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Date: 8-3-06 01:35
From: m20ohtwo in Mountain View, Calif.  
Subject: M20 six-banger saga  
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Now that I've gotten to a significant point in ths project I thought I'd share for the first time and maybe get feedback.
Some of you may remember this- I posted it over a year ago. My first attempt at drifting and the nearly stock '02 did well. It did take me the better part of a day to get it down though. At the time all I had was cut springs, some old bilstein shocks and a junkyard 3.91 LSD.
The engine blew a few weeks later so it had to come out.
My son enjoyed that part.
And a new one was dropped in - at least for a test fit.
I found a 2.7 eta engine on craigslist for $150, an "I" head at the junkyard for $100 and the proper "super eta" pistons to fit it all together for $175 on an E30 forum. A local machine shop did some honing and all new rings, bearings and rod bolts were used. I lightened the flywheel substantially to 17 lbs.
The lower cover that holds the front crankshaft seal had its belt cover portion milled off.
Here's another picture of an earlier test fit. I've made my own motor mounts and gotten it mounted and lined up well. I took measurements for the drive shaft shortening before I took the whole mess out to rebuild the engine. I'm using the 323i transmission to make things a bit simpler. I may put the 325i tranny in if it breaks. Hammering on the tranny tunnel was a breeze. Making the transmission mount from scratch was a little more difficult.
I will post more update photos later of the mounts and how it fits. Until then, here are some photos of the car when I bought it and then what it looked like after I got my hands on it.
mmmm my perfect dash.
At the Golden Gate fields drift event in early 2005.
This area was previously rusted through like swiss cheese (just below the window between the door handle and the mirror.) I welded it all up, sprayed it with $15.00 worth of touch up paint and now you can't even tell.
Someone resprayed the car without removing the trim while living near the ocean. A recipe for surface rust. The rest of the paint is nice and the body is real straight. There is no structural rust. The rust issues are also being addressed during the engine swap.
Here it is in front of my other pride and joy, my autocross winning 1975 VW rabbit. It runs Megasquirt EFI, which I also plan to run on my bimmer.
I also have two sets of suzuki gsxr throttle bodies and a hacked off 325i intake manifold. It would end up pretty much like this:
Either that or a nice turbo - or both! We'll see what happens! _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
Last edited by m20ohtwo on 4-20-07 08:05; edited 5 times in total
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Date: 8-3-06 02:55
From: TMK-001 in Geelong, Victoria, Australia
Subject: Re: Daniel's pastel blau six-banger saga
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Daniel... bad as F***!! I love the first shot!
Great to see your son out giving you a hand at such an early age... that is when I got hooked!
I love your Golf too... I noticed you did a bit of wheel swapping.
I bet it will go awesome with the ITB set up of the GSXR!
Good luck, keep us informed.
Todd _________________ 
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Date: 8-3-06 03:08
From: oz_tom in Melbourne - Australia
Subject: Re: Daniel's pastel blau six-banger saga
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I'll be gawking at those ITB's for a while! :-o
Nice work _________________ 
72tii - Whitey
74 - Blacky
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Date: 8-3-06 05:49
From: Harv in Willoughby Oh.
Subject: Re: Daniel's pastel blau six-banger saga
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Looks great!
I love that Rabbit!!!!!
John _________________ "Chicken make no good house pet!"
"Less brake, more accelerator"
#1665778
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Date: 8-4-06 12:06
From: m20ohtwo in Mountain View, Calif.
Subject: Re: Daniel's pastel blau six-banger saga
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The rabbit gti wheels fit well. They are offset inward more so I had to make 1/8 spacersI think- maybe it was 3/16 inch. Cant remember. They come very close to rubbing on the front strut. The wheels came from the '83 VW gti I drove everyday before I got my '02. It was a very nice example but was totalled in a rear end collision, which indirectly started my love affair with this car. In a pinch to find a new daily driver I found this thing for $800. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 8-6-06 10:35
From: m20ohtwo in Mountain View, Calif.
Subject: an update
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A load leveler is a must for the M20.
Here's the engine mounted rock solid and centered with homemade mounts.
The driver side mount. The mounts are only 1/8 inch thick, but with the additional bracket welded on top of this one its plenty strong.
The passenger side mount. I just followed the instructions fron the write up "six into two does go" and crossed my fingers. It worked well with some slotting of the two holes on the subframe for the rubber mount.
I just thought this picture was funny because the four cylinger looks so massive.
I repainted this inner fenderwell over the weekend with a can of color matched spray paint.
I also cut off the two upper frame rails that square headlight cars have to make room for my radiator and possibly an intercooler. I'll post pics later. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 8-6-06 11:10
From: m20ohtwo in Mountain View, Calif.
Subject: Re: an update
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Hey, another San Jose resident. Yeah that Nova was my first hot rod project. I built a nice 383 stroker engine, converted to a 4 speed and rebuilt the rear with an LSD. At this point my father owns it. Someday I will buy it back. It would make a real nice drift car. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 9-19-06 09:38
From: M20oh2
Subject: Re: an update
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So the project has been coming along slow and steady now for a while. My diveway was a sandbox for a few days as a sandblasted rust off the body and engine compartment. I used a can of color matched spray paint to touch things up temporarily until I'm in a position someday to strip the whole car for a repaint. The rest of the little spots of rust I used a rust converter on called MarHyde, which turned the spots a nice translucent purple. Not perfect, but looks a hell of a lot better than rust.
