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E-steering, wilwood pedals, cooling, and it looks closer to done!

maikell77

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All along with this project there were a few things I knew would be the big issues to get over.

1.       Engine and transmission install – it fits and it’s mounted

2.       Adapting the new transmission to the BMW dif, this is next….

3.       Building a new pedal assembly – done over break

4.       Fixing the rust and bodywork – done over break

5.       Rewiring the whole call – TBD

6.       Making the rack and pinion steering work – finally finished over break

As you can see the list is getting shorter.  The bodywork turned out much worse than I had hoped.  I did not spend as much time blocking the car as I should have.  At some point I may go back and redo the bodywork and paint to have a nicer looking car.  At this point it’s ok from a distance, and for its intended purpose its fine.  This car was rotten and not worth saving.  As bad as my bodywork is, it’s still miles better than what I found.  All that to say, here it is, on all four wheels in the sun!

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Next up was the pedal assembly.  I worked with Wilwood to size the master cylinders to work with the 240 front calipers and the 320i rear drums.  I will also be running a Wilwood master cylinder for the clutch.  The other interesting part I had to add was the electronic throttle pedal to work with the LE5.  The pedal is typically firewall mounted and top hinged.  I flipped it and mounted it to a subframe with the other two pedals.  I have them all hinged at the same point and in the same plane.  I may need to tweak the throttle to prevent miss-steps.

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The steering was the next big challenge.  The size of the engine dictated the change to a 320 rack.  Further complicating matters was my choice to run the electronic power steering column.  This arrangement required 3 U-joints!  After getting everything installed with a bearing on the long shaft it seems to work well.  I have however, discovered that the power assist is not needed.  This means I may got to a manual column or shift the steering attachment points to tighten the turning radius.  I fear as is it will be larger than a suburban.

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Finally, I built up a bracket to support my hand me down electric fan from my new radiator.  The whole assembly is removed as one.  It should help with serviceability down the road.

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The goal is to be road worthy this August.  I am hoping to drive the 5 miles each way to make a portion of the Woodward Dream Cruise this year.

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4 Comments


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This looks awesome -- I went with a 320 rack and pinion paired with an underhung Wilwood setup. What size master cylinders did you go with?

 

NGT

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3/4" front and 7/8" rear is what Wilwood recommended and I purchased.  They seemed to be confident that that would be close to balanced as is. 

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How has fitting the EcoTec?  What modifications did you need to make it fit?  

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The ecotec fit well....The matching transmission was not so easy.  it is much much larger than stock BMW trans.

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