My E46 & E30 Kit Car

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My E46 & E30 Kit Car
Topic Started: Wed 14 Dec 2005, 14:26:52 (1,445 Views)
JazzMan	Wed 14 Dec 2005, 14:26:52 Post #1
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	[/QUOTE] I bought a BMC carbon dynamic airbox for my kit car. I though I would give it a go on the E46. http://www.msportster.co.uk/bmc-cda.avi standing still http://www.msportster.co.uk/bmc-cda2.avi out for a run And my kit car this is still under construction but will be running an M20 2.5ltr and uses 3 series running gear! There's loads more pictures on my website: www.msportster.co.uk :)
	M20 Powered Marlin Sportster


Daryll	Wed 14 Dec 2005, 14:31:02 Post #2
Unregistered	That airbox does sound sweet! So do you have 2 x E46's? Lucky sod! :bmwdance:
Unregistered


JazzMan	Wed 14 Dec 2005, 14:55:20 Post #3
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Daryll Dec 14 2005, 02:31 PM That airbox does sound sweet! So do you have 2 x E46's? Lucky sod! :bmwdance: He he :) That's my mums E46 ;) My dad has an E31 and my brother an E36 Compact! We're a BMW family ;) :bmwdance:
	M20 Powered Marlin Sportster


Daryll	Wed 14 Dec 2005, 15:00:04 Post #4
Unregistered	Very nice too! My old man has an E38 and my best mate has an X5 but thats about it! In the next 2 years the wife will have an E30 cab. :bmwdance: :bmwdance: When will the kit car be finished?? I remember seeing on the zone earlier in the year..have you managed to get much done in the last few months?
Unregistered


JazzMan	Wed 14 Dec 2005, 15:05:09 Post #5
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	No as much as I would have liked, but I'm using the excuse that its bloody freezing in the garage! Although I now have a fully working handbrake system, fuel pipes and brake pipes run, radiator mounted and the prop shaft in place. I'm currenlty trying to figure out where I'm going to put the airbox as there really isnt much room under the bonnet!
	M20 Powered Marlin Sportster


RickyE30BMW	Thu 15 Dec 2005, 03:26:30 Post #6
Unregistered	thats cool :skid:
Unregistered


wilson325i	Thu 15 Dec 2005, 06:28:55 Post #7
PE30 Private 2nd Class Posts: 27 Group: New Blood Member #34 Joined: 10-11-05	damn!! that airbox sounds nice :coolman:
	Have Your Car Featured www.upurspeed.co.uk


JazzMan	Thu 15 Dec 2005, 16:37:00 Post #8
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Space in the Sportster is very tight for that airbox, so if it does not fit my E46 will inherit it!
	M20 Powered Marlin Sportster


