84 533i turbo build thread

[r.martin]

So aside from supercharger fitment issues.... I have a swaybar fitment issue...

The new steering rack interferes with the swaybar under maximum lock, and this issue is exaggerated when the suspension gets lower... Joy.

I guess I am now looking into a custom swaybar among other things. I guess I am just glad that I did not buy a high end sway bar.

Here are the pics.

[r.martin]

Fixed the sway bar issue. I wasn't thinking last night, all I needed to do was extend the swaybar links.

[spaze34]

What clutch is that if you don't mind me asking.... clutchmasters?

I am unsure of the pressure plate, I purchased it based on dimensions, perhaps not the smartest idea.


The block is supposed to get machined this week........


The head was being assembled last I was at the shop.
Note: I did correct the builder on the use of the lock collars and shims as I had failed to provide the documentation.




And I believe the gearbox we now have is a Getrag 265 as it has a detachable bellhousing.



And there is one experimental idea that I am working on, that I am withholding details on until I am confident it will work, as I have seen two other threads where the OP posted about similar plans and then flamed out.

[r.martin]

Spaze, that is one I had custom made from California Clutch, I called told them the measurements and input spline dimensions. Those guys were really good. I dont recall the costbut it was reasonable, maybe ~$350.

[r.martin]

So here is the suspension maxed out. It was one hell of a weekend, and thank God that I bought that old lathe, one of the most useful tools. This was not nearly as easy going as Stanceworks made it out to be, but now knowing the caveats of air installation I could probably do it again in half the time.

I still don't have the air manifold so I can only show max height right now.

[r.martin]

Ok, FINALLY, my block is being assembled, thank God, as it feels like an eternity since there was a motor in this car.

But first here is a photo I forgot to include of me cutting the suspension top mounts. A 6" lathe is perfect to cut these.


Fitting and gaping the rings.



The builder was quite impressed with the construction of our stock rods.


I took this photo in case anyone is looking for the data on the pistons I've used. They are from RaceTec and here are the numbers. they are modeled for a stock~ bore m30b32.

[r.martin]

Thankfully allot has happened since the last post.

The engine is finally done... or at least as far as the shop is concerned...






And the air bags are functional.

[T_C_D]

Why is the MLS so thick?

[r.martin]

Why is the MLS so thick?

our concern was higher boost pressure with the compound compressor setup.


I have run into an issue, with blower positioning which I knew was coming. Sounds stupid but the oild dipstick is right in the same space that I want to put my output chamber and AWIC from the eaton. I know I can install an electronic level to check oil but I am leary about relying on an electronic sensor for something so crucial. This dipstick issue presents an excellent opportunity to alter the oil system, to a system where I can check the oil by eye and free up some ground clearance, as well as put vacuum to the drain line of the turbo.

[r.martin]

What is this? We could not figure out where this went.

[r.martin]

Finally something you guys may actually be interested to see.
Got the motor in for mock up purposes.


Did some test fitting and confirmed that the dipstick has to go, and machined this plug. Made it a bit oversized in case I need to reverse this later.

Pressed into the block


Did some drilling on the blower adapter plate, then had it milled.



And most important, I made headway in getting the blower mocked up. Still need to source a water to air core but here is as it stands.



Any comments or feedback is welcome, sometimes I start to think it is just me here.

[2dye4]

Amazing work, cant wait to see the final build.

[r.martin]

Amazing work, cant wait to see the final build.

Thank you, much appreciated.

[marc79euro645]

definitely a cool project, I'm real interested in how it turns out.
good luck!

[mitch5]

What are your plans with the intake? I would mock up all the powersteering stuff before starting on the intake. Maybe its just the camera angle but it seems like the blower is mounted fairly low. I would aim for a fairly straight shot from the output of the blower to the intake port.

Do you have back up plans for a dipstick? you could probably heat the tube up and bend it so you can access

[r.martin]

Marc, Thanks for your feedback, nice to hear that others are as interested in this project as I am.

What are your plans with the intake? I would mock up all the powersteering stuff before starting on the intake. Maybe its just the camera angle but it seems like the blower is mounted fairly low. I would aim for a fairly straight shot from the output of the blower to the intake port.

Do you have back up plans for a dipstick? you could probably heat the tube up and bend it so you can access

Hey Mitch, if you look back on the first page of this thread, you'll see that I have converted the steering to a manual rack and pinion, therefore no PS pump. As far as the intake manifold your point is valid, however I have some components that need to fit between the blower and the head hence the low positioning. It will be obvious once they arrive and I can get fabricating.

I am up in the air about the dipstick as I need to finish the intake first, I could modify the oilpan to take a dipstick, or go drysump and check the oil level at the tank.

[r.martin]

Props to everyone who told me how difficult this would be, there are a hundred tiny things that have to be redesigned. making progress have the blower nearly in its final position, working on the tensioner, then time for the manifold nightmare.

[mitch5]

Props to you for continuing on, your build will be more about the fun of getting to the end rather then ever getting to the end. This endeavor has the makings of the guy over on grm with a ferrari 308, one of the best build threads i have ever seen

https://grassrootsmotorsports.com/forum ... 959/page1/.

