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Thread: E30 saga continues

  1. #41
    BMW Master bawareca's Avatar
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    Finally I can see some systems finished. This gives me strength to continue, although I am almost ready to postpone the project for a few months. This much work for only 5-6 months is way over my head. The aesthetics of my work are decreasing exponentially, but the car has to be finished.
    Planned shakedown for March is actually doable, if nothing major comes in the way.
    Seat back brace finished. Doubles as a belt retainer.


    Spa 4L mechanical system with 4 nozzles in the cockpit and 3 in the engine bay.



    Remote master switch disconnect, as per Moti's guidelines.


    Coolant system is complete and functioning. Radiator exhaust duct is complete, with a 16" Spal fan built in.


  2. #42
    Senior Member fatbillybob's Avatar
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    I like non- back poker back braces!
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  3. #43
    BMW Master bawareca's Avatar
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    Got a parcel from Finland today. There goes another racing dollar ("racing dollars" are almost equal to "boat dollars"-exchange rate is 1RD for ~1000USD )
    But seriously, this kit is around 1/2 of other offerings on the market and is executed brilliantly. Takes care of the camber curve and the bump steer, moving the lower joint out and front in the same time. Also cuts the steering ratio by 15-20%.




    Even the stance guys can be jealous of the wheel-flare relation






    It is hard to see on these pictures, but the tip of the screwdriver shows approximately where the original wheel outer wall was once. The car is 10"-12" wider than stock E30.
    Last edited by bawareca; 02-28-2017 at 07:29 AM.
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  4. #44
    Senior Member fatbillybob's Avatar
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    I must be really old because I'd rather see this kind of racecar porn than the other kind...

  5. #45
    BMW Master bawareca's Avatar
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    In the meantime I got sidetracked a bit by this project: (of course I told my wife the truth, blame goes to the treehuggers on that Trackhq forum )


    But the work on the E30 never stops, even when I sleep. The driveline is installed and fully functional, got a nice 3.91:1 diff with 4 clutches and zero preload. Brakes and clutch are installed and functional. Rear suspension needs only height adjustment once on the gorund, front needs the cooling ducts finished and the sway bar connecting points. The engine is now out of safe mode and is insane at 6000 RPM, I cant even imagine what would it be at 8k. I may need a few pairs of ear plugs








  6. #46
    Senior Member robburgoon's Avatar
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    Quote Originally Posted by fatbillybob View Post
    I must be really old because I'd rather see this kind of racecar porn than the other kind...
    Yeah, I don't like the car porn where everything looks fueled by vanity. This is more like it.
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  7. #47
    BMW Master bawareca's Avatar
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    Quote Originally Posted by robburgoon View Post
    Yeah, I don't like the car porn where everything looks fueled by vanity. This is more like it.
    My hat's off to the guys that do showroom stuff. As much as I like thinkering with stuff and building, I dont have the skills, equipment or the patience to do it amazing. I am also trying to not get too attached to the car so I am mentally prepared to write it off any day of the week.
    Last edited by bawareca; 04-10-2017 at 08:33 AM.

  8. #48
    BMW Master bawareca's Avatar
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    Yay, finally on it's own feet


    Did a wedgie to the trailer today




    And gained 6" height. Hopefully i will not be very sorry.

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  9. #49
    BMW Master bawareca's Avatar
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    Looks almost ready for the track

    This time i went with a shorter and inefficient splitter, but hopefully it will stay together for much longer. I plan to build a better front end someday, but for now duct tape is the king.




  10. #50
    Senior Member fatbillybob's Avatar
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    I assume the short dovetailed boards are screwed down some way? You are such a good fabricator I would like to see you diamond plate the top of the trailer. Cut a hole in the diamond plate and make a door so you can change the oil while Bimmer is on the trailer.

    I want to take some laps in that beast. Well done!
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  11. #51
    BMW Master bawareca's Avatar
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    Quote Originally Posted by fatbillybob View Post
    I assume the short dovetailed boards are screwed down some way? You are such a good fabricator I would like to see you diamond plate the top of the trailer. Cut a hole in the diamond plate and make a door so you can change the oil while Bimmer is on the trailer.

    I want to take some laps in that beast. Well done!
    Thank you for the good words, but I am not really a good fabricator, more of junk warrior guy You are very welcome to drive the beast anytime you want.
    Went to BRP yesterday and had some fun/troubles. The power steering fluid overheated in the first lap, which was probably a 2:30 lap. I dont have a power steering fluid cooler, but there is something else going on there. Need to investigate, or install electric power steering pump and call it a day. With this PS pump from E46 M3 the steering felt overboosted, like the front tires were 155, not 255. I was able to find and install a shorter belt and eliminate the PS pump, but what a workout that was. With ~9 degree camber, 255/17 tires and steering ratio cut another 30% it was close to impossible to turn in most corners with my hands on 3 and 9 position. I had to do a pull-push and use my knee as a support in Riverside
    Even with just a random base line adjustments the car felt so much better than before. The front end follows whatever the steering wheel turns (whenever I was able to turn it ) and the rear end can be easily controlled with the throttle.
    With dual 1" master cylinders and no brake booster the brakes could probably scare F1 driver It takes a lot of force to make the car stop, but I like it. The pedal has 1/2"-2/3" travel and after that it is rock hard. The pressure is modulated with changing the applied force, but the pedal does not move at all.
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  12. #52
    Chest hair required Olitho's Avatar
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    Quote Originally Posted by bawareca View Post
    The power steering fluid overheated in the first lap, which was probably a 2:30 lap. I dont have a power steering fluid cooler, but there is something else going on there. Need to investigate.
    I don't know about BMWs, but C5 Corvettes on the race track foam up the fluid if you overfill the reservoir and then they don't work well. It is better to fill them to just the very bottom of the dip stick and they work great.
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    To the right of The Sheriff. Isn't everyone?

