Classic Daily 1975 BMW 2002 Turbo M42 Swap

[jakeb]

These little guys are to mount the intercooler at the top. I am trying to make things as hidden as possible so they weld to the underside of the core support.



Terrible picture and not pretty welds but you get the idea...


Some welded in captive nuts at the bottom.


Then bingo a pretty big intercooler in a 2002. (for those 02 guys...you can see there has been a little bit of cutting that took place here to fit things how we wanted)


This car is getting AC as well so next up we need to fit a condenser.


Sandwiched in there




Then pulled out so you can see the upper/lower brackets for the condenser

captive nuts to bolt the condenser in.


We are running a disco potato on this build...so Garrett GT28RS (dual ball bearings, blah blah blah)

Time to make it fit...






Enough for now...more coming soon.

[CorvallisBMW]

Weird, the engine looks pushed really far off the the passenger side. But I suppose the crank it actually dead center.

[jakeb]

Weird, the engine looks pushed really far off the the passenger side. But I suppose the crank it actually dead center.

Yeah the intake makes it looks off. The crank is dead in the center tho.

[jakeb]

Building the turbo manifold










Adding the wastegate connection












All welded up for the most part


Welded the port side..


Sometime on the belt sander

[jakeb]

It's hot and humid in the shop today so it's time to spend some time in the AC office and update build threads. It's hard to find time to do everything....gotta try and keep up on them and share. Pictures are a little out of order but will show them by job...

Made these little mounts for the e30 m42 lower radiator bumpers.




Welded in. Notches are to help clear the bottom of the radiator


sits pretty nice


upper radiator mount in progress








I wanted to use an OEM fan from something. This happens to be from a 2010 mini cooper and should fit the bill nicely.






made a shroud to mount it to the m42 radiator.





A little cad work


Some time at the band saw and you end up with these guys


Some welding and more cad...


and...




Will then be powder coated!!

[jakeb]

Continuing on...working on the intercooler plumbing

Made this tool to be able to put a bead on the IC piping.


Short one from the turbo to the IC


I'm getting better and better an aluminum....


From IC to Throttle Body


Pulled back a bit


BOV placement


BOV flange welded on


Air filter setup...



This car will have AC so it needed a spot for a drier. Using a e30 drier as it is easy to replace if needed.
Small bracket..cad first


then metal




welded in and drier fitted with lower AC line mocked up


Then making other AC lines...
had to weld to the 318 compressor fitting and add a crimp connector.




on the car (mock up compressor)




low side mocked up


and welded


Line from drier to evap in car. Fill port comes up from down low.


Low side...this was later changed a bit.


hold downs for everything


All the lines mocked up




Crimped and painted


Inside the car


crimper


crimped


installed

[jakeb]

We are using an updated HVAC unit in this car and it required some sheet metal work to make it all fit....



Cut a hole in the firewall (this is where the old fan would have popped out)




Fitting better


Made a mount for it







Mount with box out



tunnel was cut a bit too


Remaking the tunnel to fit




had to make a box to cover up the hole...
Start with some cad...


test fit




Then made from metal

[Dj Buttchug]

Nice work!

[Chase Bays]

This is so badass

[fresh_TD]

Subd!

[Maikkeli]

This thread is full of win. Love the effort you've put to keep the ac.

Keep up the good work

[bangn]

I think you did a brilliant job on that manifold however its really let down by that head flange.. I would be cutting it off and doing it again.

[sam_]

great job on the manifold - excited to see what is to come

[willworkfore30s]

Any more progress on this?

[shootnjunky]

nice build