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Date: 5-26-08 03:10
From: oz_tom in Melbourne - Australia 
Subject: Tom's Stealthy Schwarz Build  
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Tom's Stealthy Schwarz Build
As many of you know, I recently restored my ’74 2002 on a tight budget to a nice daily driver standard. See Here . I was happy with the car after the resto and simply wanted to improve it slowly over the next few years and eventually turbocharge it. Unfortunatly, about 7 months after the car was on the road, a nice lady decided to re-arrange my rear bumper and tail panel, subsequently writing off the car (totalled) – This was largly thanks to BMW Australia’s pricing policy for parts. I was pretty shattered after this occured, but luckily im insured well and I walked away with nothing more than mild whiplash (and some annoying headaches).
Insurance has finally paid out for a total loss and this blog is now going to document the damage repair and future mods to the car including turbo and conversion to Megasquirt EFI using EDIS among other things. The aim is to keep the car looking fairly stock and for it to be a bit of a ‘sleeper’ – no bodykit or spoilers, just plain simple ‘02 goodness. The only modifications visable from the outside will be a drop in ride height and the use of 15” Alpinas.
Now for the pics… because everyone likes pics. Originally I got the car on the road using e21 turbines because they were the only wheels that had roadworthy tires on them. I changed to 14” Superlites briefly before finding some 15x7” all round Alpinas. All of these wheels don’t really have the right offset for the 02 and even with no fender lip, im still getting some rubbing. Needless to say, bodywork ahead - The car will fit around the Alpinas. Worse case scenario ill move to 16” Alpinas (hey, its not really that bad of a scenario!)
Ive got parts on the way from cj and Ireland Eng. so updates will come soon. Looking forward to this build!
Tom _________________ 
72tii - Whitey
74 - Blacky
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Date: 5-27-08 05:52
From: oz_tom in Melbourne - Australia
Subject: Re: Tom's Stealthy Schwarz Build
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| H_Krix wrote: | | man, I can't believe that damage totaled it! I take it you're replacing the whole rear tail section? |
Neither can I - no creases over the wheels either! Ill see how the tail panel is when i take off the bumper. Ill probably just use a block of wood, a hammer and my spare red (i know LOL!) short rear bumper to get the car registered and RW again THEN take it to my body guy to fix it properly (whether thats a new tail panel or not, i dont know yet)
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 5-27-08 09:42
From: oz_tom in Melbourne - Australia
Subject: Re: Tom's Stealthy Schwarz Build
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| devilspace wrote: | | Then comes the 400psi turbo? :) |
Then comes supporting mods (fueling, oiling, suspension, brakes)... then 400psi turbo!... wow thats alot of boost! :-P _________________
72tii - Whitey
74 - Blacky
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Date: 5-29-08 07:03
From: oz_tom in Melbourne - Australia
Subject: Re: Tom's Stealthy Schwarz Build
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| bingbong wrote: | | I'd like to see any car running 400psi, let alone an 02! |
lol me too. Bing Bong, pics of your car on the road need to be posted in your blog stat! _________________
72tii - Whitey
74 - Blacky
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Date: 5-29-08 09:15
From: oz_tom in Melbourne - Australia
Subject: Update May 30th, 2008 - Parts Arrived
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Todd (TMK001) and i orderd some parts from IE and they arrived today. Heres my lot:
Polished aluminium radiator (do not try and send this international - its expensive!)
22/22 Sway bars & bushings
Front end bushings
Urethane motor mounts
Crank windage tray
Oil pan baffle
 _________________
72tii - Whitey
74 - Blacky
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Date: 5-30-08 06:18
From: bingbong in Sydney - Australia 
Subject: Re: Tom's Stealthy Schwarz Build
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| oz_tom wrote: | | bingbong wrote: | | I'd like to see any car running 400psi, let alone an 02! |
lol me too. Bing Bong, pics of your car on the road need to be posted in your blog stat! |
yes these are needed but there are none good enough, maybe I will get some this weekend. That sump baffle looks more like a crank scraper, when i get the pics of my CUSTOM sump baffle, they shall be posted. _________________ I dont understand the german gauges!
'75/74 2002 Golf Yellow running!
