Das Beast: My E30 track / street build

[peterman]

Remember this nice piece of work? I picked it up from an E30 guy on eBay. Using it to scope out the fuel rail situation. Obviously not using the stock rail. :devil: Might make my own.

Catching up on your work. It looks great! Keep going!
I would look into a better plenum for the intake. This looks good but I think you will have some pretty big losses in the number 6 cylinder. It's a turbo so it won't be sooo bad, but I bet once you get it up and running, a new plenum will let it breathe a lot nicer.

Great job!

[dvallis]

Hey Peterman. Flow should be similar to this. Yeah, it could be bigger at #6, but we'll see. Rob wants to learn TIG welding anyway, so we'll just make our own if this one sucks :devil:



Flow rates for above model



Slight differences but same theme for all the ones below

[peterman]

Hey Peterman. Flow should be similar to this. Yeah, it could be bigger at #6, but we'll see. Rob wants to learn TIG welding anyway, so we'll just make our own if this one sucks :devil:

If you are learning TIG welding - which I highly suggest you do its incredibly useful - you may want to spring for an AC/DC system so you can TIG aluminum too.
I am looking into picking this one up in the near future.

http://www.everlastgenerators.com/product/tig-stick/powertig-200dv

Side note:
Glad you're doing a little flow analysis.
However, it seems like you did a simultaneous flow which is not really indicative of the velocities and pressures in a 4 stroke motor. Without getting into it too much, you will need to set up a multi step simulation with variable pressure outlets (simulating vacuum caused by intake stroke of piston at a given RPM) with a boosted gage pressure at the inlet. The outlets will need to change from "pressure outlet" to a "wall" after their intake stroke has completed. The problem is a difficult one because you should never define inlet and outlet pressures in simulation - it makes convergence a real problem.
It becomes a major pain in the butt.
Or what you can do is let the flow develop for one cylinder, stop the simulation and use the final results as initial conditions for the next cylinder in the simulation. It won't be AS accurate but it will be closer.
All this assuming you have the time and desire to do the simulation.

If you don't have the software you can check out www.Simscale.com
They have free CFD software that is cloud based. It runs off of OpenFOAM (open source) which is arguably the most powerful CFD out there.

[dvallis]

Hmmmm. I have a crypto currency rig that pulls 200 MH/s. Might need to repurpose it for CFD runs. That would be cool. Thanks for the simulation tips.

Wasn't there a guy on here by the name of DF Buttchug that has a flow bench? I could just have him test this instead of getting into all the simulation.

[dvallis]

Dash Beast

Got the new tails all polished and installed. One more thing down on the way to getting done.



Decided to tackle the dash today. It's sitting off center in the car. Left side needs to be trimmed.



After the surgery. Made room for out relay box under the switch console as well. If you'e never cut fiberglass before, don't do this indoors. The freaking dust gets EVERYWHERE.



New gauge template. This will get transferred to aluminum.



Here's the new layout. Big tach with programmable shift light, oil pressure, fuel pressure, water temp and fuel level (missing). I looked at a DTM style layout (smaller tach, two more gauges) but really, there's nothing else I want front and center when on the track.



Custom fabricated aluminum enclosure for relays, data acquisition etc. will go here.



Transfer worked out Ok. Called it a day since I don't have a 4-1/2" hole saw for the tach.

[wworm]

oh man dash is going in! Are you planning on leaving it white? I think you should flock it. we recently flocked an e36 m3 dash for a canyon/track build and its quite lovely. A white dash also might be pretty harsh on the eyes...just some food for thought

[dvallis]

I'm leaning towards flat black paint. Flocking looks like a major pain in the ass. :devil:

[peterman]

I doubt you will get a 4.5 inch hole saw. You will need to use a knock out punch, but a 4.5" costs about 300 bucks. See if there's a fab shop around you that would have one or willing to throw it on their laser/plasma cutter for you - which is more likely.

That fiberglass dash looks awesome. I'll have to search backwards to see how you did it.

[peterman]

Y



Harder. What's this doing in a BMW?

Is this a 700? That's crazy that they have one if so.

[dvallis]

Ye of little faith. Behold the 4-1/2" hole saw. $18 from Amazon with next day delivery. Freaking amazing how fast they deliver random stuff.

[dvallis]

Peterman, you're right. That was a BMW 700. Never even heard of it before, much less seen one. Very cool.

[wworm]

I'm leaning towards flat black paint. Flocking looks like a major pain in the ass. :devil:

It takes about ten minutes. Did it last weekend. It’s just dusty is all.


Sent from my iPhone using Tapatalk

[dvallis]

Looks messy. Obi Wan would have a stroke if we did this in the garage.





It does look nice, but seems like a hell of a dust catcher.



Video here. Since we can't embed youtube any more. (PAGING MODERATORS!!)

https://www.youtube.com/watch?v=Z2BnfI8LLAk

[dvallis]

Hmmmm. Flocking can look good on an E30 race dash.

[kronus]

if you don't want to flock, use texture paint. you mostly want to break up big flat reflective areas, since they'll be shiny even with flat paint.