JazzMan	Sun 2 Apr 2006, 18:29:11 Post #9
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Thought I would post the build log so far this year for the Sportster: The holiday season has given us time to sit next to the car and think about how and where to run things. The intake is going to be a rather interesting one. I'll let the pictures do the talking once all the bits turn up from Rally Design. Ordered are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with. Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste. The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend. The Rally Design order came today, so we've been able to start putting the intake together! Here are some pictures: Oil cooler Intake system Steering column bracket test fit --------------------------------------- I spent a little time today revising the layout of the intake, its now shorter and less complex. The shelving rail and brackets need replacing with something a bit better :cool: : ---------------------------------------- The oil & water unions are here! What I didnt realise is that the T piece had the right thread for the oil pressure sensor so I have one too many bits. Anyway on to the important stuff: Installation: Parts: ---------------------------------------- We got the brake pedal back from a friend who was able to bend it for us. Now the positioning is much better giving more room between the accelerator mand brakes (we've got big feet!): ---------------------------------------- Oil cooler fitment and revised radiator fitment: ---------------------------------------- Order from Car Builder Solutions turned up today, placed on Friday afternoon! One heater and plume, a rivnut gun, universal band and a set of dash warning lights (I really didnt like the ones that came with the kit so I order these instead): I've done a lot of work on the steering column bulk head mounting on sunday, it was nice and sunny so out the driveway! I've not put any pictures up yet. ---------------------------------------- A number of new items this week! The modified tank is complete, the oil pipe connections are prepared for clean up. Finally much of the coolant system is planned out and ready to finalise: ---------------------------------------- Time for another version of the radiator bracket! Its now bolted along the sides with two strips of metal either side of the rad. Bolts need shortening to and a lick of paint to clean it up. All the water pipes for the front of then engine are now cut to size and routed. Currently the bottom pipe is zip tied to the bottom of the radiator - I'd like to find a more elegant solution for this but it will do for the moment. Oil pipe test fit, not sure yet how we're going to run these so these are just where they will fit at the moment. The oil cooler connectors we have are the straight type so are most suitable for running the pips this way. 180 degreee connector would work for going under and along. More research need on this one! ------------------------------------ Today we installed the fuel level sender in the fuel tank - sounds easy but it took most of the day! Stage 1 was to figure out the numbering system as the chart that came with the sender only when down to 180mm deep tanks. The Marlin tank is 160mm. Luckily it was quite an easy one to figure out - 160mm depth, 67mm pivot, 63mm radius. Next on the list was to make the hole that the send goes in. It was all going well until the dremel (110v 20 odd year old model) finally giving in and died leave the rest of the cut out and clean up to me done by hand. Still turned out quite nicely: There was a lot of mess in the tank, but luckily one of the vacuum cleaner attachments fits in the hole! This only leaves figuring out how to attach the fuel hose to the tank and mounting the filter/pump! ------------------------------------ Busy weekend! We've installed the car builder solutions heater and put the oil cooler pipes in. The oil return pipe on the engine recieved a new spring, washer and o ring. The steering column is back out to clean up the bracket that holds it and adjust the bottom bracket. ------------------------------------- A quick trip to B&Q and one hardcore MAPP blow tourch later the two oil pipes are bent out of the way of the steering column with ease! CBS Throttle cable through the bulk head. The thread on this had to be chopped back so the pedal could move all the way up. We've bolted on throttle cable at the other end - the cable is current 5m long which is a bit much! The throttle is still a bit stiff with the long cable - We're hoping that it will loose a bit once its shortend. Parts from the donor heater system - The two pipes use opposite connector types therefore when connected we can use this as an inline electric controlled valve to regulate the amount of hot water that flows through the system from a control on the dash - much nicer than a manual valve hidden under the dash! ----------------------- Following on from this thread: http://www.talkaudio.co.uk/vbb/showthread.php?t=151195 I'm looking for someone to build an exhaust for me: black-cat Patrick, do you want something good or something loud, badly made and bad for the engine? :) Do you need the manifold making too? Something good and something that's less than 101db (1 meter from tip - SVA req.) Yes need a manifold too. EDIT: Budget wise I've got around �800 to play with - maybe a bit more if its something really good. Looks wise I'd like pipes out the side of the engine bay - like this only evenly spaced: Finishing with the pipe on the side - similar to this only with 6 pipes: ------------------------------------------ Heater pipes added - CBS sent the wrong size pipes - too small, managed to get them on anyway but they kink on the bends so will have to replace them. Probably with two 90 degree silicon hoses. Fuel pipe straps - Doh! hmm should really have thought of this before making a big hole in the tank - never mind just moved the straps over. Fuel pump, filter and connection in place: ----------------------------------- Wire, wires everywhere! We've started on the loom this weekend while waiting for the fuel pump! There's only a few bits on construction work left, the main one being the brackets for holding the AFM, airfilter and header tank. There's a few minor bit hose left and lots of hose clips! On to the pictures, some working in progress on the wiring loom: ----------------------------------- Decided to use the BMW header tank using Robin's car as a model! AFM bracket part 1 - this fixing is not yet strong enough - the metal flexs too much to hold it safely. We'll need to add a more solid metal bracket up from the bottom. Other end of the bracket - holds the carbon airbox and the bottom of the header tank. The carbon airbox can be moved further forward by shortening the blue silicon hose making more room at the back for an intake pipe. This bracket used to hold the diagnostic port in addition to the two sensor plugs - theres not much room here anymore so were going to move the diagnostic connector else where. The bracket has been cut and attached at a different angle to normal.
	M20 Powered Marlin Sportster


loopylee	Sun 2 Apr 2006, 19:23:15 Post #10
PE30 Sergeant Major Posts: 5,038 Group: Admin Member #35 Joined: 10-11-05	not sure where you are based mate but this company http://www.custom-chrome.co.uk/ made me a sweet backbox while i waited for �100 with twin dtms i know they make complete systems to order as there was a old mgbgt there that was running a big v8 and it had twin exhausts down each side and it looked really good they use mild steel or stainless if you want they are in nuneaton HTH lee



