single piece:


Next I should try if it fits in the engine

[Miuge]

Clutch setup arrived, probably not going to use twin mass flywheel


Now that I also got silicone hoses I continued welding, first mounted a throttle body:


Then the other side, that's the only place where I was able to mount blow off valve:


Some coolant pipes and new mounts for the power steering pump:

[Miuge]

I had some struggle machining the oil pump back plate manually, I did two versions which didn't turn out too good. I also tried a shortcut welding a sleeve into the orginal cast cover.. Because of the high Mg content welds won't hold even if they would look good, here's the result of light hammering, crispy:


It was time to start over, I did some changes to model and discarded the idea of a water jet cut blank because of it's ridiculous price. I happened to find a company which would machine the part for me very cheap with their 5-axis machine. I just confirmed it fits by 3D printing a mockup:

The final part (made of AW-7075) should arrive in three weeks