e30 M3 minor rust repair.

[xworks]

With the engine now back in place focus could turn to some of the item's that
would need relocation thanks to the bulky addition of that new airbox.
First on the list was the brake fluid reservoir..........



With the new airbox proudly now sitting in the space where the old reservoir
pictured above used to be, a plan needed to be hatched.
Common wisdom suggests that a good sized hammer can almost always make
two objects occupy the same space at the same time, however, since the airbox
"kit" I had purchased came with the bits to relocate reservoir, I decided to
save the hammer approach as "Plan B".
Below is a picture of the reservoir that came with the kit.......



theres absolutely nothing wrong with it and I'm sure it works fine, for reasons
still unknown to me I decided to endure a lot more hardship to make the
reservoir below work instead.........



The one slightly large difference between the two reservoirs above is the
"kit" one has the required 3 outlets (2 x brake master cylinder feeds, 1 x clutch master
cylinder feed) and the one I had decided to use had a big, useless, threaded lump
of an outlet.
So, the threaded fitting was removed for the reservoir and an hours worth of beating,
drilling and brazing had it looking a bit more functional........



After which it was a simple matter of fitting the two supplied elbows to
the master cylinder.......



and then connecting everything up with the correct spec. hose.......



What the above picture doesn't show to well is the feed from the reservoir
down to the clutch master cylinder, which travels down behind the brake servo.
I had actually taken a separate picture of this, but, due to my continuing startling
incompetence with a camera, it came out pitch black.
Gifted.

One thing probably worth mentioning before we move on is about the
hose used to carry the brake fluid. I can't remember the part number for the
Gates hosing used here,( it's late and if I go searching the net for it I'll just get
distracted by porn sites or cheap shiney shite on e-bay), but if you find yourself
doing a similar job it's worth spending a few minutes checking the manufacturers
website to see if it's compatible with the type of brake fluid you intend to use.
Some hoses have difficulty containing synthetic brake fluid and will slowly weep
it all out over your nice clean engine bay. Which is fun.

With the reservoir plumbed up all that was left was the small matter of mounting
it somewhere. Small bit of stainless steel cut and bent to the correct shape..........



and a few holes drilled and taped into the underside of the strut brace......





bingo......





more tomorrow.........

[Beach Bum]

such a great thread :)

How many people will die when this car gets its first scratch, rock chip, or ding?

I direct you to this post:

http://www.r3vlimited.com/board/showpost.php?p=1702982&postcount=37

Was asked the same question on another forum a
short while ago and the answer is when it's done,
it's going into a carcoon humidified cover and carefully
parked up in the garage so it'll keep it's future value
as a collectors item hopefully. I may take it out for
some car shows, but only during the summer months
when the weather is sunny. Might drive it to the odd
show instead of trailering it all the time to keep things
from seizing up, but it would be heart breaking to get
any stone chips on it.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.

BOLL*CKS TO THAT CARRY ON,
I plan on driving the door handles off it 7 days a week
till fossil fuels run out. There's no way I could put this
much effort into a car only to keep it "garage queened" for the
next owner to enjoy. Sure it'll get stone chipped and scratched
as time goes on, but I guarantee you I'll enjoy every mile while
collecting them.

[excess106]

My friend this is an unbelievable thread. If i was the CEO of BMW M Division i would call you for the first ride officially in Germany.Thank you for all the details of the rebuilding.

[acolella76]

such a great thread :)

How many people will die when this car gets its first scratch, rock chip, or ding?

he said earlier in the thread that he doesn't care because he's still going to drive the car like it's supposed to be instead of garaging it for the rest of its life.

[Sagaris]

such a great thread :)

How many people will die when this car gets its first scratch, rock chip, or ding?