People including myself love pictures so keep updates coming. If you have pictures people are more likely to respond of give feedback.

[r.martin]

Props to you for continuing on, your build will be more about the fun of getting to the end rather then ever getting to the end. This endeavor has the makings of the guy over on grm with a ferrari 308, one of the best build threads i have ever seen

https://grassrootsmotorsports.com/forum ... 959/page1/.

People including myself love pictures so keep updates coming. If you have pictures people are more likely to respond of give feedback.

Thanks Mitch! I really love the guys on this forum, such a genuine and good community. It definitely is about the journey at least at this time. I am blessed to have no time crunch and to be able to build this exactly as I want it. I spoke to a my new fabricator, describing what I want for the intake manifold, if we can pull it off, I will have something really beautiful for you guys.

For now I do have some new photos of some small but crucial parts that were just made.

Water pump delete, in favor of an electric pump there will be coolant pipes fitted once I have a better idea of the cooling setup.

[r.martin]

So I have run into a packaging issue, and may have a solution if I can re locate the injectors. our manifold will not be this specific design, but has anyone ever seen injectors placed like this? My tuner is concerned that at high RPM when the valve closes, a shockwave will occur spitting the fuel back out of the trumpet. Can anyone back this theory?

[mitch5]

I am not sure about a shockwave occurring and thinks thats a lesser worry with just this being a bad design, which is probably why it is just a rendering. Carbs and tbi inject fuel way farther away from the valve and operate fine. This setup would just not be very efficient, having the injector in the pleum would result in very uneven fuel to the individual cylinder. You want to have a tuned port inject TPI not throttle body injection TBI setup. TPI is way more efficient and that is why it requires atleast one injector per cylinder. Not to mention fabricating that would be a nightmare.

So your real issue is packaging, what is getting in the way of the injectors in their stock location?
Is the distance between your blower and intake port to short?
Is something going on top of them?
I ask because the stock location of the injectors is pretty good in terms of packaging.

[Nebraska_e28]

Nice progress! You definitely have some determination.

I've been plotting an m90 build for a while, but have yet to make time. I'll be curious to see intake design. No use in me recreating the wheel if you can pull it off.

What compression ratio are running?

[r.martin]

Thanks guys for the info, I think that I may have a slightly more traditional solution that is packaged better.

Nice progress! You definitely have some determination.

I've been plotting an m90 build for a while, but have yet to make time. I'll be curious to see intake design. No use in me recreating the wheel if you can pull it off.

What compression ratio are running?

I'll share full details of the intake design once it is underway, we are running 7.9:1 CR

On a side note I had a little extracurricular excursion and made this purchase:

2014 MV Agusta F3 800

[r.martin]

To all who are awaiting developments on this project know that I haven't quit. The scope of this as well as other things has necessitated a stand alone shop rather than working out of my father's garage. This may be uninteresting but I felt that I owed you guys an explanation.


Setting up racks for a mezzanine office space

My right hand man, kind enough to offer his truck

[Shadow]

this thread feels years old already.

so on that damper thing do they sell water/alt pulleys for it or is that something
you just have to custom make?
looks cool might be the ticket to rev out the m30 but not like that m30 makes power past 5.5 anyway.

[r.martin]

this thread feels years old already.

so on that damper thing do they sell water/alt pulleys for it or is that something
you just have to custom make?
looks cool might be the ticket to rev out the m30 but not like that m30 makes power past 5.5 anyway.

Like most projects I've had, they seem to go far longer and far more expensive that anticipated, I really want to drive it this summer. Still building out the shop but making quick progress on that actually. The MRT damper adapter kit is just the adapter and trigger wheel, you choose your own ATI damper and are left to make it work, I'm sure that you could adapt some of the shelf pulleys with a little work.

[r.martin]

My apologies to all who are feeling that this thread is dragging on. I know that is always a frustration of mine when following someone else's project. So as of now, the e28 has been moved to the new shop, we have a lift installed and our electric finally figured out so we can run the welders. I have made a new association with a CNC shop that makes aerospace components, my point of contact was able to pull dimensions from my hand built supports for the supercharger, so we are making headway on that. Still setting up my office so that I can do the CAD work needed.





I used the original seats to make a matrix style workstation. I still need to finish the foot rests but it is working nicely so far.



Here are some sample pieces that my contact at the CNC shop has made, the quality is more than adequate for our needs.

[Tiit]

Thanks for the update.

[r.martin]

Alright guys, I am determined not to become another story of a guy with ambitions who talks then disappears. This past year has brought a lot of change, moving, new job, etc. but the e28 is constantly on my mind, I have continued to play around with my hand made blower mounts and the pulley is always off by a few degrees, determined not to scrap the blower I have decided to remake all of hardware that attaches to the block. I have a new idea of how to make the mounts and have designed it in freeCAD which I am not excessively familiar with, need to figure out how to get it to print to size so that I can verify the bolt holes line up with the block before I take it to the waterjet cutter.
Sorry to keep you guys hanging.

[Tiit]

Keep going