s50b32 e30 325i tech1 project

[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

[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]

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

[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.

[mikeedler]

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

[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.

[Massive Lee]

I am watching your wheels. They are gorgious.

Lee

[HybridNz]

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

[HybridNz]

Update [Special edition]

wheels are back.

testing the caps (not pressing them in just yet .. will let the paint harden another week)


custom black anodised bbs bolts









B)

[JamesE30]

Hell yeah this is going to be sweet!! that's the colour I want to paint my wheels when I next rebuild them!

[CorvallisBMW]

I like the airbox, probably the most professional I've seen done here on R3v period. The wheels are fucking SEXAY!

[HybridNz]

http://www.youtube.com/watch?v=GAWxkU-8N7g

http://www.youtube.com/watch?v=fokH-4nj3w4

[Iain]

Sounds fantastic, looks fantastic, goes fantastically well...

Yep, you scored the trifecta. Congrats on a great car!

[Mr. Horsepower]

Love your build!!! :D

When using the Treehouse racing S50 --> E30 wiring loom adapter, did you manage to hide it behind the firewall trim?

[HybridNz]

Love your build!!! :D

When using the Treehouse racing S50 --> E30 wiring loom adapter, did you manage to hide it behind the firewall trim?

It was the one from AKG Motorsport. and yeap all tucked away nicely