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JackBenny's 1991 318is Project

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    JackBenny's 1991 318is Project

    At the urging of some friends and family, I have elected to start a project thread. To this point, most of my posts have been in either the For Sale or Group Buy threads and after about 3 years of lurking, it's probably time to get that post count up.

    A little background...

    I used to have a bike. A 2004 Kawasaki Z1000. It was fun to blow off steam and I even rode for 6000 miles on trip with some buddies through the southwest. But I lived in Fort Worth, Texas and traffic was not pleasant to ride a motorcycle with. That coupled with keeping my fiance at the time a nervous wreck just made it an experience that was not so pleasant. She would rather have me on 4 wheels and surrounded by metal. I can't really say that I was against the idea so we both agreed that I would sell the bike and look for a project car with the full understanding on her part that the financial implications would be much higher than a bike...i.e. it's gonna cost waaaaaay more money. She agreed, we sold the bike and the search was on.

    What to get though? Oh there was a lot of stuff I wanted. An early 911 with a 993 motor stuffed in the back. An Alfa GTV. I thought about reliving my days right out of college and getting another Mustang Cobra Quad Cam. No ultimately, I think I wanted something boxy. A Datsun 510 would be nice but so would an E30 M3. Mental exercises commenced on both counts and I ended up leaning towards the BMW. The cost of entry for an M3 is steep and given all the stuff I wanted to do, I decided it might be best to look for a 318 or 325. A colleague at work (rcko) had a 325 that he liked so I focused the search on BMW's.

    After a while of searching, I discovered a friend of a friend who was selling his 318is. After looking it over, it didn't have too many problems. The suspension had just been redone including the dreaded sub frame bushings. The suspension was using the Bilstein BTS coils and dampers. The two biggest issues were an impact in the back (more on this later) and an oil leak on the M42 (more on this sooner). We shook on it and I drove home my new project/toy/money pit/emotional release.

    The canvas:









    The first thing that needed to be done (other than fixing the passenger side seat belt so I could annoy my wife) was fix that oil leak. The car dripped from under the steering rack but I would later find that the oil simply pooled up from its various sources. Many gaskets were replaced at the front of the engine. Each time one leak was fixed, I would find another one somewhere else on the front of the engine. This was disheartening and not the pleasant experience I was hoping for. The car was drivable and even a joy to drive but what wasn't fun was the pool of oil it would leave in my garage. Luckily, Christmas was around the corner and my wife got me something to cheer me up.



    Yep, they're Rota RB's. It seems that these are hated almost as much as SportsMaxx. But I like them. I think they look good in the E30 Racecar Thread and part of me still misses the Datsun 510 that could have been. Specs on the wheels are 16x8 ET20 and the good folks at 18racing.com were very helpful with my wife when she called to order them. For tires, we went with Hankook RS-2's in a 245 section width. Yes, I know this is completely unnecessary with an M42 but I like the beefy tire look and I hoped I would have more power someday. The fenders out back were rolled flat and the front fenderwell was massaged a bit to get the wheels mounted:







    -Josh

    Check out my build thread...
    http://www.r3vlimited.com/board/showthread.php?t=131055

    Need parts? Support the community!


    http://www.gutenparts.com

    http://www.blunttech.com

    #2
    looks good! liking the rs2'?
    Zach@Zakspeed.us

    Comment


      #3
      Continued...

      I finally decided to fix the oil leak once and for all. Luckily, my parents lived in Plano so it was only an hour or so drive. More importantly, my father had a lift that was available to use. Up on the lift, we could see just how dirty the dripping oil had made the undercarriage of the car.





      Again we chased the oil leak. The top timing case gasket was fixed. The valve cover gasket was replaced. I fixed the tensioner because oil was leaking around that. We discovered the timing case cover was a little loose and so we torqued it down.





      Then we discovered the source. The backside of the timing case (the side under the cylinder head) was cracked and slathered with JB Weld. There was so much dirt and oil that it was hard to see until the AC Compressor was removed. This was disappointing. That meant the head needed to come off in order to fix. I decided to take a breath and ponder the best way to solve this problem.



