szacsi72's 1984 Zinnoberrot 535i Build

General conversations about BMW E28s and the people who own them.
Mdreamer
Posts: 532
Joined: Feb 12, 2006 12:00 PM
Location: Atlanta, Georgia

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by Mdreamer »

Thank you for sharing your audio choices. How did you hide your antenna? Also, did the tweeters you used in the A pillars fit into the factory 535is housings, or did you make others?

As for the speaker covers, I like the right version because it highlights the speakers you've chosen.
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Mdreamer wrote: Apr 01, 2023 3:16 PM Thank you for sharing your audio choices. How did you hide your antenna? Also, did the tweeters you used in the A pillars fit into the factory 535is housings, or did you make others?

As for the speaker covers, I like the right version because it highlights the speakers you've chosen.
Hi!

My original antenna was deleted by PO. I've bought a low profile antenna, that you can stick inside of your rear window. This: https://www.ahifi.hu/belteri-ontapados- ... nt-33.html

I can't tell, my car didn't have tweeters from the factory. I'm in the process of 3D printing some housings.
Thanks for your opinion!
camplo
Posts: 125
Joined: Dec 02, 2016 6:38 PM
Location: Bay Area

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by camplo »

szacsi72 wrote: Mar 29, 2023 11:37 AM I had some free time today so I've designed some speaker covers/grilles. I decided I like the Blaupunkt Trypophobia version the best. It suits the car, since it's very similar to the stock version, but just looks.. slimmer, lighter. Probably due to the one more hole layer around the mounting holes.
I also hate the somewhat rounded sides. I've come up with two versions:
Image Image Image

The main differences is that that the right one is filled in around the speaker, and only the holes that are all the way trough are the "active" ones, like most covers. This version has no speaker cloth added.
The left version has a removable inner plate, that I can wrap in cloth and glue in place:
Image

The left version requires more work, but I >suppose< it is the more elegant way.

Please let me know what you guys think! The rear one will be very similar, just in a different size to accompany the 6.5 inch midbasses.
I like the left side version. I would imagine the right side one wouldn't look as uniform and you would be able to tell where the active holes are. Would you mind sharing the stl?

Also where did you get the 4" mids from? I have some generic ones I bought from parts express but they don't sound great.
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

camplo wrote: Apr 17, 2023 4:05 PM
szacsi72 wrote: Mar 29, 2023 11:37 AM I had some free time today so I've designed some speaker covers/grilles. I decided I like the Blaupunkt Trypophobia version the best. It suits the car, since it's very similar to the stock version, but just looks.. slimmer, lighter. Probably due to the one more hole layer around the mounting holes.
I also hate the somewhat rounded sides. I've come up with two versions:
Image Image Image

The main differences is that that the right one is filled in around the speaker, and only the holes that are all the way trough are the "active" ones, like most covers. This version has no speaker cloth added.
The left version has a removable inner plate, that I can wrap in cloth and glue in place:
Image

The left version requires more work, but I >suppose< it is the more elegant way.

Please let me know what you guys think! The rear one will be very similar, just in a different size to accompany the 6.5 inch midbasses.
I like the left side version. I would imagine the right side one wouldn't look as uniform and you would be able to tell where the active holes are. Would you mind sharing the stl?

Also where did you get the 4" mids from? I have some generic ones I bought from parts express but they don't sound great.
Hi! I'm located in Europe, Hungary. I bought it off a local seller. They are Audison AP-4. Not sure if you can get them in the US.
For the STL, I'll happily share the design later, when I know it's good. I don't want to share a faulty CAD. :)
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Life has been everything but easy lately, unfortunately I made little-to-none progress. The only thing I did in the past one month is fit the new rear brakes.

Unfortunately for me, I had to destroy a perfect set of M5 rear rotors.... They were almost brand new, no wear whatsoever. The b*tch was stuck so bad I had to hammer the shit out of it for it to move.... oh well. What can I do. Not like I planned to re-use them, but they could've been a great backup.
Image

Once off, nothing special. Some trimming of the heatshiekd is need to fit the 911 calipers, and it's a pretty tight fit, so had to play around for a bit... But other than that, basically bolt on.
Image Image Image

Fixed calipers on grooved E34 M5 discs.. Looks much better than the E28 M5 brakes I had, that's for sure!
I'll give the discs a black paintjob and call it a day.
Image
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Final piece of the puzzle. The only thing missing now is time.
Image


Aand got some bling. I'll 3D print some adapters so I can run them on my naked M-Systems.
Image