Rich	Sun 2 Apr 2006, 19:27:58 Post #11
PE30 Staff Sergeant Posts: 1,243 Group: PE30 Members Member #38 Joined: 10-11-05	Looking very good Jazzman, when do you think you will be ready for the SVA?



JazzMan	Sun 2 Apr 2006, 21:07:01 Post #12
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Thanks for the link, I'm in central Hampshire so Im looking around this area. Custom Chrome are a bit far away :( SVA, not sure yet probably mid to late summer depending on how it goes :skid:
	M20 Powered Marlin Sportster


JazzMan	Sun 23 Apr 2006, 22:24:30 Post #13
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Here's the last few weeks worth of progress: Spent all day in the garage but the only really constructive thing to come out of it was a mounting for the fuel pump: --------------------------------------- Misc items done such as finishing the steering column mount and putting the pedal box in for the last time (we hope!) New tubes added AFM Mount: Also started wrapping the engine wiring loom ready to go back in the car. -------------------------------- We've spent quite a lot of time on the engine wiring loom this weekend, routing elements of the loom and placing key bits of kit like the ECU. Decided to put the ECU on the passenger side - there's plenty of room there. Also the whole engine loom will enter the car through the bulk head with the rest of the element routed around that. The coil pack as moved over to the other side of the engine bay - with a bit of cable rerouting there is no need to lengthen the cables to this. The motronic diagnostic port has a home on the top of the bulkhead where its easy to access. We've also painted up verious brackets and created a panel to cover the hole in the bulkhead that the engine wiring loom is passing through.
	M20 Powered Marlin Sportster


loopylee	Sun 23 Apr 2006, 22:28:58 Post #14
PE30 Sergeant Major Posts: 5,038 Group: Admin Member #35 Joined: 10-11-05	its coming togeather well mate looks like youve been a busy bunny



Andy	Sun 23 Apr 2006, 22:59:47 Post #15
Site Designer Posts: 2,270 Group: Site Security Member #3 Joined: 1-11-05	brilliant thread if i havnt said so before :D are u using the e30 chassis for the build?



JazzMan	Mon 24 Apr 2006, 10:50:17 Post #16
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	johnono Apr 23 2006, 10:59 PM brilliant thread if i havnt said so before :D are u using the e30 chassis for the build? Thanks :) The chassis completely new from the kit manufacturer. The main E30 bits I'm using are: Engine Gearbox Diff (3.91 lsd :D) Rear trailing arms Drive shafts Steering column Front struts (modified, top lopped off) There lots of other little bits and pieces too.
	M20 Powered Marlin Sportster


Daz	Mon 24 Apr 2006, 10:58:54 Post #17
Return Of The Jedi Posts: 7,454 Group: PE30 Members Member #2 Joined: 30-10-05	gotta say im really enjoying this project its nice to see someone daring to be different keep up the good work mate :bmwdance:
	[img=http://img132.imageshack.us/img132/6317/bhgbwkkgrhgookkqejllmwt.th.jpg] How do you get 20 assylum seakers in a shoebox? ( tell em it fkin floats ) www.dangerfm.co.uk


JazzMan	Fri 28 Apr 2006, 18:53:38 Post #18
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Thanks, I've got next week off work so I should be able to get a lot done :bmwdance: I hope to do some engine work to it once its done. Its already getting a carbon air box and custom exhaust. Planning on BBTB and zone chip as well. Might give Birds a call and have a chat about getting the engine bits of the H26 conversion done. I've also been thinking about an Emrald or megasquirt ECU.
	M20 Powered Marlin Sportster


jonno	Sat 29 Apr 2006, 21:01:24 Post #19
Posts: 9 Group: New Blood Member #329 Joined: 3-01-06	Hi, your Marlin is starting to look good. I always liked the purple one with the M lump in (think it was a demo car for a while). Its gonna have great power to weight when your done : ) Sorry i know its not a E30 but my toy
Posts: 9 Group: New Blood Member #329 Joined: 3-01-06


