Thought I'd post a quick update. I finished up the wiring, built a relay bank, which is mounted in the trunk where the battery will go, and, finally, finished up the exhaust.
Wiring mess.
Thankfully, one night when it actually rained here, I went through the entire wiring harness, labelled everything, and removed some questionable additions and kill switches added by the previous owner.
This mess has to get through two small holes on the driver's side firewall.
Relay bank I built with Hella waterproof relays. The two right side relays are Derale relays that I am using for the fuel pump and fan. Both are ground triggered by the ECU / ECM. The Derale relays incorporate a blocking diode specifically for ground triggers by the ECM. The diode prevents amperage spikes traveling back to the ECM that can occur during motor dwell. I eventually added inline fuses to all ECM relays.
From Left to right
FAN,
Fuel Pump,
Hi-Beam,
Low-Beam,
12v constant trigger by Position 3 on the ignition switch,
ignition switch 12v input for coils,
ignition switched 12v input for cams, vanos and air valve,
and ignition switched 12v input for injectors.
Mounted in the trunk. My plan was to use a distribution block from a e39 BMW, but mini fuses are surprisingly difficult to find, especially in low amperage.
So, I created positive bus bar and went with the original circuit breaker bank, and added a negative ground block just behind the strut bar. 20 amp for the ECM wiring and 30 amp for the fan and fuel pump. I did add inline fuses with lower amperage for the ECM relays.
Engine wiring mess.
Random shots of me figuring out stuff.
I have cleaned up most of the wiring with friction tape and will soon add some wiring loom tubing to give it a nice look.
Engine bay and ECM in place. I wanted to mount the the computer inside the cabin, but the loom was just too short. Stupid brake fluid reservoir keeps breaking off.
You'll notice I mounted and expansion tank where the washer reservoir goes. It's from a Volvo. I was going to us a Mercedes tank, but the Volvo's was more compact and only has one inlet and outlet. The washer reservoir tucked up and under the cowl is from an e36. I just wired it into the original loom.
another shot.
And a shot of the ECM in its home. Picture's a little blown out. I'll clean up all that wiring this weekend.
On to the rear end.
Order a 4.10 LSD medium case for an e30. It may be too low a ratio, but I can always swap the 3.73 from my e30 if this doesn't play well on the highway.
Cleaned up and rebuilt the differential. New seals and all.
On to the subframe and the sway bar mounts.
Originally, I had tack welded the mounts to have the sway bar go over the top of the trailing arms, but the bar interfered with the driveshaft.
Mounts I fabricated.
Close up of mounts. With camber adjusters welded in place. Yes, I am wearing socks with mandals, cause it's comfy.
Full frontal.
Wide.
The rear suspension is hung. There is a bracket to swap out the rear solid discs for e36 vented, but I'll worry about that later. I rebuilt the calipers before installing
Another angle.
The subframe, differential, trailing arms, sway bar, and half shafts mounted. I rebuilt all the brake lines on the trailing arms as well. You will notice that this picture of the trailing arms has the shock mounted in double shear. It is also gusseted to add strength.
Shot from rear of driver's side suspension arm and shock. The shocks are Koni adjustable dampers with Eibach springs. If the sway bar ends up hanging too low once the car is on the ground, I will affix it to the chassis, like an e30. The trailing arms are sitting much lower than they'll be sitting at ride height.
Another shot.
Finally, the exhaust fully tig welded being protected by my guard dog, Preston. All mandrel bent 304 stainless. Flat section is the subframe underpass. 1.5"x6" and has more volume than the twin 2.5 tube. I built it full flow with no restrictions. Going in the car on Saturday if the weather isn't disgustingly windy.
Tomorrow, I am going to the pull-a-part to get the firewall mounted throttle bell crank and gas pedal out of an e30 (it had better still be there) and get ride of the stupid throttle arm, which keeps slipping. I made one with a clamping collar, like other members have done, but it still slips. Going to fix this problem once and for all.
Headliner and windows will go in next week, and I plan to fire the engine.
That's all for now.
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