  13. #53
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    I can't wait to see this beast. Such a nice project.

    Are you using the E30 steering rack with the E46 PS pump? Is it possible to use the E30 PS pump? These things are designed as a system I would imagine and the E46 M3 rack requirements are probably a lot different than the E30 from a pump standpoint. Of course the E30 pump was never designed to spin at 8k rpm so that may open up a whole bunch of other issues. I've been considering electronic PS for my E46 but the pump (mini) is heavy compared to the stock PS pump and mounting is an issue so I've put it off for now.

    Mark
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  14. #54
    BMW Master bawareca's Avatar
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    I use E36 M3 steering rack and the PS pump that came with the S54 engine. It has been done many times and the compatibility between the parts has been proven. On thing that has my attention is that I have used the original E30 high pressure hose between the PS pump and the rack. All old school BMWs have a restrictor as part of the high pressure line-possibly archaic method to even the pressure thru the RPM range. I have never had a problem with the original E30 PS pump, but the E46 one feels like it is producing higher pressure(overboosted steering feel). The fluid may be bubbling and overheating while passing thru the restrictor, causing the problem. I plan to start the car and measure the temp around the restrictor while turning the wheel left and right.
    There are other PS pumps that can be fond on Ebay for a decent money. I like the 2010-up Volvo pumps with integrated tank. If I only new how to control the pump to keep a steady pressure I'd buy one in a heartbeat.
    The high pressure line with the restrictor pressed in and the restrictor itself can be seen on these pictures.
    23mq64y.jpg

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  15. #55
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    Yeah, I would have thought that combo of parts would be fine.

    When I was researching, the pumps the E46 M3 racers were using were Mini, Porsche Motorsport, and Mercedes Class A series pumps. Easiest and cheapest to obtain of the 3 was the Mini so that is where I started. The Mercedes has the integrated reservoir which could be a plus but otoh it limits mounting options.

    Mark
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  16. #56
    Senior Member fatbillybob's Avatar
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    How about an underdrive pully and ps cooler?

    And restrictors are critical for pulsation control and other flow limiting. Improper restriction can cause pressure rise and burping out fluid from reservoir and fool you into thinking you got an overheat problem.
    Last edited by fatbillybob; 05-15-2017 at 08:34 PM.
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  17. #57
    BMW Master bawareca's Avatar
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    Ok, time to put up all this E46 sh!t and love&hate confessions and get back to real stuff
    To fill-up the gaps for the last 6 months, i was able to take care of the power steering cooling problems and now everything flows cool and slow. After the initial overheating the steering rack started to drip fluid from the steering shaft seal. After opening it i found that not only the seals were melted, but also one of the bearings' plastic separator was complete melted away.
    After the 2nd test day in June in the ACS I figured out that my engineering skills are very poor. Due to extreme angles of the front swaybar endlinks some suspension parts ended up bent and some shock parts were broken.
    After revising the components it was a time for the 3rd track day, and it almost did the charm. I was having fun this weekend at ACS, but was still on the cautious side. It paid off at the end as another problem ensued, fortunately with little consequences.



    The inside bracket of the front control arm broke, happily for me in 5-6 and not in 1-2. Using my bad engineering skills I calculated that this bracket carries from 1600 to 2000 lbs weight and many harsh impacts.

    Last edited by bawareca; 11-05-2017 at 07:44 PM.

  18. #58
    Senior Member fatbillybob's Avatar
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    Quote Originally Posted by bawareca View Post
    The inside bracket of the front control arm broke,
    You got lucky! I do all kinds of things to make sure stuff does not break. The 1st thing is stick to OEM unless proven otherwise. That bracket needs some real thought. If you reweld it will pull out again. It needs more engineering like reinforce the area welded to and then weld the bracket to that.
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  19. #59
    BMW Master bawareca's Avatar
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    Quote Originally Posted by fatbillybob View Post
    You got lucky! I do all kinds of things to make sure stuff does not break. The 1st thing is stick to OEM unless proven otherwise. That bracket needs some real thought. If you reweld it will pull out again. It needs more engineering like reinforce the area welded to and then weld the bracket to that.
    Agree on all points. I do prefer OEM, but there are no good OEM solutions for this. My old setup was OEM based, but no adjustment.

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