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    Correct. We are not done yet. :-)

    "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

    1987 E30 3L Turbo Stroker Das Beast
    2002 E39 M5

    Comment


      Ahh! I should have kept quiet. You know what you're doing! Good stuff, man.
      P.O.S 1989 325is - aka Project Sh*tbox

      Project Shitbox - Restomod and other stuff - soon to be 328is

      Comment


        Race Car Porn

        Ground Control camber/caster plates arrived today. Even my wife thought they were cool. :devil:

        "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

        1987 E30 3L Turbo Stroker Das Beast
        2002 E39 M5

        Comment


          More front subframe

          Welded the centers. Badwella will be happy. :-)



          Gotta be creative when dong metal fab. The reinforcement tabs don't exactly sit flush into the frame. Needed to build it up on the side. Motor mount backing plates are already welded in place.



          Clamps are your friend when welding. Can never have too many.



          Turned out pretty good. Obi Wan has been teaching me well.



          Sway bar reinforcement tab ready to weld.



          It's actually triple reinforced, since the IE kit comes with yet another backing plate.



          Front subframe reinforced and ready for paint. Time to call it a day.

          "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

          1987 E30 3L Turbo Stroker Das Beast
          2002 E39 M5

          Comment


            Originally posted by dvallis View Post
            Welded the centers. Badwella will be happy. :-)
            Yes indeed. :D
            P.O.S 1989 325is - aka Project Sh*tbox

            Project Shitbox - Restomod and other stuff - soon to be 328is

            Comment


              More suspension

              We're fitting the new IE 22mm rear sway bar. In case you've ever wondered, here's what it looks like fitted in place. IE gear is nice, but they have an aversion to written instructions.



              Here's how it actually connects to the rest of your suspension. Easier to see this way.



              Same thing. Side view.



              Rob welding on all the rear trailing arm reinforcements



              Custom sway bar attachment points. Will get ground down and cleaned up.



              Gusset plates



              Triangulation bars fitted. Will weld them tomorrow.

              "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

              1987 E30 3L Turbo Stroker Das Beast
              2002 E39 M5

              Comment


                Originally posted by dvallis View Post


                How do you like that combo shear/slip roll/press brake?
                P.O.S 1989 325is - aka Project Sh*tbox

                Project Shitbox - Restomod and other stuff - soon to be 328is

                Comment


                  It's awesome for body sheet metal. Not good for subframe though. It won't bend 11 gauge. :devil:
                  "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                  1987 E30 3L Turbo Stroker Das Beast
                  2002 E39 M5

                  Comment


                    Thursday Subframe Extravaganza

                    I am not finding a lot of good pictures on R3V documenting a fully adjustable reinforced rear subframe, so here is a detailed guide.

                    Rewind to the rear trailing arms. This bar triangulates the trailing arm and wheel bearing carrier adding substantial strength.



                    Cleaned up all the brackets and surrounding areas before welding.



                    Reinforcing the rear subframe differential mounting points.



                    Reinforcing gussets welded to rear trailing arm outer mounting brackets.



                    Gussets welded to inner mounting brackets.



                    Now, here's where it gets interesting. Rear subframe is shown with left trailing arm attached. Adjustable camber and toe plates are test fitted. Inner plates are oriented vertically, allowing camber adjustment. Outer plates are horizontal, allowing toe adjustment. (Stop for a second and think about it)



                    Side view of the same setup.



                    Here is a close up of the inner bracket. Camber goes more negative (top of tire IN) as bracket slider moves down. Looks like there is only 3 or 4 clicks down available from stock position shown. Nobody is ever going to need more positive rear camber (slider UP), so the IE design could really be a lot better.



                    Close up of the outer bracket. Notice how it's not parallel to anything? That's annoying. :devil: Toe goes more positive (front of wheel IN) as bracket slider moves forward. (To right in photo) Go back two pictures and look at the subframe/trailing arm again. There are 6 clicks forward available which should be enough. Again, why the heck would anyone ever need massive negative rear toe? Bracket design could definitely be better.



                    That's all for today.
                    Last edited by dvallis; 05-17-2020, 08:29 PM. Reason: typo
                    "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                    1987 E30 3L Turbo Stroker Das Beast
                    2002 E39 M5

                    Comment


                      Saturday Suspension SuperExtravaganza

                      Back on the road to re-assembly. The press is finally getting some work. Here we are pressing in the trailing arm delrin bushings.





                      Metal core getting pressed in. Silicone lubricant helped.



                      Upon closer inspection, this is total BS! Garagistic bushing metal core has inside diameter of 0.525". Stock trailing arm bolt diameter is 0.390". How the hell would that not slop around every time the trailing arms went under heavy load?



                      Ireland Engineering bolt is not much better. It's only 0.460". To keep the IE kit I'd need to hog out its slots to 0.525 and get different bolts. Or design new metal cores in CAD with a 0.465" ID and get them fabricated for $100 each. Either way, its not looking good.



                      So, what would we gain going through all those gyrations? Here is the subframe and trailing arm mocked up. Top of the yellow post-it note is at diameter of our tire. Vertical edge indicates neutral position. Lowering the inner trailing arm bushing by the maximum amount possible, we only get 1/8" negative camber.





