E21 project thread
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#1 Nice idea on the jig. that is pretty much what I had in mind also.
#2 Use SolidWorks.
#3 My vote still stands for "oval out the holes either with a dremel" after drilling.
If you muff it up you can always just scrounge the internet for the next 10 years looking for another BAE intake manifold for sale. No big deal.
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If you muff it up you can always just scrounge the internet for the next 10 years looking for another BAE intake manifold for sale. No big deal.
Yeah cause that really helps my confidence in not screwing this up royally. Lol!
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Yeah cause that really helps my confidence in not screwing this up royally. Lol!
don't worry, it's only permanent, like forever, all eternity, cannot be undone.
you'll be fine
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More parts collected for the job. 318i fuel rail/fpr, 318i coolant neck to tap for coolant sensor, m50 tps, jeep idle air stepper motor, #24 injectors, and aluminum injector bosses to be welded in manifold.
Also, time to make more adapters!
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I'm diggin' the progress Dave!
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Ok so I ran into fitment issues with the injectors and fuel rail with the manifold I have. Its just simply not going to work in the location normally used. After going through many many iterations on what I could do to make it work, I stumbled upon injectors from a 1.8t VW or Audi. They are considered EV12 injectors that are skinnier as well as having an extended tip on them. I found a used one on ebay for cheap to see if it would work with the CIS injector ports that are on my head.
CIS Injector
EV1 Injector
EV12 Injector (1.8t)
After fitting the EV12 injector in the head port exactly how I got, it seems to be a perfect length with the extended tip. The only issue is the headport hole being larger than the injector and o-ring causing the injector to not seal correctly.
To me it seems like if I could find a thicker o-ring with the same ID as the EV12, but a larger OD then I would be golden. Well, when comparing the two styles of injectors side-by-side I noticed that the EV1 injectors have thicker o-rings. BRILLIANT! I swapped the EV12 o-ring for an EV1 o-ring and BOOM! the injector now sits within the head port steady and seals well too. Now to get 3 more used ones or go for 4 new EV12 injectors.
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I finished the adapters for the IAC and TPS today and got them mounted to the manifold. Vinyl cutter came in handy when cutting some gaskets for the sensors and throttle body. Mounted the throttle body adapter and throttle body to the manifold as well.
I also finished up some wiring on the megasquirt for the idle stepper valve control. Works great! Cant say that for the m50 TPS tho. The one I got turned out to be a dud after hooking it up to megasquirt and attempting the calibrate it. I opened the sensor up to find a broken wiper arm. Ggrrr! Time to search for a new one now.
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Yesterday I removed all the CIS and K-jet turbo parts from the engine bay in prep for the EFI turo install.
Along with that I also removed the complete wiring harness. I will need to tear it apart and get rid of everything I wont need and integrate everything I will need into the MS harness.
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Keep it up man.
Excited one day I may actually see it running in person
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Well, the 318i coolant neck has been drilled and tapped for the MS temp sensor along with getting cleaned and painted. The BOV also got a sprits of fresh paint (not the greatest, but no one will see it anyways, lol).
I also removed the Megajolt unit (which is for sale by the way)
And I went ahead and tore apart the oem wiring harness. This was definitely an interesting thing to do. So much wiring was removed it shocked me.
What was removed
What needs to stay
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Looks like a ball of yarn in that first wiring pic. Should help to keep the bay clean!
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Did some more work today on the beem. I ended up cutting the grooves in the injectors for the clips to hold them to the rail.
Fitted them in the head and found out the hard way that the FPR hit the head, not allowing the fuel rail to sit correctly. So, off came the FPR from the stock e30 318i fuel rail. I will be welding the hole shut on the rail and redrilling it on top of the rail in the same location as it was. Then, welding an injector boss (since the FPR has the same diameter o-ring as the injector) and the FPR mount in the new spot.
After cutting the FPR mount off I fitted it to the head with the injectors and seems like it will be perfect. Until I put the intake manifold back on.
The hose nipple that I was using for the feed to IAC interferes with the fuel rail, so off it came too. I jb welded it closed and will just need to smoothen it out inside the tb which isnt a big deal.
So things are back on track once I get that fuel rail and FPR stuff welded and clean up throttle body. She's getting there!
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I thrive to be different and do things in a "think outside the box" manner. Plus, I like the intake manifold I have vs the ugly stock e30 318i one.
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