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75 2002 Sleeper - M20B32, ITB, LSD


tinkwithanr

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Nope. At least I'm not sure yet. I have a couple of paint schemes I choosing between. But once I get the main car done I'll paint the HW car to match, whatever that ends up being.

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

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Had a busy Black Friday. Here's a small teaser of the payload.

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Ti Lug Studs and Nuts. Cause nobody likes rusty nuts.

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

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Share on other sites

Here's the rest of what I picked up over the weekend.

New assortment of sockets. I've been using my old craftsman "121" piece set for the past 4 years, and finally decided it was time to upgrade. The main difference is a greater range of socket sizes for each drive size, as well as a whole lot more deep well sockets. The old set only had 1/4 and 3/8 drive DW, and only 10 total. This set has pretty much everything from 4-22mm in DW, 12 and 6 point. It also came with standard and metric ratcheting wrenches. Half off as well!

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Next up I got the inserts for the front suspension. Koni 8611-1259 double adjustable's. I'm still working on getting the compression adjustment mods figured out on the strut itself, but it should do the job nicely. It also leaves plenty of room in the strut housing to shorten it.

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Then I sorted out the rear suspension. I decided to go with QA1 Double Adjustable shocks with Eibach Springs. These have urethane bushings in each end, but if that ends up deflecting to much I can change them out for spherical bits easily.

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They are also very easy to adjust, just reach under the car and turn the knobs.

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Then I got all my AN fittings and hose for the fuel system and oil system, as well as the necessary wrenches to put them together. I still need to get the hard lines for the long runs under the car, but I should be able to get the engine bay lines run.

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More fuel system goodies including a billet fuel rail, fuel filter and adjustable regulator:

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Last but not least the new set of wheels came in. I already split them before I remembered to grab a couple of pictures, but they are Epsilon Meshes. Once I rebuild them to the right specs they should be 16x8 front and 16x9 rear with gold centers and polished lips. Kinda like a poor mans BBS E50.

Centers:

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Lips:

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For those that haven't seen them in good condition this is what they will look like when done:

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Happy Holidays!

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

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Share on other sites

  • 2 weeks later...

Wrote up a nice update and it deleted itself right before I posted it, so I'm just gonna throw a bunch of pictures up and maybe explain it later lol.

New storage for the socket sets. I laid them out how I wanted and drew it up in CAD. Then used that to engrave some signs and underlaid that with plywood:

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Fits in the drawers of my craftsman box:

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Then I worked on the front struts. Removed the spring perches and cut them in half. Then I turned down what was left of the perches on the lathe and trued up the cut edge. Could use the lathe on the bottom half of the strut housings because the spindle didn't clear the ways, so I trued those ends by hand. Then I made an aluminum spacer that will keep the halves in line when I go to reweld them. With the welding done the spacer will then be cut down and used to space up the Koni inserts from the bottom of the strut tube (they are shorter than the housings, so they need to be spaced up for the gland nuts to have something to hold on to).

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Happy Holidays!

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

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Share on other sites

Thanks Tom!

Got a lot of prototyping done today. First up was to get the strut tubes bead blasted and welded back together:

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Here you can see how much shorter they will be compared to a set of stock '02 struts. It turned out to be ~1.75":

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Hmmm, what could these be for...

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With the housing welded back together I cut a 1" hold in the bottom of them:

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Then I went over to the other side of the building to use the large horizontal band saw. First I cut the welding spacer into two pieces 3.15" long (with some left over):

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Then I also cut out some 4"x4" billet alum 1.25" long, which will be used for the roll center spacers that go on the bottom of the strut housing:

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Everything all cut out and ready to go:

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Here's the two strut tube spacers along with the CAD dwg I made up. Took some notes and got one spacer turned out.

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Finished Piece:

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Then I took some 1/2" stainless bar stock and made this guy:

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He fits into the receiver on the bottom of the strut insert for adjusting the compression damping like so:

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All the parts for the strut insert spacer laid out:

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And assembled outside the strut tube:

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And how it looks with everything installed in the strut housing:

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This is how the roll center spacer will hold the second gear. Because the steering arms and outer ball joints for the front suspension mount directly underneath the strut housing, access to the compression damping adjustment screw is blocked. The gear assembly will let it be adjusted from the side of the roll center spacer, full external adjustment.

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Moving on, I used the fly mill to square up the 4" chunks of aluminum to ensure the top and bottom are parallel and even to each other:

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Then I machined a bunch of holes in it.

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Parts for the roll center spacer laid out:

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Assembled:

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Then I added one M3x0.5 set screw for each of the bearings in the assembly:

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And this is everything in place:

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And how it will be covered with the steering arm installed:

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Overall I'm very happy with how the assembly turned out. The weak link right now is definitely the plastic gears. I started with them mostly because of cost, they were $3 each while the equivalent steel gear is $20 per. I wanted to make sure the theory and practicality of the setup would work before spending the extra $80 on gears. Keeping that in mind I designed it around a gear size (d.p. and basic dimensions) that is available in both plastic and steel. The other reason why I wanted to try out the plastic gears first was corrosion resistance. Even though the assembly will be pretty much sealed from the elements, I'm sure water and grit will find it's way in there somehow. The mild steel gears may start to rust, so I'll need to pack the assembly with grease before putting the steering arm on to help prevent the gears from rusting together. All that's left is the drill the mounting holes for the roll center spacer to the housing, and the steering arms to the roll center spacer. Then I just have to rinse and repeat for the other side.

Thanks for looking!

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

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Maybe. It depends on how the wheels and tires fit under the flares to begin with. I don't want to run a crazy amount of camber, and the camber plates should give me what I'm looking for. At the same time the extra track width would give me more clearance for the pedal assembly on the driver side.

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

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Share on other sites

  • 4 weeks later...
  • 2 months later...

Hey guys, it's been a while. I wish I had a lot of great progress to show from the past few months, but truth be told I haven't really touched the car since December. Without getting into to much detail, I had some pretty big changes to my life that made me reconsider a lot of things, including whether or not I wanted to continue with this project. The good news is that I'm doing much better now, and have decided that I want to continue working on her.

I've also spent the last couple of weeks rethinking some aspects of the project, and let's just say things are just getting started. I've decided to change or modify a number of aspects of the car, including bodywork and engine. There is one thing in particular that I'm very excited about the possibilities of. I'm not going to go into any details right now because it's still very early in the design process, but when it's all said and done it should be pretty monumental for not just my personal car but the entire BMW community.

And I promise I'll try and have some progress to report in the next week or so!

Tinker Engineering - 2014

 

Mica - 2000 BMW 323i - The one that started it all

Fiona - 1975 BMW 2002 - The Definition of Project Creep

Heidi - 1988 BMW M5 - The piece of BMW history

Silvia - 2013 Subaru WRX - Stock, for now

Link to comment
Share on other sites

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