Bades2001	Mon 1 May 2006, 09:45:10 Post #20
PE30 Specialist Posts: 100 Group: PE30 Members Member #771 Joined: 25-04-06	Wow great project mate! Your M20 looks Hot :drool: Cant wait to see the final product :cheers:



JazzMan	Mon 1 May 2006, 11:28:41 Post #21
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	jonno that looks really cool :D yeah the purple one was the demonstraighter - unfortuantly they'ed sold it before I went to see them! I think mine going to end up with a coat of mystic blue as seen on new BMW's Its got really nice shade changes in the sun! I went to the Stoneleigh kit car show at the weekend - lots of pictures include quite a number of finished Sportsters: full gallery with 195 pics here: http://www.msportster.co.uk/detail.asp?cat=12&offset=0
	M20 Powered Marlin Sportster


jonno	Mon 1 May 2006, 18:45:44 Post #22
Posts: 9 Group: New Blood Member #329 Joined: 3-01-06	Some nice pic's there, love the ultima's (hmm one day i hope) good luck with your build : )
Posts: 9 Group: New Blood Member #329 Joined: 3-01-06


Bades2001	Tue 2 May 2006, 11:46:09 Post #23
PE30 Specialist Posts: 100 Group: PE30 Members Member #771 Joined: 25-04-06	I want a Nobel M12 gto :cry:



JazzMan	Tue 27 Jun 2006, 21:54:54 Post #24
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	It's alive, nearly a year after it last ran its alive!! http://www.msportster.co.uk/itsalive.mp4 You'll need Quicktime to play as its off my phone :bmwdance:
	M20 Powered Marlin Sportster


Daz	Tue 27 Jun 2006, 21:59:41 Post #25
Return Of The Jedi Posts: 7,454 Group: PE30 Members Member #2 Joined: 30-10-05	:bmwdance: cant wait to this finished mate bet ur buzzing now :skid:
	[img=http://img132.imageshack.us/img132/6317/bhgbwkkgrhgookkqejllmwt.th.jpg] How do you get 20 assylum seakers in a shoebox? ( tell em it fkin floats ) www.dangerfm.co.uk


loopylee	Tue 27 Jun 2006, 23:31:51 Post #26
PE30 Sergeant Major Posts: 5,038 Group: Admin Member #35 Joined: 10-11-05	didnt sound too healthy to start with m8 but once it was started it sounds sweet keep up the good work mate cant wait to see it finished lee



JazzMan	Wed 28 Jun 2006, 08:04:38 Post #27
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Yeah I was a bit worried to start with, but once it got going :rock: Need an exhaust now, or we'll go deaf :LOL:
	M20 Powered Marlin Sportster


JazzMan	Mon 31 Jul 2006, 12:00:38 Post #28
PE30 Lance Corporal Posts: 194 Group: PE30 Members Member #193 Joined: 13-12-05	Yesterday we replaced the busted clutch slave cylinder & also replaced the master at the same time! Bolted on the old E30 exhaust. There was nothing stopping us from taking it for a quick spin! (Literally as I found out with the rather sharp clutch on the first run or two ) http://www.msportster.co.uk/sportster.avi (6.1 Mb DivX 5)
	M20 Powered Marlin Sportster


loopylee	Mon 31 Jul 2006, 16:33:26 Post #29
PE30 Sergeant Major Posts: 5,038 Group: Admin Member #35 Joined: 10-11-05	its coming togeather now :bmwdance: lee



Mart	Mon 31 Jul 2006, 18:37:38 Post #30
Moderator Posts: 3,461 Group: PE30 Members Member #343 Joined: 5-01-06	Nice one mate! Its a great feeling when "it lives again" after so much time and effort. Been there (not like this) 24 yrs ago but still remember when it took its first breath again! Mart. :bmwkick:
	Nice one Cloud


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