SLC: 1989 Zinno coupe. Superlight, Super Functional *6spd swap inside*

[mitchlikesbikes]

way too much going on with the car right now. i dropped off all of my components for powdercoat, that should be done by this weekendish.

also fitting the oil pan a 12an turbo drain fitting since turbo plans are in the near future so i won't have to pull the pan with the engine in the car. i will just cap the fitting for now.

i am waiting on an order of random bits from FCP euro as well. front sway bushings and endlinks, oil level sensor block off plate, o ring, and some other knick knacks.

my diff reseal kit is on the way from ECS as well.

main project right now is the differential. based on lots of research i did i determined that i would swap the 3.25 ring gear on to my limited slip carrier, then install that into the case of the open 3.25. that way i don't have to remove the pinion for the 3.25 gearset and deal with resetting preload and pinion depth. with this setup i will just need to shim for gear pattern/preload/backlash. i am hoping that i can use the shims i have and get it set up properly so i don't have to buy a shim kit.

i also couldn't help myself and ordered another clutch disk and dog ear from thayer motorsports. i will be adding this with my 2 current clutch packs that are in good condition. i was actually amazed on the condition of the clutches as this diff has well over 200,000 miles on it as far as i know. to be fair the car has never had much more than stock power and i've also been running fat sticky tires since i've owned it that are very hard to break loose with 140ish HP haha. anyway, here's some photos of the diff after disassembly:









the diff build has felt very familiar so far, as this clutch setup is very similar to the wet brakes that are used on german forklift axles (which i have rebuilt before at work a couple times).

i also found this great DIY if anyone is considering an LSD rebuild/upgrade:

http://buildraceparty.com/diy-tech-how-to-rebuild-a-bmw-e30-differential/

my clutch components should be here tomorrow or wednesday so i can put it all back together. i ordered gear marking compound to verify the gear lash and got a dial indicator to check backlash when i'm done. luckily my coworkers used to build absurd racecars and will hopefully be able to help me verify the diff setup when i'm done so it doesn't make a bunch of noise or blow up.

once the diff is done my next priority will be some minor engine bay prep and touch up painting the bare metal where i remove the insulation attachment studs, ABS module brackets, etc.

i need to get the removable core support wrapped up and paint that whole shit show soon too.

[mitchlikesbikes]

my custom DSSR from garagistic arrived yesterday. based on the shit prototype i built and sent them they did a great job on it. i did some test fitting outside the car and had to do some minor clearance grinding on the bottom of the shift carrier to clear the dssr. i may have to do some minor shaving on the dssr itself once i get it in the car but i was able to get into all 6 gears and reverse outside the car so i feel pretty good about it. i forgot to take pics of test fitting because i'm a failure but heres a couple photos of the DSSR:





lately i've been thinking about my options for my differential. i decided my best bet was to reseal my known working and solid 3.73 lsd and just swap the gears inside to a ratio better suited to this trans. my friend steve had an extra medium case 3.25 from an e28 laying around and was nice enough to give it to me so i will be stealing the ring and pinion from that for my diff. i was also planning on a clutch rebuild but i did the breakaway test on the diff and it held to about 50 ft/lbs (factory spec is 40-60 with 60 being the best) so i don't think i'm even going to bother busting open the clutch packs or anything right now since those components are so expensive and i would be wasting money to rebuild a diff that's still well within spec.

i have more parts on the way and will be getting after it more in the next few weeks, hopefully will have the car ready to go this spring.

[mitchlikesbikes]

when you say peanut grinder are you talking about a Dremel? cause that's impressive. Good work man. hopefully i'll get to see this when it's running, or if you need a hand on something.

oh jesus no, i could have spent my whole life on those things with a dremel. i call my 4.5" angle grinder a peanut grinder because that's what my grandpa always called them haha


in other news, i just sent garagistic my payment for the completed custom dssr so hopefully that will be here in the next few days!

[jeenyus]

i did them myself. i didn't shorten them though. if i would have needed to i probably would have found someone with a bandsaw i could use for that. i just chopped off the stock/shit spring perches with my peanut grinder and welded the gc perches on.

when you say peanut grinder are you talking about a Dremel? cause that's impressive. Good work man. hopefully i'll get to see this when it's running, or if you need a hand on something.

