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75 2002 Sleeper - M20B32, ITB, LSD


tinkwithanr

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Nice fine, not sure those are S54 though. The throttle position sensor mounts look completely different, as well as the ports for the common vacuum line. Either way it should be fun lol.

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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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Got some more work done on the manifolds. I'm not completely happy with how they turned out, and so I may end up casting another set, but this time as one complete 6 runner manifold as opposed to three dual runner manifolds. This would help to cut down on some of the machining issues I ran into. Also, I need to pick up a proper bit for machining the stud faces. I was able to get them done, but it's not as clean as I want the final product to be. That being said these will let me mock up the rest of the intake system and engine bay for now.

These are how they looked cast:

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In the process of machining:

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The fist test fit onto my spare 885 head:

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And finally some pictures of it bolted up in the engine bay:

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I still need to finish the oil return line. It will probably just consist of welding a little more material and then either machining out the hole stock style or an AN fitting and running a line down to the block. Another thing I noticed is the intake system will most likely take up all the engine bay room above the steering column, which in turn means the stock brake booster definitely won't be going back in place. I'm not 100% sure what I'm going to do for the brake system yet, I like the idea of the stock dual circuit system but it adds a lot of complexity.

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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Now that I'm out of school I've been able to really dive in over the past week. I can't begin to say how nice it is to actually being working on some of the stuff that's been floating around in my head for the past year. It's hard to believe I started really taking her apart last January, it's almost been a year since I last drop her :(. Should be worth it in the end though. But anyway, enough reminiscing, onto the progress.

Never realized how many parts I've accumulated over the past year, there is a lot of crap that goes into a car lol.

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First I got the block bolted up to the engine stand. I also ordered the gaskets and bearings so hopefully I can put that together sometime in the next few weeks. Also, I was going to primer and paint the block in anticipation of assembling it but then decided to wait until next week when the weather would be warmer. The building isn't well insulated so the recent cold temps would have kept the paint from curing. As it sits it's patiently awaiting it's new lease on life:

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I also took the time to order the radiator from Summit Racing. Sadly it hasn't come in yet, so I'm waiting to mock up the rest of the engine bay. However I did start on making my removable front clip, a.k.a. I cut off the front clip. My plan is to gut the inside of the original nose to make room for my larger radiator and other misc. The radiator itself will mount to a new tube structure so that the nose can be taken to give more access to the engine bay. The front tube structure will also tie into a minimal interior roll cage and the rear shock towers.

Looks a lot roomier without the front panel:

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The next thing I tackled was to get my new seat mounts drilled and mount the seats back up. Unlike the original Recaro mounts, these utilize the stock '02 sliders and let the seats sit roughly an inch and a half lower in the car. Sadly I forgot to get pictures of the mounts, but I'll be sure to show them when I take them back out for powder coat. The only issue with the lower seating position is that the steering wheel now felt a lot higher. So I took some 0.75" aluminum plate I had and machined a spacer to go between the steering column and the dash mount. This dropped the steering wheel the perfect amount. Here's the mount intstalled:

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With the new seat mounts and steering wheel position figured out I put the e46 e-brake handle in place. To do this I cut off the original mounts for the '02 handle, and then welded in a flat plate with the correct mounting studs. The e46 handle just bolts down in place, with the stock brake cables running up from the stock location.

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About 2.5" of clearance between the handle and the shift assembly. Plenty of room...

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With the rest of the interior pretty much figured out I wanted to start working on the custom dashboard. I've always liked the look of the stock '02 dashboard, but also missed the 'driver-centric' aspect that the 3 series dashboard have. I also really like how the 'hood' of the dashboard on the original M1 extends over the center of the dashboard. So taking all that into consideration I began cutting into a perfectly good, if not a little cracked dashboard.

Another original dash I have for comparison's sake:

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The original M1 for inspiration:

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What followed was a mixture of cutting, cursing, mdf dust, old german plastic and foam dust, and some screws. I also cannibalized a 'hood' from a 3-piece dash I got on ebay a while back. And while there is still a very long ways to go I'm pretty happy with the progress. The finished product will be finished with some bondo to smooth the seams, and if necessary some fiberglass. In the end I really want it to look like it could have come from the factory like that, just with more room for gauges and other cool things like that.

View from the Drivers Seat:

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View from the Passenger Side:

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The MDF back structure, this will be covered with bondo/fiberglass to smooth it out into the stock dash:

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Smoothing the stock dash lines into the new center console plate:

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This really shows how the console will be angled towards the driver:

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That's all for now, hope to get back into it later next week or after the 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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I like the way you did the trans tunnel, I'm in the process of fitting up a g260 in mine also. I am adding a port for the slave cylinder bleeding and one up top for the fill port also. I'm interested in how close the go pedal is to the tunnel now on yours. I plan on doing the wilwood reverse mount and shifting the clutch and brake over a hair then adding a cable type gas pedal that hinges off the brake/clutch mounting bracket.