The engine is about to go in now. All thats stopping me is that I need a starter to bolt on this beast.
Since my last post I've:
Cut off the extra bumper frame rail in the front and welded in patches, painted the engine compartment, lots of places around the car and under the hood, filled in the front side markeers, shortened the original 2002 shifter to fit the longer 323 trans, resurfaced and lightened my 325e flywheel, bought a reground 323 cam and started lapping the valves and replacing the valve seals. Soon the head will be on and this engine will be in the car before I know it. Once it is, this project will move alot faster I'm hoping.
I still need to shorten my driveshaft, buy a radioator and fan, build an exhaust, get a second front exhaust manifold, buy and build a megasquirt ecu, buy and install a high pressure fuel pump, and finish my ITB manifold.
Wish me luck.
-Daniel
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Date: 9-19-06 09:40
From: M20oh2
Subject: Re: an update
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So the project has been coming along slow and steady now for a while. My diveway was a sandbox for a few days as a sandblasted rust off the body and engine compartment. I used a can of color matched spray paint to touch things up temporarily until I'm in a position someday to strip the whole car for a repaint. The rest of the little spots of rust I used a rust converter on called MarHyde, which turned the spots a nice translucent purple. Not perfect, but looks a hell of a lot better than rust.
The engine is about to go in now. All thats stopping me is that I need a starter to bolt on this beast.
Since my last post I've:
Cut off the extra bumper frame rail in the front and welded in patches, painted the engine compartment, lots of places around the car and under the hood, filled in the front side markeers, shortened the original 2002 shifter to fit the longer 323 trans, resurfaced and lightened my 325e flywheel, bought a reground 323 cam and started lapping the valves and replacing the valve seals. Soon the head will be on and this engine will be in the car before I know it. Once it is, this project will move alot faster I'm hoping.
I still need to shorten my driveshaft, buy a radioator and fan, build an exhaust, get a second front exhaust manifold, buy and build a megasquirt ecu, buy and install a high pressure fuel pump, and finish my ITB manifold.
Wish me luck.
-Daniel
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Date: 10-14-06 11:38
From: m20ohtwo in Mountain View, Calif.
Subject: Re: an update
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Date: 11-28-06 04:28
From: -=Charley in SoCal
Subject: Re: Daniel's pastel blau six-banger saga
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holy F! thats gonna be badass! get some fender flares ;) _________________ King of Avatar
M20-02 blog
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Date: 1-4-07 03:23
From: m20ohtwo in Mountain View, Calif.
Subject: Re: Daniel's pastel blau six-banger saga
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I just finished shortening the driveshaft myself. It was quite a bit easier than I thought it would be. The "sticking point" was trying to press the tube back onto the driveshaft end after it was shortened 3.5 inches- it required some sanding and polishing to get it to fit and then a torch to expand the tube. After I used a dial indicator to make sure it was straight I welded it back up with my mig welder.
I will post a picture later to show where it was shortened - at the back end of the front section just in front of the rubber center support bearing- if that makes any sense. _________________ -Daniel
M20 swap blog: http://www.bmw2002faq.com/component/option,com_forum/Itemid,57/page,viewtopic/t,277525/
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Date: 1-22-07 11:32
From: robspeed in alabama,,,, waaa!!! :P
Subject: Re: Daniel's pastel blau six-banger saga
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| m20ohtwo wrote: | I just finished shortening the driveshaft myself. It was quite a bit easier than I thought it would be. The "sticking point" was trying to press the tube back onto the driveshaft end after it was shortened 3.5 inches- it required some sanding and polishing to get it to fit and then a torch to expand the tube. After I used a dial indicator to make sure it was straight I welded it back up with my mig welder.
I will post a picture later to show where it was shortened - at the back end of the front section just in front of the rubber center support bearing- if that makes any sense. |
HEHE Hey it was nice to stumble across you at the MVV! Your 02 project is looking awesome although i have REAL doubts about those 1/8" motormounts!! I say that having broken the 1/4" thick stock mounts.. (yes, the metal part on the motor-side.. ;) anyways fantastic work, and i got a huge kick out of seeing yer rabbit! ;) _________________ - Rob S.
Check out Jenna's NEW site: www.jennaishealed.org (*FINISHED* consolidating all the various "blogs" into one)
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Date: 1-23-07 11:17
From: robspeed in alabama,,,, waaa!!! :P
Subject: Re: Daniel's pastel blau six-banger saga
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| m20ohtwo wrote: | | Hey Rob, thanks for stopping by this thread and the MVV. We'll have to have a San Jose 2002 get-to-gether soon! We can put my motormounts to the test. muahahah. |
hehhe i bet if you try real hard, ... ;) _________________ - Rob S.
Check out Jenna's NEW site: www.jennaishealed.org (*FINISHED* consolidating all the various "blogs" into one)
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Date: 2-19-07 11:14
From: Hef
Subject: Re: 1975 Rabbit
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I like your Rabbit, what are some good forums?
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Date: 2-19-07 04:21
From: Hef
Subject: Re: 1975 Rabbit
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Thx
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Date: 2-21-07 05:28
From: Hef
Subject: Re: 1975 Rabbit
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Can u post pics of ur rabbit i love it so much
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Date: 3-3-07 12:39
From: m20ohtwo in Mountain View, Calif.
Subject: Re: 1975 Rabbit
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