Russell's build thread. (tons of pics!) Dyno day.

[hella 325]

Had this up on e30tech for a while, but figured I'd post here too.

I bought the car for $1 and it was in bad shape back in 2004... Here is a slide show of the early years of the e30. From the day I bought it.


Here are a couple before/after for those who dont want to watch the whole slideshow.

When I bought it. 2004




The "after" shots from 2005.





At this point it became my DD and was relatively unchanged. Until August 2009 when i bought a e34 as my DD.

Then I was able to begin working on it again and started with a Zender rear apron..



This is going to take a little work.


Fits ok, I'd like to see better.


I also have a slightly nicer garage to work this time.



Well time for a change. I have been gathering parts, and working evenings on the car. Here's the progress.

Garrett t3/04e .60/.63 stage 3 57trim. Bought it a few years ago.



Figuring out where to put this big thing...


Works nicely there


Tight squeeze


Drivers side pipes.



BOV mounted



Gettign closer


This doesn't fit....


Now it does


The first test fit, turbo on a stock set of manifolds, with pro turbo adapter and 50mm waste-gate provision.


Tight


First mock up with turbo and waste-gate and finished downtube. I got akg motor mounts, and they raised the waste gate clearance some.


Finished up the exhaust,3in w/vbands to Magnaflow 3"-2x2.5" muffler.


Looks tame.


New wheels 16x8 xxr 15 offset


Next to a bottle cap.


BFG kdw's 225/45-16


Mounted




Ceramic painting the pro turbo adapter w/ 50mm waste-gate provision and matching down tube


I thought my intercooler pipes were kind of ugly, so I grew some out of this cardboard.


Wrapped the manifold and downtube after the paint had fully cured.


It took about 3 days for the wrap to fully dry, but after it did. I super high heat silicone sealed it.


combined the manifolds


Installed the boost and AFR gauges.

[hella 325]

Relocated oil filter







NGKBPR7ES


Manifold fitted


Turbo


I got some more pics of the progress up.

Turbo oil supply -10an


Supply and drain. Supply is -4an with a .065 restrictor.


Drivers side painted pipes installed.


Minus front valance.


and hood


Things came together nicely.

[hella 325]

Its about time it came together...

Made this to test for boost leaks.


My real type s diaphragm cracked so I have another BOV on order.


Got everything buttoned up except the two leaks. Here is the video of the very first attempt to fire it up.


I'ts filthy, covered in pollen, and still unfinished but its home. so here are some updated pics of the car.







BOV came


Updates, I just got back from Prague last Monday and have been playing catch up at work and home. I'll upload pics of Prague soon. I do have a couple more updates on the e30.

The car is driving on the street nicely, I put a weaker spring in my BOV and loosened it up, relocated the WG signal to right after the compressor outlet, and shortened all vac lines as much as possible. These things have almost completely reduced the flutter. I am planning on tapping a fitting directly to the manifold for the BOV and see if that will completely eliminate it.

This came in, looking forward to getting it installed.


Found my MBC that I never used. TurboXS high performance.


And still need to get Roberts skid plate installed, it's been sitting right here since I got it. =( I need a welder.


Another update.

I got the front end on, had to cut quite a bit away, but it still looks clean imo. Now to figure out the fog light situation.




Thanks man, I spent the day at the shop today getting small stuff done.

I got my BOV signal moved from a T fitting to the vacuum nipple under the TB. It helped with my partial throttle surge. I've been meaning to do this for a while.

I also finally tucked the DIYPNP up where the factory ECU sits, and put the inside glove box cover back on. Now there is just a LC-1 connection and a com port in the glove box. Sorry for the bad pic, and the unfurnished look. My latch broke so I unplugged the light switch.


I also picked up a set of Hella 550 yellow fog lamps to try and fit something in the stock location. I saw em at the Summit store and thought "man, those look like they could fit!" So I bought them completely sans measuring.


Turns out they could, with a bit of work. I cut open the gaps some. And had to notch the valance for the new mounting location.