      It turns out the best way to solve the problem was to buy a crate...



      With an S52 in it of course.

      I found an S52 out of a 2000 M Roadster with 38,000 miles on it. It came with the engine, harness (OBDII), transmission and final drive. I had no doubt that this would fix my leaky M42.

      Unfortunately, later in this process, the economy would start to go downhill and I became worried that my job might be threatened. Since my wife and I are both engineers working in Aerospace, I put some feelers out to see if there were any opportunities. The sad part is that no work occurred on the car due to the unknown. Luckily an opportunity presented itself for the two of us in Mobile, AL of all places working for Airbus North America. We managed to find a nice house with a three car garage and got settled in. And right before I was set to start removing the engine we found out we would be working on a project the next 3 and a half months...in Hamburg Germany.

      Again the car would have to wait.

      While in Germany, getting accustomed to a new culture and enjoying all the German automobiles, deals were to be had here on R3vlimited. I picked up a set of C3Motorsport Suspension complete with the modified struts from ldsbeaker. I also thought I would jump in on Massive Brakes new street kit. It was like Christmas when I returned and I could get to all my new parts. I had missed Thanksgiving with my parents so they decided to come visit for new years. Little did my father know I would be putting him to work....



















      With the engine out, we rolled the car to the center of the garage for maximum space and started to prepare the patient for surgery.

      -Josh

      Check out my build thread...
      http://www.r3vlimited.com/board/showthread.php?t=131055

      Need parts? Support the community!


      http://www.gutenparts.com

      http://www.blunttech.com

      Comment


        #4
        Are those aluminum block's out of the m roadsters?
        Zach@Zakspeed.us

        Comment


          #5
          Awesome! I love project threads that have progress in them.
          cars beep boop

          Comment


            #6
            Nice e30! Welcome!

            Where about in Ft Worth do you live??

            Comment


              #7
              Scalpel....

              After getting the car settled and in the air, I thought I would refresh the struts that ldsbeaker sent me. The backing plates were bent (and wouldn't be used with the brake kit) and the struts were pretty dirty. I decided I would clean them up and repaint them.





















              Since I was refreshing the front suspension and I needed to install the final drive in the back, I thought this might be a good time to do the same to the rear suspension. With the car in the air, I began to remove the bolts that held the rear subframe to the car....

              A couple of hours later, it was out.





              A couple more hours passed, with many expletives uttered aloud (well, lets be honest, they were screamed) and I managed to have the whole thing in complete disarray.









              I decided that since I had a bad CV joint (the boot was missing) I would grab a couple from the local auto parts store. In addition, I would clean up the subframe and trailing arms, get new bearings, clean up the drive flanges and rebuild the calipers. Best get cracking...











              (yes, that is a computer in the garage and yes that is a picture of me driving on the Nurburgring while I was in Germany)













              The furniture dolly was nice in that it allowed me to roll it under the car and get it positioned exactly where i wanted it. From here, it was a matter of putting a jack on either side and slowly raising it up.







              I couldn't resist simulating ride height. Yes I know the tire is on backwards...





              -Josh

              Check out my build thread...
              http://www.r3vlimited.com/board/showthread.php?t=131055

              Need parts? Support the community!


              http://www.gutenparts.com

              http://www.blunttech.com

              Comment


                #8
                Damn man, nice work. I myself am dreading those rear wheel bearings.

                Comment


                  #9
                  About that engine....

                  While the paint dried, my knuckles healed and I contemplated which expletives I should use next I decided to remove the intake manifold from the engine in preparation for an OBD 1 swap. While I did have just about everything I needed to do an OBD 2 swap, I felt more comfortable with going OBD 1. I also plan on running 24lb injectors and a 3.5" HFM. Cams are on the list but further down after I get the car running and I am satisfied with the swap. I removed the OBD 2 intake...