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I like the way you did the trans tunnel, I'm in the process of fitting up a g260 in mine also. I am adding a port for the slave cylinder bleeding and one up top for the fill port also. I'm interested in how close the go pedal is to the tunnel now on yours. I plan on doing the wilwood reverse mount and shifting the clutch and brake over a hair then adding a cable type gas pedal that hinges off the brake/clutch mounting bracket.

Don't you have an M10? How are you bolting the G260 up to it? I've never tried, but from reading around I thought the bellhousing/block bolt patterns were different.

Nice to see you're getting something done! I'm very jealous of the shop space, I spent like 3 hours last night cleaning up my garage around the car just so I could work on it again. I've been painting in the cold, mostly using epoxy spray paints which dry fairly quick. To help, I pre-heat the metal with a heat gun and then leave a space heater running next to them. So far that's worked even when I could see my breath inside the garage.

We'll see who gets to the nose first! I'm still a solid 2 weeks out on my agave before I can think about starting on the turb02 again. We did get Aaron's M20 swap running, with all the little things still to fabricate it should be on the road early January.

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Don't you have an M10? How are you bolting the G260 up to it? I've never tried, but from reading around I thought the bellhousing/block bolt patterns were different.

Nice to see you're getting something done! I'm very jealous of the shop space, I spent like 3 hours last night cleaning up my garage around the car just so I could work on it again. I've been painting in the cold, mostly using epoxy spray paints which dry fairly quick. To help, I pre-heat the metal with a heat gun and then leave a space heater running next to them. So far that's worked even when I could see my breath inside the garage.

We'll see who gets to the nose first! I'm still a solid 2 weeks out on my agave before I can think about starting on the turb02 again. We did get Aaron's M20 swap running, with all the little things still to fabricate it should be on the road early January.

yes I'm running the M10, I believe there were 2 different bell housings on the g260 one for the m10/m20 and one for the m30? the one I got bolts up perfectly to the m10

My shop is actually smaller than yours it looks like haha, and it is extremely cluttered right now aswell. I've got engines and complete rear subframes/driveshafts that I have to walk around.

I am not going to be laying down anymore epoxy for awhile, getting all the fab work done and spraying a coat of self etch on there to protect it until I get the whole thing soda blasted inside and out probably in the spring. Then give the entire car a coat when it is warm out.

I just started on the floor board and luckily only have a few places to patch and it is going smoothly, using 16ga, on the thick side but it is also going to have the trans cross member brackets welded to it.

where did you get that shifter from? I might have missed it. I was just planing on using the stock shifter I got from a member here (the aluminum rod one not the stamped steel) and running some small u-bolts through the built up shifter tower (like yours) to hold it in place (left to right movement) I like your e-brake upgrade, I'm still stuck on what to do with mine considering the wilwood calipers I'm going to run don't have a mechanical e-brake. Might attempt a hydraulic solution or mechanical spot calipers.

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yes I'm running the M10, I believe there were 2 different bell housings on the g260 one for the m10/m20 and one for the m30? the one I got bolts up perfectly to the m10

My shop is actually smaller than yours it looks like haha, and it is extremely cluttered right now aswell. I've got engines and complete rear subframes/driveshafts that I have to walk around.

I am not going to be laying down anymore epoxy for awhile, getting all the fab work done and spraying a coat of self etch on there to protect it until I get the whole thing soda blasted inside and out probably in the spring. Then give the entire car a coat when it is warm out.

I just started on the floor board and luckily only have a few places to patch and it is going smoothly, using 16ga, on the thick side but it is also going to have the trans cross member brackets welded to it.

where did you get that shifter from? I might have missed it. I was just planing on using the stock shifter I got from a member here (the aluminum rod one not the stamped steel) and running some small u-bolts through the built up shifter tower (like yours) to hold it in place (left to right movement) I like your e-brake upgrade, I'm still stuck on what to do with mine considering the wilwood calipers I'm going to run don't have a mechanical e-brake. Might attempt a hydraulic solution or mechanical spot calipers.

The shifter is from AKG Motorsports. The only downside would be that you have to use fairly stiff motor and trans mounts so the shifter doesn't move in relation to the transmission. Aside from that I really love how high it moves the shift knob and how short the throws are.

Any particular reason your using those wilwood calipers? It seems that it would be cheaper to just get a proper caliper with the mechanical linkage instead of adding another caliper just for the ebrake. I'm sure you've thought of it more than me lol.