Lots of measuring, and a couple of holes later, they fit.





The Zender rear valance had a spot that had been melted by the PO's exhaust. So I started working on that.


3m bumper epoxy should do the trick.


It's working nicely. Have another coat and some more sandind to do.


But I decided to go ahead and start the sanding on the side pieces too.


It was a good full days work. But I got a lot accomplished.

Here is a little audio clip my friend recorded earlier today and emailed me.

http://s306.photobucket.com/albums/nn257/Rrklem/e30/?action=view&current=e30ehaust.flv

Couple more updates, didn't get nearly as much as I wanted to get done this weekend. I partied way too hard. But I did get some more work done on the Zender. I think it's repairing nicely.




I also got everything pulled ready for the new clutch.


I've been asked to provide a list of all my components ETC. so i will.

Engine:
M20b25 block 325k or so
head has been decked .04 and 5 angle valve grind with minor porting/polishing.
PS removed
A/C removed
clutch fan removed
Spall 16" super thin puller on thermo w/manual override
coolant tank relocated to face lift loc
pro-turbo adapter w/50mm HKS WG provisions
HKS 50mm external gate
Garrett t3/04e made in the USA
2.5" alumidized charge pipes
26x3x14 (i think) intercooler
greddy type RS BOV
Turbo XS hp manual boost controller
DIYPNP ecu
Volvo 850 TPS
GM IAT
Relocated oil filter
Aftermarket oil cooler
3" exhaust w/magnaflow 3"in 2x2.5" out muffler

Drivetrain/suspension
Spec stage 3 clutch/pressure plate (hd pressure plate, sprung 6 puck)
H&R race springs
Bilstein sport shocks
power flex urethane bushings
AKG 75d motor/trans mounts

[hella 325]

Well I finally just sucked up the heat and busted ass for a day.

I got the rear main seal changed out. It wasn't leaking bad earlier, but I figured why not while I'm there.

It proved to be a pain to get the old seal out.





The machined flywheel back on.


Spec stage 3, sprung 6puck w/hd pp.


She is back on the road now, for a grueling 500 mile break in period... It's hard to baby it, but at least its back on the road.


A couple more updates. Worked on it a little after work. I put a new front roundel on, alternator belt, new fuel filter, my 123's, and got the splitter mounted.

Sorry, it's filthy right now, and they are crappy iphone pix.

[Kershaw]

good fucking work man.

that looks awesome.

i have a 4puck in my rx8. i dont think i'll ever buy a pucked clutch again. its golden when moving, but what a pia to start in first. good luck.

[QBANG]

Very nice work!

How much would you say you have in the project?

[hella 325]

I'm not sure I have a binder and 2 folders filled with receipts. I don't really want to think about it. But if I had to take a stab I'd say 6k ish.

[trackjunkie21]

That is so fucking win! What do you think you put down at the wheels?

[hella 325]

We find out Wednesday at 9am! :D

[AbsorbantNut]

Nice turbo build! 5 angle valves? damn, I've only seen 3 angle. Keep up the good work!

[JK_E30]

Wow very nice stuff here!

Also interested in what power this thing is making!

Great work!

[Civilian]

Looks awesome. Those wheels look fantastic.

Since I don't know, are there advantages for using an external wastegate?

Good job.

[hella 325]

Well I bought the turbo w/o a waste gate b/c it was an awesome deal. it also helped get it positioned and fitted just like I wanted.

The benefits would be higher flow, to provide less chance of creep and more solid boost control. The huge ones can deal with higher boost too b/c they a-flow more and b- can be huge.

With that being said, a internal wastegate matched with appropriate boost and with a good signal will control boost just fine.

[hella 325]

Well today was dyno day. It went as well as it could have. I'm satisfied. Took 2 hours to get it all straightened out. I'll let the chart do the talking.

Turbo w/ DIYPNP vs. NA w/ DIYPNP

327whp 324wtq

[AbsorbantNut]

Titties..........thats ridiculous:hitler: