The complete repair, rebuild, repaint, and v8 swap of my early model sedan

[MR 325]

Love it, perfect (tight) fit! The BMW V8 is definitely wide.

[JGood]

Thanks guys. Yeah, it really is a very tight fit, lots of grinding, cutting and bending required.

I ordered my Flaming River steering joints, they should be here this week, then I'll begin modding the e38 exhaust manifolds to fit. This is probably going to be the most challenging part of the swap for me. I've never done any welding on exhaust before, so I may practice on some scraps.

[drutt23]

This is looking very good man. Mad props for all your work so far. I look forward to seeing this (and Garey's of course) finished and tearing up the pavement! Keep it going!

[Jhonno]

Apologies if I have missed it.. But detail on the steering linkage setup? U/J's and shaft from where?

[alpinaclone]

Very impressive stuff. Having had to do maybe 50% of the rust repair that you have done on an e30 really makes me appreciate how hardcore your effort has been. The v8 should be fun too.

[JGood]

Thanks guys!

Apologies if I have missed it.. But detail on the steering linkage setup? U/J's and shaft from where?

I'm not sure if I mentioned it before. I'm going to use u-joints from Flaming River, they are the correct BMW spline on one side, and a 3/4" D-shaft shape on the other. So you get two of the u-joints, a D-shaft cut to the proper length, and you have yourself a thin, heavy duty steering shaft. They should be arriving tomorrow, I'll post pics.

[JGood]

Spent a few hours tonight verifying something awesome.

I previously m50 swapped this car with a 94 525i engine. I cut off the factory e30 C101 connector and wired in an e34 X20 connector, so I wouldn't have to butcher the engine harness, or use a harness adapter.

Turns out, the m60 and m50 e34's in 94 are wired identically. So all I have to do is plug my e30 chassis x20 into the engine x20, and everything will work flawlessly. No wiring work needed for this engine swap.



I could go out into the garage right now and fire that thing up......

[Dj Buttchug]

I could go out into the garage right now and fire that thing up......

and your not because...?

[JGood]

and your not because...?

No oil in the engine, and it's somewhat torn apart. I was exaggerating of course...

Here's one of the steering joints and the shaft. It's chrome moly and has a serviceable needle bearing, a very nice part. I checked fitment on the rack and column splines, it's perfect.

Thanks to Bruce and Garey for finding these. It will be a huge help in getting the exhaust manifolds to fit while also using the e36 steering rack.

[MR 325]

What's the cost on that thing Justin?

[JGood]

What's the cost on that thing Justin?

They are ~$70 each, it was $160 shipped. Then you also need the 3/4" DD shaft, which you can find for $30-$40. You only need 5" or so.


You can see how much thinner it is, providing the necessary clearance for the exhaust manifold:







Also did some work to the firewall, since the master cylinder is shifted to the left, it can't use the same firewall hole. I welded in a plate with a hole cut out to fit the master cylinder grommet. Was a PITA, with how cramped that area is with the wheel housing in place. The hard line clears the brake linkage movement where it is.

[JGood]

Got the strut tower support brace welded in. I created a hole for the linkage rod to travel through, now I just need to clean it up a bit. Also need to figure out what to do with the upper support brace. I can't think of any reasonable way to connect it to the knee bracket on the firewall, as it is in the e34's, without seriously compromising the strut tower support brace. But we'll see.

[bmwmech1]

Got the strut tower support brace welded in. I created a hole for the linkage rod to travel through, now I just need to clean it up a bit. Also need to figure out what to do with the upper support brace. I can't think of any reasonable way to connect it to the knee bracket on the firewall, as it is in the e34's, without seriously compromising the strut tower support brace. But we'll see.

I would make a flat plate to bolt it to the strut tower brace on both sides and be done with it. If it abuts the strut tower brace on both sides and relatively in the same plane, it will function similarly as if it were one piece...

Garey

[JGood]

Yeah, that would work. In addition I could run a pipe right through the support brace, cut it flush on the ends, and weld it in place, that would remove all doubt of it warping the thin sheet metal on the brace, and guarantee the load will be transferred between the linkage assemblies, as designed.

[bmwmech1]

Yeah, that would work. In addition I could run a pipe right through the support brace, cut it flush on the ends, and weld it in place, that would remove all doubt of it warping the thin sheet metal on the brace, and guarantee the load will be transferred between the linkage assemblies, as designed.

I don't think it will deform the tower brace, but yeah, that would guarantee the load transfer. Seems like a lot of extra work, but it would be effective. Don't forget the captive nuts...

Garey