*!Build of the year candidate!* Strange PNW Build: E30+Volvo

[adam.nonis]

Ah, right. What I guess I meant was, make the conversion really nice, so that when
some butthead like me tries to pick it apart, all the potentially messy 122/e30 joints
look like they were always like that.

t
with an amazon and 2 e30s in the barn.

I'll do my best to make you proud. :)

[adam.nonis]

Made myself a 2" dimple die for panel work. A bead roller just isn't in my budget right now. The family and I have taken on a foster son so money will be tight for a while.

[adam.nonis]

Just been doing a bunch of boring stuff on the car lately. Tying the Volvo cowl inlet to the E30 cowl/fan area. Making sure there's water drainage. Tying the two cars together in the under dash area, seam sealing, etc. I'll post some pics when there's something cool to look at again.

[iansane]

I love this. Nice job.

Sent from my SM-G935V using Tapatalk

[adam.nonis]

Thanks to spiDmang I was able to grab some bits to play with during "quiet time". Also, since I know the two chassis' will fit together, I can start playing with the stuff I WANT to. Following the ITB DIY I read on here I started a similar route.

First I took a stock intake and cut most of the runners/plenum off



Then I flipped it and drew some 2D CAD of the head side (mostly in case I decided to make my own flange for the head





Then I did some 2D CAD of the cut side





I'm going to use GSXR600 throttle bodies since they're 38mm which is almost exactly the same size as the runner, they are seperatable (I don't think that's a word) so I can set the spacing and they're cheap. I bought two sets of four for +/- $70 total





Instead of using silicone couplers, I'm going to use o-rings around the bottoms and make a flange to weld to the leftover OEM intake. I'd like a solid mount instead of flexible couplers and I know it's best to have the throttle plate close to the valve



More 2D CAD





I like to mock up with MDF since it's cheap and machinable











I'm going to use the stock injector port for fuel



And the motorcycle port for vacuum accessory pull off rail



I found a calculator online to help determine length of runner for the velocity stacks. I think I'll use a second harmonic tuning length



I still need to mill the OE manifold part at an angle to kick the ITBs up at an angle and to hopefully even up the runner cross section from the middle (4) runners and the outer (2) and then cut some actual aluminum parts. For phase 1 I'm going to run a plenum on the stacks and keep the AFM in the chain similar to the E30 M3

[spiDmang]

You're such a fuckin gangster.

Amazing work, Adam!

[TobyB]

This just keeps getting better.

t

[LateFan]

That is genuinely impressive.

What sorts of software and milling machine are you using?

[adam.nonis]

That is genuinely impressive.



What sorts of software and milling machine are you using?

For my personal stuff I just use BobCAD and Mach3 to control the router. The machine is a Kelling KL6090 I got off Amazon years ago. I'm not sure it still exists.

[parkerbink]

Thanks to spiDmang I was able to grab some bits to play with during "quiet time". Also, since I know the two chassis' will fit together, I can start playing with the stuff I WANT to. Following the ITB DIY I read on here I started a similar route.

First I took a stock intake and cut most of the runners/plenum off



Then I flipped it and drew some 2D CAD of the head side (mostly in case I decided to make my own flange for the head





Then I did some 2D CAD of the cut side





I'm going to use GSXR600 throttle bodies since they're 38mm which is almost exactly the same size as the runner, they are seperatable (I don't think that's a word) so I can set the spacing and they're cheap. I bought two sets of four for +/- $70 total





Instead of using silicone couplers, I'm going to use o-rings around the bottoms and make a flange to weld to the leftover OEM intake. I'd like a solid mount instead of flexible couplers and I know it's best to have the throttle plate close to the valve



More 2D CAD





I like to mock up with MDF since it's cheap and machinable











I'm going to use the stock injector port for fuel



And the motorcycle port for vacuum accessory pull off rail



I found a calculator online to help determine length of runner for the velocity stacks. I think I'll use a second harmonic tuning length



I still need to mill the OE manifold part at an angle to kick the ITBs up at an angle and to hopefully even up the runner cross section from the middle (4) runners and the outer (2) and then cut some actual aluminum parts. For phase 1 I'm going to run a plenum on the stacks and keep the AFM in the chain similar to the E30 M3

This is beyond awesome! If you were to offer these I'd be in for a set!

[adam.nonis]

This is beyond awesome! If you were to offer these I'd be in for a set!

I'm not looking to make any extras. I'd be more than happy to share any CAD files though.

[adam.nonis]

Been going to work early, and getting home late these days. That plus family weekend obligations, and I haven't gotten much sheet metal work done on the chassis. I did pick up some Amazon roof skin panels to help with some transitions last weekend. I did play around a little more with the ITBs though. Everything is getting closer. Relocating the battery to the trunk as well.



Still need to make the throttle body mounts, the fuel rail mounts, the vacuum collector/chamber and blend the transitions a little.

[spiDmang]

[adam.nonis]

Anyone wanna wager a guess what this is for? And yes, it IS project related.

[parkerbink]

Really long shoelaces for driving boots?