[mitchlikesbikes]

purple sounds cool. Did you have someone fix the strut housing local in SLC?

i did them myself. i didn't shorten them though. if i would have needed to i probably would have found someone with a bandsaw i could use for that. i just chopped off the stock/shit spring perches with my peanut grinder and welded the gc perches on.

[jeenyus]

purple sounds cool. Did you have someone fix the strut housing local in SLC?

[mitchlikesbikes]

there is some nice fabrication going into this build. Are there 5 lug plans for the build?

Thanks! I tossed it around but it would involve too many compromises since I already have big brakes and suspension built around the 4 lug setup. Plus I don't mind the 4 lug wheel selection available, most people are unsatisfied but I'm fine with cheap rep wheels made for hondas and VWs until I can afford something really nice and/or custom in 4 lug someday

[MCreally?]

there is some nice fabrication going into this build. Are there 5 lug plans for the build?

[mitchlikesbikes]

Very nice! I'll need to look into that trans. Im sure it's alot cheaper than the G420 from the E46 M3?

i'm not sure actually, i didn't buy it. basically i traded my WRX to a friend for cash + the m50, 6 speed, UUC clutch and some other swap parts. i think the transmissions go for like 500-1000 depending on where you get it unless you got lucky and found one at a cheap junkyard.

i do know that most people consider this trans to be superior to the getrag in the e46 m3. the input shaft has more splines (can't remember how many) and it also has a dual front mount for the shift carrier so it has less slop even with standard rubber bushings. i've also heard this trans is smoother and more appealing to use but i can't say for sure as i havent driven an e46 m3 and 6spd 330i at the same time to compare. this ZF also came behind an s54 just like the getrag, but only in the z4 M.


here's a photo of all of my stuff ready for powder. reinforced subframe, custom trans mount, GC converted strut housings, and sway bar brackets. i'm trying to decide if i should go boring black or something cool like purple for these components. the general nature of the build is sort of subtle but i think on somewhat hidden parts like this a better "pop" color might be cool.

[spiDmang]

Thank you!

The trans is a ZF gs6-37bz from an e46 330i

Very nice! I'll need to look into that trans. Im sure it's alot cheaper than the G420 from the E46 M3?

[mitchlikesbikes]

Diag port in original location works fine.
All my relays are also in the stock location. Shouldnt have got rid of that part...

yours all appears to be different due to RHD and other factors. the original location for the diag port on my car was at the front d/s of the engine near the AFM. your relays are in a different spot than mine were from factory too.

[ba114]

also, anyone reading this who has done a 24v swap, how did you mount your diagnostic port and engine harness relays? i tried to find mounting brackets on realoem but couldn't find anything. i sold my m20 relay bracket with the engine so i no longer have that and i'd like to mount them somewhere on the passenger side near the firewall. maybe i'll have to hit the junkyard this weekend and see if i can find brackets of some sort.

Didn't browse your thread, if your using m3 covers, has provisions for the relays to sit there, if not, try the fuse box where the auxiliary fuse box is?


Sent from my iPhone using Tapatalk

Diag port in original location works fine.
All my relays are also in the stock location. Shouldnt have got rid of that part...

[mitchlikesbikes]

Awesome build! I missed it along the way, but what trans are you using?

Thank you!

The trans is a ZF gs6-37bz from an e46 330i

[spiDmang]

Awesome build! I missed it along the way, but what trans are you using?

[mitchlikesbikes]

I loved the PMC shifter on the Aluminum Monster.

This go-round Im trying to keep it as silky smooth as I can get the OEM feel.

The solid stuff is definitely for the "fun" car and less for the daily car IMO

Yeah I mean I'm already running ltw flywheel, solid engine and trans mounts, all solid suspension bushings, and fairly stiff GCs so it's not going to be very daily driver friendly when I'm done anyway. But yeah I was really happy with my old OEM+ setup so if this can at least match that in crispness and slop I'll be happy for a while.