                  I also shopped on ebay for the famous headers. There were many to choose from but I ultimately decided on some JVT headers. Getting them on engine proved difficult as there was some interference with the passenger side engine mount. I decided to remove it, install the headers for a test fit and put the engine mount back on. I'm glad I did.



                  hmm, something's not right...



                  Good thing to find this out now! Replacement is on the way. Here are the rest of the header pictures:









                  some "tweaking" appears to be required.

                  and the sad motor mount:



                  That brings us mostly up to speed now. I have a few more things that I've done but I will save those for another day. I am excited about this car and even more important, I've got a lovely wife who is willing to help me out there (she cleaned my swap oil pan but refuses to let me post pictures and let's face it, I'm not about to piss her off after all this.)

                  For those who hate the Rota's, I will say I have another set of wheels currently being made that I think will do alot for the look of the car. And no, they are not Work VS.
                  -Josh

                  Check out my build thread...
                  http://www.r3vlimited.com/board/showthread.php?t=131055

                  Need parts? Support the community!


                  http://www.gutenparts.com

                  http://www.blunttech.com

                  Comment


                    #10
                    Originally posted by Bimmerista View Post
                    Nice e30! Welcome!

                    Where about in Ft Worth do you live??
                    I used to live in south Fort Worth just north of Burleson. Now I'm in Daphne, AL. Used to work at Lockheed Martin.
                    -Josh

                    Check out my build thread...
                    http://www.r3vlimited.com/board/showthread.php?t=131055

                    Need parts? Support the community!


                    http://www.gutenparts.com

                    http://www.blunttech.com

                    Comment


                      #11
                      wow dude, impressive build! your wife is most certainly a keeper after all of that.


                      Need OE BMW or Aftermarket Parts? Shoot me a PM! | Leave me feedback here
                      info@omgmotorworks.com

                      Comment


                        #12
                        Originally posted by moatilliatta View Post
                        looks good! liking the rs2'?
                        Originally posted by moatilliatta View Post
                        Are those aluminum block's out of the m roadsters?
                        I like the RS2's The car has way more grip than it needs and looking back I probably should have gone with 225's Easier to fit and just as beefy. But for less than a 100 bucks a tire, I am pleased with what I got out of them.

                        I believe the Roadster S52's are still iron blocks. The surface rust on certain parts of the block would seem to correlate that fact as well.

                        BTW, anyone who quotes Day of the Baphomets is alright in my book. My favorite song on Amputecture.
                        -Josh

                        Check out my build thread...
                        http://www.r3vlimited.com/board/showthread.php?t=131055

                        Need parts? Support the community!


                        http://www.gutenparts.com

                        http://www.blunttech.com

                        Comment


                          #13
                          Originally posted by e30esque View Post
                          Damn man, nice work. I myself am dreading those rear wheel bearings.
                          Rent the bearing puller from a parts store or go to Harbor Freight and get the kit. I found that much easier to that than use a slide hammer and wear yourself out. One of the threads in the FAQ is pretty good and was what I used.

                          It still wasn't fun, but wasn't as bad as I thought it would be.
                          -Josh

                          Check out my build thread...
                          http://www.r3vlimited.com/board/showthread.php?t=131055

                          Need parts? Support the community!


                          http://www.gutenparts.com

                          http://www.blunttech.com

                          Comment


                            #14
                            Originally posted by dude8383 View Post
                            wow dude, impressive build! your wife is most certainly a keeper after all of that.
                            Yep, she's a cool chick. When we drove on the 'ring, we had an instructor sitting right seat while we took turns. She did 4 laps out there and had a blast. She can't wait to go back.

                            <in best Mr's Burns voice>
                            Exxxxxcellent

                            I'll have to post some of those pictures one day.
                            -Josh

                            Check out my build thread...
                            http://www.r3vlimited.com/board/showthread.php?t=131055

                            Need parts? Support the community!


                            http://www.gutenparts.com

                            http://www.blunttech.com

                            Comment


                              #15
                              Great project coverage and beautiful camerawork. Keep the progress reports coming.

                              1991 325ic and 1991 318is

                              Comment

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