My alternator is broken, the engine shakes and I'm getting random cut-outs. So, I went and bought a Stage 2 KM Cams 292° cam, along with 12 forged steel rockers. This must be the fix.. right? Off with its head, I say!
Image
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Changed the emblem today to new, original 50 Jahre emblem. I think I liked the other one better, but I could only find matching rim caps for this version, so be it. But when I went to replace it... PO has put in a rivet with electrical tape and drilled to size... Some next level hack job.. Luckily I had new OEM pieces, so I drilled these out, and in went the new one.
Image

I will need to 3D print some adapters and glue them into the rim, as it was never meant to have rim caps installed. But I think it will look great. The empty hole looked really unfinished and unoriginal.
Image

Finished up the front brakes fully. The colour is not Brembo-Red, no no. It is Zinnober, to match the paint perfectly! :)
Image Image

Here's the finished assembly. I ended up using brake lines meant for a random PSA car (Citroen). It is 460mm long, M10 on both sides. I'll get a friend over to help me bleed somewhen next week. Can't wait to drive it again.
Image Image Image
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Here's an update on what direction the car is going.
Since I wanted to tune the car anyway, and I'm having some ignition troubles, I'll just standalone it at this point.

Here's the setup that I've planned:
-ECU: MS3++, MS3 based custom board made by a guy in Hungary. Allows me to go fully sequential both ignition and fuel.
-Ignition: COP using BERU ZSE061 Audi coils.
-Fuel: Bosch EV1 injectors, probably something around 250-300cc
-Control: Bosch M50 TB and M50 TPS
-Crank sensor: stock M30B35 with stock 60-2 wheel
-Cam sensor: M50 Non-vanos
-IAT: integrated into MAP sensor
-MAP: Bosch Motorsport PST1
-CLT: M50 non-vanos
-ICV: Volkswagen 2 pin PWM

Supporting mods:
-New intake piping
-New exhaust (I will do 2x2" with an X-pipe where I will mount the wideband, don't want to cut up the OE exhaust)
-Adapter plate for the MAP, and a mount for the ICV
-Distributor block-off and Cam sensor mount
-ECU and Fuse-box relocation, and re-wire-ing

Image


Will this car ever run? Who knows. But I'd rather take another year and make everything right, and enjoy it after for years than having to take it apart every second month.
Galahad
Posts: 540
Joined: Sep 06, 2016 9:08 PM
Location: Beverly/Worcester, MA
Contact:

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by Galahad »

what standalone are you using?
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Galahad wrote: Jun 12, 2023 1:52 PM what standalone are you using?
szacsi72 wrote: Jun 11, 2023 8:59 AM ...
-ECU: MS3++, MS3 based custom board made by a guy in Hungary. Allows me to go fully sequential both ignition and fuel.
...
It's an MS3 based custom ECU. He's a well reknown guy, I believe he's a software engineer? Imagine the ECU this way: it's better than a standard MS3 and cheaper. He uses only high quality connectors and componenets, for a reasonable price - and his ECU can do more. Built in inj drivers and ignition drivers up to 12 each.. etc. Not a bad deal if you ask me! Costs roughly the same as a microsquirt.
Zeuropa
Posts: 109
Joined: Mar 12, 2016 10:22 AM
Location: Denver, CO

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by Zeuropa »

Wow! Apparently, I don't surf mye28 enough. This build is awesome! Love the attention to detail and super clean mods.

Curious what size rotors you're fitting front and rear???

Keep the updates coming please!
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Zeuropa wrote: Jun 14, 2023 12:13 AM Wow! Apparently, I don't surf mye28 enough. This build is awesome! Love the attention to detail and super clean mods.

Curious what size rotors you're fitting front and rear???

Keep the updates coming please!
Thank you for the kind words. I do try to make everything right. I hate making mistakes and doing things twice. So I normally end up doing them three times instead..

I'm using 330x24mm front and 300x20mm rear. E92 328i and E34 M5.
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Not many updates, I have not had any time to continue my jorney.
However, I did collect some parts in the meantime:

ECU is here:
Image

KMCams Steg 2 + Steel Rockers:
ImageImage

R8 Coils:
Image

I've also designed some stuff to go on the CNC machine for the MS3 conversion:
Image
..and a custom distributor plate, because I really didn't like the ones on the market. They house sensors that are too fat for my liking.

Hopefully next week I'll have some time to actually continue the build...
1st 5er
Posts: 21859
Joined: Jun 13, 2008 12:15 AM
Location: Cypress
Contact:

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by 1st 5er »

We'll be here. :popcorn:
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

I am not dead! Just not alive.

Some rough months behind me, really didn't have any time whatsoever to continue the build. But I'm slowly catching up with my things, hopefully I will be able to start late november. I won't work for 3 weeks in Dec-Jan, I plan to finish most of the stuff in that period.

