1970 BMW Gruppe 2 2002 (M20B29 Turbo) Build

[kid325e]

That feeling when you make that first cut into the tunnel.

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[88SuperETABD]

So not a lot of progress. Been working a lot on a promotion and finally got it. So hoping that now I can have some more free time.



I started with stripping the interior to prep for the transmission tunnel modification. Then decided I should clean up all the tar so I can paint inside after.




Here's after some serious scraping/wire wheeling. The dry ice trick kinda worked but still needed a lot of labor to remove the tar.



I decided it's time to cut. I wanna make sure there is plenty of room under there. Some say they've gotten the g260 to fit with a hammer but that won't look too nice beaten to hell, so i'm gonna widen/heighten it a bit.

A family friend who owns a body shop told me to cut like a hat instead of cutting the top off and peel it up like a can. This cut was sketchy.



Also making the g260 smaller. Cutting off nubs that are not needed.



A friend came and took some pretty shots of the car...I need to take the time to take non-iPhone pics.









These pics show all the hard work in polishing that turbo ;)


This maybe a little cliche but I want to find a chassis for this! Little project I did yesterday.




Also working on an idea of how to get this e30 rear suspension into this 2002. I finally crawled under there and put it up. It's about 1.5" wider than 2002 mounting points. I will be re-designing the way it mounts. Hope it's not too janky.










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[rzerob]

Good to hear :) I feel lucky to find one local from a friend.

I traded a set of plastic bumpers and front valence with fogs for mine.

[88SuperETABD]

So got impatient and skimped on the body work. Decided to just prime it and see if the new turbo manifold fits.



Figured this was good enuf sanding for now. I can sand more later when it's time for paint since motor will be out again.

Layed down some expensive ass 1k primer.



And got the motor in. Had to take off the turbo to fit since the exhaust side of turbo has 1/4" clearance to fender.

But still accessible to put turbo on and off



Then a kind friend came over and brought me 2 3" J bends I'm gonna make a Downpipe out of.



Made first measure and cut. Gonna tack it
To the flange next.



I haven't worked on it for a couple days. Just been looking at it haha.

Cuz next I gotta hack up the trans tunnel to fit this g260.







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[88SuperETABD]

I love my 3.46lsd in my E30. It is the perfect ratio in my opinion.

Good to hear :) I feel lucky to find one local from a friend.

[ThatOneEuroE30]

I am jealous of that 3:46..

[rzerob]

I love my 3.46lsd in my E30. It is the perfect ratio in my opinion.

[88SuperETABD]

Slow progress cuz body work sucks. Filled the rest of the holes and now using ever coat metal glaze putty to get the low spots of the weld/patches.




As I was grinding my welds down I ground a little metal plug flat, which ended up falling out. Creating one more hole to fill.


Now that they're flat. Gotta get the low
Spots.


Need to do a bunch of sanding now.


Because I'm sick of sanding I decided to take a break and cut out the fenders since my motor is going back in after.


So I marked where the flares were and made a rough cut. Gonna probably grind it back a bit more.



Plenty of room now ;).
When the motor was in, the fenders were resting on the tires.

Also got a 3" flange for my hx35, gonna make a downpipe. E30 friend is coming over and we're gonna redo a section of his exhaust.



Need to get this bay done so I can get back to the fun stuff.

Picked up a 3.46LSD from a friend. This will let me start the e30 subframe swap.






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[pandaboo911]

Sweeet. Lemme know the text time you work on that subframe. I'm down to help.


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[88SuperETABD]

Didn't work on the car as much as I'd like to lately. But did some things. Filled some more
Holes in the engine bay, but was later and didn't wanna make a buncha noise.

So I welded the turbo up.



Started with the pin. I was having trouble getting the two to weld at first. It took a lot
Of heat. I wonder what type of stainless it was. But the 309 wouldn't puddle Into it for a while.



Then I tried using the 309SS to the cast iron. Without preheat. I did a small section and looks like it was working, but I had to turn up the amps cuz the cast wasn't puddling enough.



I went some more and let it cool and it cracked...guess preheat is mandatory.

So went back and preheated with two torches. And went back over the weld. Then I attempted to do the inner side, against the wall, but was failing. A buddy of mine who had better TIG experience just decided to weld it to the side wall instead of the base. The whole goal is just to block the hole and make sure it doesn't get loose. I don't think it's gonna move.


Now turbo is ready for a 3" DP. Or Up? Haha



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[88SuperETABD]

Kronus- this car is being only built by me. Only thing I'm considering to pawn off is final dyno tuning and full cage. Gonna tackle this rear end myself. I have the design skills. Just not sure on the fab skills...but only one way to find out! I have the tools...but I will also go true coilover in the rear like the pic you have.



Test mounted with 3 screws on the flares and 2 on the valance with my friend Oliver (think he's on here).



The brake ducts interferes with the bottom of the nose, and it was all bent up anyways. I decided to cut it off.





I kinda feel bad I'm using this cut off wheel So much on this car.
Gonna go work on it now.



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[kronus]

also, looks like jake has a jig for his subframe. maybe see how much he wants to make you one?

http://www.bmw2002faq.com/forums/top...c-into-a-2002/

[kronus]

that's a lotta tire

here's a pic of an e30 subframe in a 2002 built by groma race fab (jacked from SkiFree):

[88SuperETABD]

Update:

Got my calipers mounted and pads/SS lines installed


Glad my wheels clear with no issues.


But it's tight :)


The front suspension is pretty much done other than gettin the booster and steering stuff back in. Which will be next since I got the missing piece of my motor build.

Steve at Blunttech let me get the first turbo manifold made by him and his partner Jake.
It's shockingly better quality than I was expecting from China. Welds look proper. Runners have nice bends and they even did some port work. I guess you can get good stuff from China if you hold their hand and make sure they do what you want them to do.


Here's Steve's pic he sent me.

And here's some detailed pics of the manifold.







Guess I got too excited to mount turbo. Don't have a pic of manifold only mounted.

But here's a nice side shot to show clearance for oil filter and how little it hangs down.




And a step back.



Love seeing everything coming together....but I need to finish deleting my internal wastegate. This is what I'm gonna try.

I got some 309L rod to weld up the internal wastegate holes.



This pin is SS and it was part of the flapper mechanism. I just cut it off and plan to weld it in the hole like so.



Then for the big hole, I plan to try to use the 309L to weld the flapper over the hole. I'm told this may work from my welding supply guy. He originally told me Nickel rod would be better but this may work as well. Any TIGers our there have experience Welding SS to cast iron?




I'll probably give the 309 rod a shot tonight.


I also started patching the holes in the firewall for the "bay shave".



Cut out some circle pieces out of 18 gauge mild steel and held the back with a magnet.


Tacked


Gonna finish weld them and grind flat. Will post more when I get the welder back out.

Also been looking into how I'm gonna get the e30 subframe mounted in the 2002 with the medium case LSD. Luckily, I don't think it's gonna be too hard. Here's the 2 subframes laying next/on to each other.


Here's the e30 suspension I got locally.



Just need to get my 3.46lsd off my friend....


And last but not least, I got my new 245/40r15 VR-1 tires! These were just released and only 145$/tire with free shipping.


These will fit my
15x10 so much better than the stretched 225/45.







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[Kershaw]

Hahaha, we have all seen that look before!