s50b32 e30 325i tech1 project

[HybridNz]

cool :) once this is all together and I do the photo shoots youre welcome to use them on your website.

[Massive Lee]

I am watching your wheels. They are gorgious.

Lee

[HybridNz]

haha, I should of mentioned that it is an existing design for an m20 engine from our race series here in NZ. Im modifiying it to fit the s50 plenium design so while the paper method would work, it would take al ot more time to do it from scratch.

PS lee ... love your brakes. they serve me well.

[mikeedler]

cool stuff, but yeah, it seems you are trying to way overengineer that box.

[Massive Lee]

To mock-up such complex 3-D part, you could simply start with sheets of paper, and draw/cut as many times as needed until you get the proper tight shape, then make your drawing according the pieces of paper you mocked-up. Chances are that it will require very little correction.

[HybridNz]

I also decided to give mounting the new radiator fan a crack... was plesantly suprised it wasn't the end of the world and I didnt need to fabricate any mounts. I just used old parts kicking around the workshop for brackets .. worked a treat! :)

e36 pusher fan


gave it a clean up with some decreaser and an airgun



placed it in the location to workout if it would fit .. and it does




The bumpers were just getting in the road so off they came :)



Needed to make up some brackets from old parts.

The bottom just bolted pretty much to the bottom lip



the top just needed some extra metal .. which I found and converted :)






All finished and I tested it up to temprature and connected a battery pack to see it bring the temp down .. it worked :)

Also note the FL smile headlights im gonna chuck on



MMMMMMM smilies





e30's are the only car I know of that actually look just as tuff with no bumpers as they do with them :D

[HybridNz]

Needed to make some room first ...

Out comes the PITA bracket

VIDEO: Time to cut some sh*t

http://www.youtube.com/watch?v=F4axAUTyW78

few adjustments to make as you can see .. I also need to buy a silicon 135 bend and alloy 89mm joiner








After this I ran around and re measured everything and marked it on the prototype where changes need to be made. We will do this process again and try the card up at the car next time. Once its all matches its off the the laser cutters to cut this out of anodised alloy :)

[HybridNz]

UPDATE:

Time to step this sh*t up a bit.

Cold Airbox time.

Big thanks for Ollie's cad skills in sorting this out from his airbox design and to my dad for cutting the mock ups and no thanks to stationary warehouse for charging me $20 per sheet of 1.5mm thick cardboard.
Dad runs a cutting business which specailises in cutting materials / foam / plastics / composites etc. Company is called cutlines.

Anyways here we go..

Top down view



3d



The design at Dads work.



measuring the card



VIDEO: explaining how to program the design for the different tools (Pen, Knife, pizza wheel, hole punch etc)

http://www.youtube.com/watch?v=yZ44KuXIC6k

Setting up the drag knife for depth



Tooling up the head





Air pressure check.



Marking the the 'origin' on the card with laser. This will be the return or known point on the card.



VIDEO: card being cut

http://www.youtube.com/watch?v=pXFVh0nq7uI

photos :)



this is seriously the best way to prototype :D



Sorting out the fold lines with the perf tool


whole system

[JamesE30]

Very nice!
The engine bay is really coming together@, I love those wiring harness' they finish the look of the whole thing. I even put one on my m20 hehe
Keep up the good work :up:

[HybridNz]

Wiring pics as promised ..
Finished up the covers weds night. Things left to do are sort out permanant earths for the engine etc, Sway bar mounts modified, clutch and expansion tanks mounted on OE brackets to body and sorting out the radiator fan and wiring.
So it starts..
Removed the e36 cover to expose the wiring. Lots of un-nessecary coppper in these things :( bit of a birds nest too for straightning out.


Separation of the loom DME plug so with fit through the firewall. I hear all sorts of stories/posts of people enlarging the firewall holes with a hole saw .. I dont get it? just pull the plug apart and feed it through and re-construct back on the other side.
Great thing with Siemens and Boshe plugs, they are meant to be pulled apart for pin additions. Taught ourselves that when doing my e46 satnav retrofit.



Through the other side.
EWS and DME wiring



Reader coil wiring and chip placement.

Fuse box wiring back to ignition

A nice little spread sheet of the e30 pre-fl vs e36 engine loom with colours.

Packing the loom together behind the new plastic shrowding for a nice OEM look and finish

[HybridNz]

cheers fellas! Brendon and I have been waiting around 2 weeks for this point. Ill post all the wiring photos when I get off easter off easter holiday. We ended up using ProgmanSSS to program it in the DME section. Realoem part numbers where the key. Enter the Base DME partner number first then pick the closest 'programmed' dme part number that suits for the replacement DME .. in this case M3 s50 programmed with cats.
supply constant 13+ volts during programming as not to brick the DME.
Make sure the chip is able to be read by the reader coil. Chip position is very sensitive. The car will actually fire with no chip however it will die pretty much straight away as the DME doesnt approve.
It is a good idea at this point once the car is started to kill it and re-diagnose the modules to make sure everything is squeaky clean.
and away it goes :)

[Jean]

OP - can you explain this further, you couldn't make sure of the existing line to the external pump? did you replace the original line from the internal pump to the external pump?

" had to run two fuel lines the one from the tank to the fuel pump was larger diameter and the one from the pump to the main fuel line was smaller. The oem pre-face lift configuration about explains why."

[Iain]

So much win... congrats!

[Jean]

Awesome build man! I was just following it on e30zone too :)

[Ray Smoodiver]

Just picturing you rollin, flossin a tec-1 on rims that isn't stolen