[xworks]

The clutch disc is sandwiched into place by the pressure plate which is
bolted on by six little bolts, shown below........



the important bit being to make sure the splines in the centre of the clutch disc
line up with that little spigot bearing in the centre of the crankshaft..........



as when you go to throw in the gearbox later on, the splines on the
input shaft (red arrow) need to slot into the splines on the clutch disc,
and the little piece on the end of the input shaft (yellow arrow) needs
to slot home into the centre of the crank spigot bearing..........



So you can see it's worth spending a few minutes now to make sure the clutch
disc is lined up correctly, rather than busting a ball later trying to fit the gearbox into
place when things don't line up. If you find yourself in the same position I do,
with both engine and gearbox out of the car, it can make sense to mate the two
of them together outside of the car briefly just to make sure things line up.

With the clutch fitted the final item to go on before the engine is lowered into place
is the gearbox bellhousing.......


(picture borrowed from google images)

As the bellhousing is detachable from the getrag gearbox it can be a lot handier
fitting this to the engine now while it's out of the car, and then when everythings
back in the car you've 4 nice studs sitting out the back of the bellhousing to
lift the gearbox onto, rather than fumbling around trying to get bellhousing to
engine bolts started.

With all the soundproofing and heat sheilds fitted to the engine bay the
way was now clear to shove it back in.....



And then with a wave of the magic wand and quite a bit of foul language
the engine and gearbox magically find their way home.........









more to follow as the week goes on.........

[xworks]

Well, it's taken what feels like an absolute eternity to get to this stage of the build,
but, finally, the engine is ready to be reunited with the chassis........















there was a few little things to take care of before the engine could be lowered
into the bay. Once the engine was off the stand the flywheel and clutch needed
to be refitted. In keeping with the theme of the rest of the engine build I've gone
with a lightweight flywheel. The flywheel weighs in at 5.3kg and is supplied by
http://www.ttvracing.com/BMWS14flywheel.html.......



With the flywheel in place the clutch could then be fitted. The clutch was
only fitted to the car shortly before it came off the road for this little make over,
and as a result has very little mileage on it and is good to go again......

[MaxBell]

Wow, just finished reading this thread. I am ashamed of how much I neglect my car.

[severnrc]

i think you should make a signature with a paypal DONATE button. everybody here, and elsewhere on the web, OWES you bigtime.

Yep! I approve this message.

[Russianblue]

i think you should make a signature with a paypal DONATE button. everybody here, and elsewhere on the web, OWES you bigtime. i can't begin to tell you how much i have learned from this thread and how many 'mysteries' you have unveiled.

you don't just do a good job on your work, you are an excellent teacher as well. one place you succeed where all the other manuals fail is avoiding the "reassembly is the reverse of removal" easy way out. that's huge. seriously. i will refer to this thread for nearly any major repair going forward. FIRST. if for nothing else just to get my head straight!

i actually had the 'pleasure' of painting part of MY car. it was a nightmare. after reading your writeup, i think.....well...it would still be a nightmare, but i would feel a lot more comfortable. i don't think people realize how much time you spent prepping that car. prepping your area. sanding without exposing bare metal. feathering edges properly. making the body creases perfectly straight. cleaning and sanding every crevice of that airdam. EXCRUCIATING work, but simply amazing. oh yeah, and then a little tranny rebuild for dessert. good gawd.

i haven't posted to R3v in years i don't think. but i couldn't let this pass me by without expressing my gratitude. thanks from me and everyone else who has ever loved an S14, M20, M30, E30, E28 or any of the myriad early BMW's to which all of these lessons apply.

[CorvallisBMW]

It's so fucking tiny.

It's like fapping to images in the 56k days when it was still loading.

Fapping is fapping, and I'm doing it

[Beach Bum]

It's so fucking tiny.

It's like fapping to images in the 56k days when it was still loading.

[acolella76]

ohhhhhh my god

dat bay

[xworks]

should have next update up for the weekend or early next week
at the latest.

[Bartholomeo]

Xworks, any teasers for us ?

for all the ones who check the thread after this bump : sorry :)