                      After a lot of standing around, talking pointing and cursing we decided to forego the adjustable rear suspension all together. Stock rear toe is a bit more than 1/8", with 2 degrees negative camber. If we want something different later we'll build a damn rear subframe with new fixed geometry brackets.

                      However, we ARE going to make the Garagistic setup better. Rob is boring out the trailing arm bracket holes to just over 0.500". We'll replace the stock bolts with M13 (0.512") x 90 units.



                      After all that drama, something easy. Pressing in the rear subframe bushings.



                      Eccentric delrin front control arm bushings getting installed.





                      New front control arm ready to go



                      The new Lump: 373 LSD. Thanks to TheRealStig for trading with me.



                      Pressing out the old rubber bushing.



                      Which unfortunately left behind this @#@#@#$ metal ring in the diff housing. Had to cut it into sections CAREFULLY with the reciprocating saw.



                      Then carefully chop the damn thing out with a hammer and chisel.





                      Delrin diff bushing in place



                      And then we started a job that was WAY too much work for the end of the day. See next post.
                      "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                      1987 E30 3L Turbo Stroker Das Beast
                      2002 E39 M5

                      Comment


                        Never start a half shaft rebuild at the end of the day

                        Quick half shaft rebuild. Rubber boots are ripped and grease is contaminated with dirt, so it had to be done. How hard could it be?

                        Hahahahah. <slightly manic> :devil: It seemed so simple.



                        Starting by removing the inner cv joint cover. What a greasy mess.



                        Once the circlip is removed inner CV joint and old boot slides right off.



                        Disassembling the rest of the CV joint is a total mess.



                        Guts of the inner CV joint ready to be cleaned.



                        Some guys have a fancy parts washer tank. We have dawn, cold water and a plastic tub.



                        Now it got even more "interesting". The outer CV joint is supposedly "non replaceable". However, with a lot of carefully applied violence the bearing race dust cover can be removed in one piece. By the end of this Rob was totally unhappy with the whole process.





                        I got to clean everything on our "parts tank" while Rob had a few beer and cursed out the half shaft designers.



                        Finally, everything disassembled, cleaned and laid out for rebuild. We were beat and called it a day.

                        "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                        1987 E30 3L Turbo Stroker Das Beast
                        2002 E39 M5

                        Comment


                          So. No such thing as M13 bolts for the trailing arm. Looks like 0.5" x 3.5" instead.
                          "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                          1987 E30 3L Turbo Stroker Das Beast
                          2002 E39 M5

                          Comment


                            Originally posted by dvallis View Post
                            Quick half shaft rebuild. Rubber boots are ripped and grease is contaminated with dirt, so it had to be done. How hard could it be?



                            Hahahahah. <slightly manic> :devil: It seemed so simple.







                            Starting by removing the inner cv joint cover. What a greasy mess.







                            Once the circlip is removed inner CV joint and old boot slides right off.







                            Disassembling the rest of the CV joint is a total mess.







                            Guts of the inner CV joint ready to be cleaned.







                            Some guys have a fancy parts washer tank. We have dawn, cold water and a plastic tub.







                            Now it got even more "interesting". The outer CV joint is supposedly "non replaceable". However, with a lot of carefully applied violence the bearing race dust cover can be removed in one piece. By the end of this Rob was totally unhappy with the whole process.











                            I got to clean everything on our "parts tank" while Rob had a few beer and cursed out the half shaft designers.







                            Finally, everything disassembled, cleaned and laid out for rebuild. We were beat and called it a day.





                            Why not just get rebuilt ones? I can't imagine it's that's much cheaper, plus it saves the kick in the balls of rebuilding them. The most expensive part of buying rebuilt ones is actually just the core.


                            Sent from my iPhone using Tapatalk
                            Originally posted by flyboyx
                            how about if i yank the anal beads out of your ass like i'm trying to pull start a chain saw?
                            Originally posted by Northern
                            beer is my new liver cleanse.

                            Henna - '84 Hennarot 325e
                            Lola - '89 Schwarz 325is - being saved
                            Christine - '88 Schwarz 325is - Spec E30 Racecar
                            '01 White F150 Lariat 4x4 Supercrew - Daily
                            Dad's '05 Interlagosblau M3

                            Comment


                              Because 2 x 33211226901 = $1000 for real BMW parts. Using $40 Chinese half shafts in a 500 HP race car is asking for trouble.
                              Last edited by dvallis; 05-21-2017, 01:00 PM.
                              "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                              1987 E30 3L Turbo Stroker Das Beast
                              2002 E39 M5

                              Comment


                                Das Beast Paint Shop

                                Decided to use a brush and black Rustoleum for the subframe. Here's a bit of advice. Buy the small can. Like a pint. This stuff has freakishly amazing coverage. I did the whole subframe ... all of it ... with less than 1/16th of a gallon. Feels like you could paint the entire exterior of a house with this one can.

                                Rear subframe looking good.



                                Front subframe



                                Rear trailing arms



                                Finally .... The Lump.



                                Will flip them over and finish up tomorrow.
                                "And then we broke the car. Again." Mark Donohue, "The Unfair Advantage"

                                1987 E30 3L Turbo Stroker Das Beast
                                2002 E39 M5

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