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Date: 5-30-08 06:36
From: oz_tom in Melbourne - Australia
Subject: Re: Tom's Stealthy Schwarz Build
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| bingbong wrote: | | oz_tom wrote: | | bingbong wrote: | | I'd like to see any car running 400psi, let alone an 02! |
lol me too. Bing Bong, pics of your car on the road need to be posted in your blog stat! |
yes these are needed but there are none good enough, maybe I will get some this weekend. That sump baffle looks more like a crank scraper, when i get the pics of my CUSTOM sump baffle, they shall be posted. |
That is a crank scraper... the baffle is to the right of the scraper :-P
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 6-9-08 08:21
From: oz_tom in Melbourne - Australia
Subject: June 10 Update
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Not a huge update - parts have been trickling in.
Picked up an early 320i manifold from the local pick and pull which will be adapted to take regular injectors. Not sure what way to go yet with the fuel rail or throttle body, but after reading through old posts im thinking m20 e34 525i Auto with TPS for MS and just making up my own fuel rail. Any other ideas for a 60ish mm throttle body?
Thanks to Kris - shortend shifter platform for 5 speed, shortend shift linkage and an Ireland Eng. short shifter. Once i have Jakes 5 speed bracket im pretty much there for the 5 speed install.
I also picked up an e30 323i fuel pump and sender. Its the lower pressure pump so im going to simply use it as a lifter pump to feed a surge tank. Will need to extend the pickup too.
Finally, the e21 5 speed i picked up a while back. Also got the tailshaft with it.
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 6-10-08 05:47
From: oz_tom in Melbourne - Australia
Subject: Re: June 10 Update
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| H_Krix wrote: | 60mm is a huge TB. are you going to be running the turbo with this as well? If you go NA with a 60mm, its going to be more like an on/off switch than a progressive throttle...
Look into a TB from a late model mustang. If I recall, they're around 58 or 60mm. |
Yep - turbo with this throttle body. Mustangs arent too common down here but i there are plenty of Ford sedans around. I might take a look at them.
Cheers,
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 6-11-08 12:53
From: oz_tom in Melbourne - Australia
Subject: Re: June 10 Update
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| bingbong wrote: | | ha again, trying to find one of those down here in australia, GOOD LUCK! Tom you might be able to find one on a holden or ford motor, Bolt pattern would be wrong but I'm sure it would be up there for size. |
Yeh, Im thinking any falco-dore would have something decently sized. Ill need to make up an adaptor to fit it but i saw that coming anyway. Plenty of VL's being parted so ill hopefully be able to pick up one for cheap.
| sam_z wrote: | Haha the only time we see crown vics are police chases in films..
Hey Tom which pick n pull did you get the 320i manifold from? |
Hey Sam,
I got it from Pick Pay n Go in Ringwood. See here: http://www.hotfrog.com.au/Companies/Pick-Pay-N-Go
Its not a bad little yard - a nice bit closer than Pick a Part. _________________
72tii - Whitey
74 - Blacky
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Date: 6-28-08 05:28
From: oz_tom in Melbourne - Australia
Subject: Update - June 28th
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I removed the rear bar and the damage under wasnt bad at all (see pics). I really see no need for a new tail panel and neither did my body guy. The panel is now being knocked back into shape and the rear resprayed - I should get it back early'ish next week.
Beer, is there anything it cant do? Needed an extra set of hands so the bar ddint fall off.
Parts hunting continues as well...
Turbosmart Plumback BOV - Going for "stealthy sleeper" so no Psscht noise.
SS Turbo manifold from Ottis - going to give it a little once over.
...and my favourite, brand new Garrett GT2860RS dual ball bearing turbo.
Compressor Housing A/R -: 0.60a/r
Turbine Housing A/R - : 0.64a/r
Turbine Wheel Trim - : 76
This should spool up nice and early and is matched well to the M10 from what im told.
Stay tuned!
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 6-28-08 10:12
From: Colin in San Francisco
Subject: Re: Update - June 28th
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Looking good. I'm watching your build with great interest.
My understanding is that turbo can be watercooled. Are you going to be routing some plumbing to it for that purpose?? _________________ www.sfrecording.com
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Date: 6-28-08 04:47
From: oz_tom in Melbourne - Australia
Subject: Re: Update - June 28th
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| Colin wrote: | Looking good. I'm watching your build with great interest.
My understanding is that turbo can be watercooled. Are you going to be routing some plumbing to it for that purpose?? |
That is the plan at this stage. I havnt looked into it much yet though so i cant give you anymore details right now. This project is 95% research haha!