Some more parts hoarding until I can start.
Ditching the E36 radiator for a new Nissens E28 35i one to keep up with the performance mods:
Image
Image

And scored myself a set of red seatbelts!
Wuhuuu! They'll look awesome. Next year, once everything is running I'll get the door cards and seats reupholstered to match the red on black interior.
Image

I've also bought a new B35 intake, that I'll also convert to "Alpina specs" - Just a bit nicer this time. And, my friend will help me paint that and some other items in BMW diamantschwarz for some true shine.

On my shopping list next:
E28 M5 clutch kit
RHD lightweight flywheel
Galahad
Posts: 540
Joined: Sep 06, 2016 9:08 PM
Location: Beverly/Worcester, MA
Contact:

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by Galahad »

I have a RHD flywheel in my M50 swap, it's a very nice piece
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

The E28/E34 3.6 M5 Sachs clutch kit is en route, and I have found a guy in Hungary who makes flywheels from billet steel. Turns out he's a well-known guy here and he has made tons of flywheels for tuners and companies.
This flywheel is based off the E28 M5 flywheel, just a bit lighter and I've asked him to remove some more material from around the outer edge. It should weight in right around 6.5kgs in the end, which I think will be nice for street driving. Better than the 14kg (RIDICULOUSLY HEAVY) dual mass I have. And I'll also loose around 2kgs from the crank pulley but that's a later episode.

Image
Image



Anyway, I finally had some time to get some wrenching done. I sold some old components/parts I no longer needed, so those had to come out:
Image
Image


Luckily, I had some help:
Image



Then the next day, I removed the cylinder head.
Image

Now, I'm not sure if I mentioned it on here but the car had some issues. It didn't run as smooth as it should have, I felt like power was not QUITE there, and it sounded bad.
However it was weird. It wasn't smooth, but not rough like if it had a misfire. The power was a bit lacking, but not like no-compression. The sound was not great, but not like a normal mechanical problem.
Many of my friends did not notice and thought that this is how an old engine runs. My dad, who's had multiple BMWs when he was younger, knew instantly something was off when he heard it.
I've also removed all plugs and noticed how #6 had some oil on it while all others were dry. There was also quite some amount of oil residue in my intake manifold..
AND one more clue: this was not always like this, AND did not go bad slowly. This happened after a burnout I did (blame me all you want, I know this is my fault however this car is not a garage queen, and not like the engine shouldn't take a light burnout...:) ), and after the burnout, the car suddenly run worse. I later realised my car was not properly bled.
I talked to Mike (@Mike W) earlier and after that I had the idea that this could be two things. Either I overheated the pistons, which caused the rings or ringlands to be damaged, or, I overheated the head, banana'd it/lifted it and now the head gasket is leaking. (Not blown, that, I would notice).
Interestingly enough the fuel economy after this was OK, no overheating (Fixed the cooling system), oil consumption is there, but nothing crazy. No residues in the exhaust system, doesn't smoke in any colour. Oil and water didn't mix.

So yes, I had to remove the head, to check what's going on, and here I'd like your input.
I've only drived roughly 500-600-700kms since this happened. So it may be harder to spot the issue...

The cylinder walls all appear OK to me. I can see some wear marks, however the honing marks go OVER that which to me means this is not new, the engine was rebuilt before me. I think this is perfectly fine.. It's an M30.
Surely if the rings, or ringland were damaged, broken, then I would see at least SOME minor scoring? (?? Or would I? Never had it happen.)
Unfortunately I couldn't take good pictures because there was too much flare, as I had to use my phones flash.
Image



The cylinder head gasket didn't really show any signs of being blown, however I have to add this was not a composit gasket but an.. interesting one. Kind of like a combination of composit on the inside, alloy on the outside? It was custom made by a random guy and has NO rubber on it, whatsoever.
I'll make pictures next time I'm in the workshop, I forgot to take pictures..... sorry.

The only signs, that are interesting to me, are the colours in the combustion chambers. Let me show you:
Image
Image
Image
Image
Image



The silver-black edges were very sharp everywhere, apart from one side in cyl #6. Looks oily, but no carbon? Remember, this is the one that had oil on the spark plug, and this comes (looks like, at least that's the direction) from between #5 and #6, which is the place I bet would let go first when overheating.

Between the cylinder, the colours were also a bit different, a bit darker. But I don't think this means much... Does it?
Image
Image




What do you guys think?
Could this be a leaky head gasket? And maybe I can only not see the marks because of the fact that the hole gasket is covered in aluminium, so this 500-700kms of driving just could not damage it?

Next week I will see if the block or head are warped, I just didn't have time last time.
I REALLY don't want to open up the block now; it would be so good to have some progress, it would set me back weeks.
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Had to jump in the workshop Anyway, so snapped some pictures of the head gasket. Please take a look and let me know what you guys think.