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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I have some pretty stiff motor mounts :) if you havn't seen them in my build thread.

only reason I"m going with the wilwoods is uniform system. I can build the system using proper sized master cylinders and caliper piston area. Busting out the fluid mechanics book since I am running booster-less. plus the narrow calipers (opposed to wider cast Oe calipers) will give me more wheel to caliper clearance. and since I have to make brackets anyways the cosmetic advantage doesn't hurt either.

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yes I'm running the M10, I believe there were 2 different bell housings on the g260 one for the m10/m20 and one for the m30? the one I got bolts up perfectly to the m10

I like your e-brake upgrade, I'm still stuck on what to do with mine considering the wilwood calipers I'm going to run don't have a mechanical e-brake. Might attempt a hydraulic solution or mechanical spot calipers.

Could you email me the part numbers on it? The M10 and M20 definitely have different bellhousing patterns, I just checked a spare M10 tranny against one of my M20s and they're no where near close to lining up. I hadn't thought about the M30, but considering the engine similarities I guess I could see that. 3pc w/removable bellhousing or 2pc? All E30 M20s had were fixed bellhousing G260s, E21 M20s I believe have a removable bellhousing but those trannies are smaller than the later M20 G260 and likely not as strong. I know some M30s had removable bellhousing G265s while some had fixed bellhousing G260 and G265s. I picked up a 3pc G265 for my volvo, but it was sans bellhousing so I can't check it.

I'd love to fit one behind my turbo M10. I would like to build that motor up more in the future, likely beyond the capacity of the E30 318i 5spd.

Edit, or just post it here. I don't want to fill up someone else's project blog, but if said person is interested, why not?

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I kinda wanted to say that the m10 and m20 bell housings were different, but without them in front of me I couldn't be sure. Definitely interested to see what trans that is.

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

post your email over in my build thread "73 sahara take it or leave it build" I will shoot you the part number tonight when I get home. I took my g240 when I went to pick it up so I could compare all the bolt holes. And it bolted up perfect to the m10. here are direct links to pictures of the 260 and 240 side by side (don't want to clutter up this thread with pics)

http://i280.photobucket.com/albums/kk165/freakygti/trans-1.jpg

http://i280.photobucket.com/albums/kk165/freakygti/trans.jpg

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  • 1 month later...

Been a while since the last update, for both good and bad reasons. Shortly after Christmas my girlfriend came into town for a week during her winter bread from Stanford (the good). Then two weeks ago my grandfather passed away (the bad). He served his country, started a very successful business and was a great friend, husband, father and grandfather.

But between all that happening I haven't had any time to really work on the car. I have been able to make some improvements to the work space though, and so I thought I would share those until I get back to the grindstone.

The first area that needed attention was the lighting in the room. When the previous tenants moved out, the only working light fixtures were 1 metal halide and 3 fluorescent bulbs. That really doesn't cut it in a 40'x60' room. So I ordered 6 T5HO kits that consisted of 4-54w bulbs each. This effectively quadrupled the lumens of the old lights, while being much more energy efficient.

This is how the room was lit before, any time I wanted to find a part in my stash I needed to get a flashlight to look through the boxes.

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How it is now, I can see everything sooo much better. I can't believe it took me this long to do it. (sorry for the cell phone quality, didn't have the d90 with me)

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With the lighting issues resolved, the next area to improve was the power sources available. When I first got into the room there was only 110V run, so I took another lead from the building main box and ran it in so I could run the single phase 220V welders. This held me over for a while, but I really wanted full 3-phase so I could run some heavier machines. At first I though this would be very involved, so I kept putting it off. But then one day last week I noticed that there was a run of wires to where an old, large air compressor was. Since the air compressor had been moved, I was able to take that run and re-direct it over to my room, giving me full 480V 3ph power. While this may not seem like a huge improvement, it let be finally bring out some bigger machines that had been sitting in the basement, not being used.

The first machine I brought up was an old Do-All surface grinder. While it probably won't get much use, it's the kind of thing that when you need it, it's the only tool that will work.

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Next was a fairly large vertical mill. It has a 4ft bed with servo feed on the x-axis, as well as a 2-axis DRO system. Also has pneumatic tool holding. While I did have access to another mill, it will be very nice not to have to walk across the building to make a small part.

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And last but not least is a recent purchase from this past week. Long story short, I kept keeping tabs on all the parts I was going to need to have made for the car and most of them were on a lathe. So for roughly the same price as paying someone else to make them, I found a 10" South Bend Lathe down the street from me. It's a little rough around the edges, but still good where it counts. I'll probably tear it apart at some point and rebuild it, but I may try and finish the car first. The coolest part is it was built sometime in 1942, I can only imagine the stuff that's been made on it over the years.

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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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