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 7-1-08 12:08
From: oz_tom in Melbourne - Australia
Subject: Damage all fixed - July 1st, 2008
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Car is now back from the body guy and wow, it looks like it never happend. Just need to get the bar on now and grab some new license plate illuminator lights. The bar is the same mangled one that was hit and it now looks brand new - judge for yourself! When i originally got it, there were 2 small dings on the end pieces as well and now they are gone too so its practically a new bar. Much cheaper than BMW prices at $2500
The over riders were pretty crap so the platers did the best they could with them. They'll do for now until i lose the plot and buy new ones at 120 odd dollars each.
Tail trim piece was fairly f'd so Todd hooked my up with a nice new (to me) one along with some brake boosters and crack free dash. Dash will be for another project car.
On a side note, my PWR intercooler arrived- looks beaut. Its an "Aero 2" off the shelf cooler so to speak. Part number PWI5428 for those who might be after one. I dont expect this to fit easily, as it is pushing the limits of space in the 02 nose, but thats half the fun. Dimensions are 500 x 210 x 68. They can do outlet/inlet at the bottom of the end tanks too.
That is all.
Tom _________________
72tii - Whitey
74 - Blacky
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Date: 7-1-08 03:28
From: CamB in Auckland, New Zealand
Subject: Re: Damage all fixed - July 1st, 2008
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Looking good! Those bumpers are awesome.
Am very keen to see how you deal with a couple of potential issues (coz it will help me):
1) fan (engine fan? or electric?)
2) fitting the intercooler into the nose. Will you try and fit an oil cooler there too?
3) adapting Otis' manifold to T25 flange. I am looking at getting a slightly wedge shaped and port matched t25 flange with studs and welding it onto my (Otis) manifold. I can't use a regular T25-T3 adaptor since it will cause the turbo to hit the guard (more correctly the wastegate actuator).
I see this guy in Aussie has something which would probably work (getting the wedge shape isn't critical I dont think):
Ebay link
What's the plan for ignition? _________________ 2002tii race car
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Date: 7-1-08 04:22
From: oz_tom in Melbourne - Australia
Subject: Re: Damage all fixed - July 1st, 2008
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Gday Cam,
Thanks, im sure ill be bouncing some ideas off you at some stage too.
1) fan (engine fan? or electric?)
Im looking at a SPAL pusher unit which is 2.5" thick. Not bad value at about 80 bucks US last time i checked for a 12" fan.
2) fitting the intercooler into the nose. Will you try and fit an oil cooler there too?
Biggest issue here apart from space, is flow. I may be a bit ambitious but ive been looking into mounting it behind the headlight bucket and then cutting out the section behind it so air can flow through and into the wheel well. Protection of the cooler will also be something ill need to address as well as getting the air to flow through to the oil cooler (directing it through from the grill). If you look up in the wheel well, there is quite a lot of space up there.
With actually fitting the intercooler, im intending on having a removable top plate, somewhat Paul Cain 3002ttiL style. He was the one that gave me his intercooler dimensions and i ran with this to figure out what size could work for me. Because im taking out this piece, i dont want the nose structure to be compromised so i will brace it somewhat like this: Skidmark Racing nose reinforcement - Only difference being im keeping the radiator cross piece and radiator mounted in the stock location
3) adapting Otis' manifold to T25 flange. I am looking at getting a slightly wedge shaped and port matched t25 flange with studs and welding it onto my (Otis) manifold. I can't use a regular T25-T3 adaptor since it will cause the turbo to hit the guard (more correctly the wastegate actuator).
I see this guy in Aussie has something which would probably work (getting the wedge shape isn't critical I dont think):
Ebay link
This is exactly what i was looking at. Im a tad worried about the actuator too but you never know until its mocked up. The more stuff i get, the more i realise im going to have to do everything at once rather than gradually.
What's the plan for ignition?
EDIS4 which is currently on its way in the mail.
On another note Cam, what are you doing regarding diff and rear brakes? Im probably going to go the 323i rear discs and trailing arms unless something great crops up. I need to make a thread on general disc. because im unsure of how this will affect how my wheels will sit and if it will push them out further. Im already having rubbing issues.
The more i think about the diff the more im leaning towards a Quaife torsion based unit. With an LSD approaching $700+ by the time you get them over here, all i have to do is blow one and im up to the cost of a Quaife anyway. Shaun (Beaner7102) was quoted NZ$1695 so its about AU$1600 by the time you get it here then another $400 in parts to make it fit in the 02 casing. Its pricey for sure, but id prefer to do it once and be done with it... decisions.
Tom _________________
72tii - Whitey
74 - Blacky
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