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Helmut the e21

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  • The Full BananaT
    The Full BananaT
    The Full Banana
    wrote on last edited by
    #27

    You are a crazy man, Wojtek! Looking good

    Tom - I have a few BMWs, an overworked Volvo 242, and now a YouTube channel called Drive, Revive, Tinker

    1 Reply Last reply
    0
    • retoropakR
      retoropakR
      retoropak
      wrote on last edited by
      #28

      I finally found a driveshaft and test fitted transmission and motor. It came out that i made my oil pan 0.5" too long and will have to redo it. 

      A bit of CSB mount relocation will be required

      I started some engine mounts. I also ripped the whole wiring harness and will redo it along with the new fusebox. 

      I cleaned up and painted rear inner fenders and applied some brush on seam sealer for some extra protection. 

      E36 steering column is a pretty good fit. I will gain a cruise control stalk which I will need for some dash display controls. 

      Initially I got garagistic e30/m20 mounts but they are bolt thru which I am not a big fan of.  I ordered the revshift mounts.FCP shipped my radiator mounts and engine mounts and I should get em by Monday. I will finish the mounts next week and will modify the oil pan. Radiator and intercooler will be next.

      HelmutHelmut

      Helmut

      HelmutHelmutHelmutHelmut

      E21

      1 Reply Last reply
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      • YoungCRY
        YoungCRY
        YoungCR
        wrote on last edited by
        #29

        Is that just a universal fuse box?

        Chris Young
        BMWCCA #458972
        1986 528e/5  | 1994 530i/5 | 1995 540i/6 | 2013 X5 35d | 1998 C1500 Suburban | 1995 K2500 Suburban

        1 Reply Last reply
        0
        • retoropakR
          retoropakR
          retoropak
          wrote on last edited by
          #30

          YoungCR said:

          Is that just a universal fuse box?

          It is LittleFuse EPC . https://www.littelfuse.com/products/dc-power-distribution-modules/configurable-pdm/epc.aspx

          Two separate buses, 9 relays, 27 fuses should be more than enough. Uses ip67 TE connectors

          I also thought about this busman/Eaton but it has relay on every circuit.

          https://www.waytekwire.com/item/46065/Dual-SSVEC-12VDC/?gclid=CjwKCAiAs92MBhAXEiwAXTi25yWbJ6SQQpt_pXWnZg-UyW1xzr7SP_NbntmXLOg5mJaHZgv6zz3WnxoC-gUQAvD_BwE

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          • retoropakR
            retoropakR
            retoropak
            wrote on last edited by
            #31

            3 months later............

            I had to redo the whole subframe. There was not enough room for decent size sump. Engine is mounted to the frame rails anyway so the middle section of the subframe was cut and pushed towards the front of the car. Don't mind crappy welds, once I hit it with some pretty epoxy paint it wont look that bad anymore.  It seems that I can tig aluminum better than I mig steel.   

            Here is the oil pan that I hat to cut a little bit to sit flush with the subframe.

            E21

            E21

            E21

            I also put together lower radiator mounts. It uses stock e36 plastic mounts that sit on steel brackets welded to the frame rails. There is enough room in front of the radiator to fit 3" intercooler.

            E21

            I also got a new daily driver. I got rid of my xc70 and got F32.  That b58 and zf 8spd combo is amazing. 

            E21

            1 Reply Last reply
            2
            • YoungCRY
              YoungCRY
              YoungCR
              wrote on last edited by
              #32

              Progress is progress! Happy to see updates on this. Congrats on the newer daily too.

              Chris Young
              BMWCCA #458972
              1986 528e/5  | 1994 530i/5 | 1995 540i/6 | 2013 X5 35d | 1998 C1500 Suburban | 1995 K2500 Suburban

              1 Reply Last reply
              0
              • retoropakR
                retoropakR
                retoropak
                wrote on last edited by
                #33

                Since the engine sits upright the stock m42 manifold (e30) or ugly e36 one won't work anymore. Miata folks are adapting honda intakes with pretty good results. After some research I decided to get a Honda b series manifold and try to fuse it with m42 intake flange. Spacing is the same +/- 2-3 mm so it should line up fairly well.

                It will get bosh DBW throttle body either in 68mm or ill go size up to 82mm if it fits. 

                Its a pro series so I expect some pro results 😁. Sadly It will sit upside down so that beautiful logo wont be visible. 

                Intake

                Intake

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                • retoropakR
                  retoropakR
                  retoropak
                  wrote on last edited by
                  #34

                  I tried honda B series manifold and it sat too low. Then I tried volvo whiteblock without one cylinder and it was a bit off spacingwise and also sat too close to the firewall.

                  Volvo manifoldVolvo manifold

                  I figured its time for some custom manifold. I got some trumpets, plenum and a bit of a runner pipe. Flange is also on its way.

                  Random

                  In the meantime I started wrapping up some other bits.

                  I welded shock mounts for the trailing arms. I started working on oil pickup and also threaded some holes for the windage tray. That cheapo oil pan came with windage tray mounts without any threads. Also internal oil pickup passage has a burr that obstructed 40-50% of the opening. 

                  Random

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                  • retoropakR
                    retoropakR
                    retoropak
                    wrote on last edited by
                    #35

                    I finished transmission  mount.

                    Helmut

                    Stock fuel tank wouldn't fit with e28 rear subframe so I had to trim it a little bit.

                    Helmut

                    I started mocking up intake plenum to see if it will fit with a stock booster. The verdict is: I need boosterless brakes. I will try to fit floor mount Wilwood pedals and if it wont work I might go with firewall mounted ones. There is just not enough room for a booster even e90 one with vert mounted motor.