I'm quite sure it's not OK, all those marks tell me the head shaving was a bad job and was done on a mill instead of a grinder (which in itself could be OK, however I still prefer a grinder).
And there are black marks that go over the combustion chamber area, which is again not a great sign... and black spots around different holes too.

Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
Image
adam_poll
Posts: 219
Joined: Jul 23, 2014 8:19 PM
Location: Kitchener, Ontario, Canada

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by adam_poll »

Hmm, that oil is coming from somewhere, either the head or past the piston. Unless you find a smoking gun I think the pan needs to come off and #6 popped out for a closer look.
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

adam_poll wrote: Nov 12, 2023 8:32 PM Hmm, that oil is coming from somewhere, either the head or past the piston. Unless you find a smoking gun I think the pan needs to come off and #6 popped out for a closer look.
The problem is that I know myelf. If the pistons come out... they don't go back in.
I would definitely start playing around too much...
B34 pistons, and even bug pistons are now annoyingly expensive. I'd like to overbore it and rebuild it with fresh cylinder walls, but I can't find any 92.5...94.0mm pistons that are reasonable priced. And I'm not looking for some fancy forged ones, just new ones
1st 5er
Posts: 21859
Joined: Jun 13, 2008 12:15 AM
Location: Cypress
Contact:

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by 1st 5er »

:wave:
szacsi72 wrote: Mar 16, 2023 12:55 PM I'd rather have an actual mechanical problem than this black magic that some call electricity.
;)
adam_poll
Posts: 219
Joined: Jul 23, 2014 8:19 PM
Location: Kitchener, Ontario, Canada

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by adam_poll »

Just get the fancy, shiny, forged pistons. You'll feel better knowing they're in there :)
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

1st 5er wrote: Nov 13, 2023 10:11 AM :wave:
szacsi72 wrote: Mar 16, 2023 12:55 PM I'd rather have an actual mechanical problem than this black magic that some call electricity.
;)
This stays true, I'm still rather pulling the engine than hunting down a miracle ground fail :D
adam_poll wrote: Nov 13, 2023 10:09 PM Just get the fancy, shiny, forged pistons. You'll feel better knowing they're in there :)
Oh, I definitely would feel good.. before the woman finds out where the money went that was meant for our new fence... :laugh:
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

No progress on the engine rebuild etc, but at least my new billet steel flywheel got delivered earlier this week!
Image

It weighs roughly 6.1kgs.
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

Removed the old master cylinder, as the new E32 unit has arrived. This was a "why not while at it" mod for me, as I didn't really felt the need but it turned out to be a good idea because my original unit was already leaking.
Image
Image

And for some extra, I've just found out that my clutch MC is also leaking. Ordered a new one..
Image
szacsi72
Posts: 289
Joined: Nov 13, 2022 3:41 AM
Location: Hungary

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by szacsi72 »

In case anyone is still following this thread.

I have not posted for a while and probably won't post much for some time either.
I've had a surgery that went horribly wrong and got some serious lung damage & radiation poisoning. I'm unable to perform 95% of basic tasks as of now, the doctor said I'll take at least half a year to recover.

In the meantime, my gearbox is stuck to the engine. I have removed every bolt, removed the started, master cylinder, etc. I tried moving it up and down with a floor jack, and prying it lightly. There is now a 1mm gap, so I'm 100% sure it's not connected but it's not coming off.
The transmission I believe is currently in third. Could that be an issue? Did they just rust together?

Thanks for your input.
David
Galahad
Posts: 540
Joined: Sep 06, 2016 9:08 PM
Location: Beverly/Worcester, MA
Contact:

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by Galahad »

Geez, I'm sorry to hear that - health problems are big issues.

I had a gearbox stuck to an engine, had to use a bunch of bolts to press it off. The end of the input shaft had rusted and gotten stuck in the pilot bearing, I broke the clutch disk during removal.

Best of luck with recovery!
Foonfer
Posts: 732
Joined: Mar 18, 2015 11:33 PM
Location: New York, NY

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by Foonfer »

oooh man, that sounds awful. Hope you make a good recovery. Radiation poisoning is no joke, don't let it go unattended.
1st 5er
Posts: 21859
Joined: Jun 13, 2008 12:15 AM
Location: Cypress
Contact:

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by 1st 5er »

Praying for a quick recovery.
jimoreno
Posts: 1547
Joined: Aug 30, 2007 9:31 PM
Location: Land O Lakes, FL

Re: szacsi72's E28 535i build thread - "The Reddie"

Post by jimoreno »

Hope your health issues get resolved soon and to your benefit.
Post Reply