                    Helmut

                    1 Reply Last reply
                    1
                    • retoropakR
                      retoropakR
                      retoropak
                      wrote on last edited by
                      #36

                      I started putting together manifold. Just some mockups for now to figure out injector positions and angles.

                      I also got a set of wilwood floormounts that i am trying to fit. Looks like  pedal position will be close to stock

                      Helmut

                      HelmutHelmutHelmut

                      1 Reply Last reply
                      2
                      • retoropakR
                        retoropakR
                        retoropak
                        wrote on last edited by
                        #37

                        First part of the manifold is tacked up. injector angle could have been a bit shallower but I don't think it will have significant negative effects on performance.

                        HelmutHelmut

                        1 Reply Last reply
                        1
                        • retoropakR
                          retoropakR
                          retoropak
                          wrote on last edited by
                          #38

                          And intake is almost done. All tack welded and ready to be finished. I got some 1/4" plate to do the end cap and to add some reinforcemnt for vacuum fittings.

                          I will use bosh motorsports dbw throttle body. I am shooting for anything between 350-500whp. I think that 68mm throttle should do. The next size up is 82mm but I worry it will be too twitchy and drivability will suck. 

                          Holesaw setup to cut 3" holes for trumpets

                          Holesaw

                          A little mockup with two runners to check the position of the plenum

                          Intake

                          All 4 runners in. 

                          Intake

                          Intake

                          Intake

                          Fuel Rail

                          Intake

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                          • P_RoloffP
                            P_RoloffP
                            P_Roloff
                            wrote on last edited by
                            #39

                            Holy smokes, this is cool. That intake looks awesome, super excited to see that come to fruition. How is the throttle body going to be mounted, out the end of the manifold towards the front of the car or out of the side like an OEM one?

                            1 Reply Last reply
                            0
                            • m42b32M
                              m42b32M
                              m42b32
                              wrote on last edited by
                              #40

                              This is awesome! A 350hp+ M42 is going to be a riot.

                              1991 318is, 1991 318i, 2022 Bronco

                              1 Reply Last reply
                              0
                              • retoropakR
                                retoropakR
                                retoropak
                                wrote on last edited by
                                #41

                                P_Roloff said:

                                Holy smokes, this is cool. That intake looks awesome, super excited to see that come to fruition. How is the throttle body going to be mounted, out the end of the manifold towards the front of the car or out of the side like an OEM one?

                                Throttle will be in front of the manifold.

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                                • retoropakR
                                  retoropakR
                                  retoropak
                                  wrote on last edited by
                                  #42

                                  I welded up the manifold. It was a pain. My 200amp tig had some trouble welding 1/4" plenum with the trumpets. Trumpets were quite thick with some sections close to 1/2" or more. I could use 50amps more.
                                  I added fuel rail brackets and end cap. I also ordered bosch motorsports 68mm DBW throttle. I still need to get the weld-on flange for this throttle.

                                  I ditched floor mounted pedals and get hanging pedal setup. I whipped new firewall plate and added the e36 column mount

                                  Helmut

                                  Helmut

                                  Helmut

                                  Helmut

                                  Helmut

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                                  0
                                  • YoungCRY
                                    YoungCRY
                                    YoungCR
                                    wrote on last edited by
                                    #43

                                    Nice work on the firewall plate

                                    Chris Young
                                    BMWCCA #458972
                                    1986 528e/5  | 1994 530i/5 | 1995 540i/6 | 2013 X5 35d | 1998 C1500 Suburban | 1995 K2500 Suburban

                                    1 Reply Last reply
                                    0
                                    • retoropakR
                                      retoropakR
                                      retoropak
                                      wrote on last edited by
                                      #44

                                      Pedal box is done.

                                      Helmut

                                      Helmut

                                      I got my throttle body flange. I use 68mm Bosch motorsports TB. Its funny that you cant get that flange in the states. I had to order one from Sweden. 

                                      Helmut

                                      Helmut

                                      Helmut

                                      Helmut

                                      I ordered my eBay intercooler. 12x18x3" core. Should be plenty to support my power goals.

                                      Next week will be finishing some bracketry and I should be ready to prep it for paint.

                                      1 Reply Last reply
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                                      • retoropakR
                                        retoropakR
                                        retoropak
                                        wrote on last edited by
                                        #45

                                        I got my fleabay Intercooler it supposed to e 3" core. Well  it is not. Its a 2.5" and has some shitty spoolgun welds.. I am not even mad I will just return it and get another cheapo intercooler hoping it will be a bit better. Anyone know ebay sellers/brands that might have decent 3" intercoolers? My 12x12 ebay intercooler that i got couple years back look much better with decent welds and nice looking 3" core. 

                                        I made upper radiator mount/ shroud/ intercooler mount. 

                                        Front frame rail  brace might come handy. The e21 chassis flexes a lot. I will most likely use this brace as a mounting point for the skid plate

                                        Strut tower brace will be next. 

                                        I also got my e90 gas pedal. It should work really well. 

                                        I started designing chassis electrical harness with my new fusebox. I got the inventory of all circuits including wire lenghts, colors, gauge and approximate splice locations.I will be ordering some tefzel wiring sometime next week.

                                        I had a bit of an issue with clutch master fitting in the bay, So I had to expand the bay a little bit. Half a pound of seam sealer and some epoxy primer and it will look beautiful

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                                        • retoropakR
                                          retoropakR
                                          retoropak
                                          wrote on last edited by
                                          #46

                                          I got a monstercooler today. I think it is a bit too much @  24x12x4" core. It fits though but I think I will swap it for something a bit smaller. It will take an hour for the turbo to fill this thing with air. I think transient response may suffer a bit.  It might require some pie cutting to connect to throttle body.

                                          Intercooler

                                          Intercooler

                                          Intercooler

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