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RUSTY 1502 M20B25 Turbo


Gholberg

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Hallo everyone! 

 

My 02 journey started with a crash in my e30’s. This winter, after a dyno day - I crashed my E30 M20B25 turbo…
As the prices on e30 is extremely high, and that I’m currently studying - I started looking for alternatives. I stumbled upon this 1502 barn find and google if an M20 would fit in the car. The 1502 has been sitting I the barn for 28 years! As stupid as I am, I brought the car.   

So yes. I’ve brought this, project. It’s a really big project, especially when you look on how must rust it has. But hopefully, it will be a car once again. On the bright side, this allows me the make the car precise how I want is, as I need the change a lot of parts anyway.

Its an 1502 from 1975, Inka orange and has always been driven in Denmark until 1993.

My plans with the car, is the keep the weight under 1000kg (2204 lbs) and with the 400 hp M20 engine.

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Hello and welcome.

Your project sure looks like a handful. I have exactly same looking 1502 sitting on my yard but that's condemned as parts car. It's originally mintgrün but painted in inka. There is a chance that yours is too far gone also when you look the lower parts of the body closer.  

At least here in Finland it would be a lot easier to find an e30 in decent condition and reasonable price than an -02.

Racing is Life - everything before and after is just waiting!

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48 minutes ago, Tommy said:

Hello and welcome.

Your project sure looks like a handful. I have exactly same looking 1502 sitting on my yard but that's condemned as parts car. It's originally mintgrün but painted in inka. There is a chance that yours is too far gone also when you look the lower parts of the body closer.  

At least here in Finland it would be a lot easier to find an e30 in decent condition and reasonable price than an -02.

 

Thanks! Although it looks okay from these pictures, don't be fooled. Its REALLY in bad condition.?

 

The lowest price round here for an E30, in reasonable condition is around 8000 EUR. I got this 1502 for 2700 EUR.

There was only round 4-5 other 02 for sale at the moment, most of them in mint condition, as cost round 20.000 EUR in Denmark.

 

I will post some pictures, when I'm a little longer in the rust progress, so its possible to show some pictures before and after. Stay tuned 

 

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  • 7 months later...

The activity has not been at its peak as far as the car is concerned. This is because last semester of school was quite time consuming. However, I have had summer vacation and I now have a less time consuming sesmster. There has been so little progress.

As can be seen, I have feathered a bit to make a clean look and to have good space for the M20.

The engine compartment has been given 3 coats of epoxy as well as paint and clearcoat

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Edited by Gholberg
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  • 2 weeks later...
  • 3 weeks later...
On 11/6/2021 at 8:06 AM, Tommy said:

Nice job in the engine bay. How about the usual rust areas? Rear axle mounts, trunk floor, rocker panels, rear shock towers...?

 

Thanks!

 

Like everyone else it is also rusty there. But for the sake of clarity, I take it one place at a time. So next time I will make the floor as well as panels, and then the rear parts :)

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Since the enginebay now being ready, i thought it was time to see if the engine would fit. It fits nicely, however, a Getrag 260 gearbox does not fit very well in a 1502, which is why I have cut out the gearbox tunnel. This will be replaced by a tunnel from an e30. But the engine is now where it should be - and in level. Here are some pictures of it, as well as the homemade engine mounts I made for the purpose

 

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  • 8 months later...
  • 1 year later...

Well. Long time no see. I have neglected the 02’ for a while. In the meantime I have converted my E30 from a M20B20 to M20B25, then M20B28 and lastly – with homemade ITB and shaved bay. Also, I have renovated a VW T3 camper that I bought in 2022, that would not run and need some love with a welder.

But now, I have finally made some progress on the 02’ again  

Motorrumm.png

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I won't gointo details with pictures and descriptions, as many 02 owners have already done so before me, and almost all 02s is rusted in the same areas.

 

New front floor pans welded in - together with E30 gearbox tunnel. 

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Then i have made a cut out for my fender flares 

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And made the last welding in the engine bay / gearbox tunnel motorruum.thumb.jpg.7aced739922659bdb67f50060b3d27e7.jpg

 

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Well, there's been a change in the project.

In Denmark, it's always been illegal to tune or swap to a larger engine, etc., in your car. However, previously, you'd just receive a notice for inspection and then had to make the car "legal". But in 2022, the police started confiscating cars. You had the choice of either scrapping the car or having it brought to, for example, an authorized BMW workshop, where they would make the car legal at the owner's expense. It would be quite expensive with an M20 turbo in a 1502.

 

There's the option of having it approved by a third-party inspection - which is fine, I've done this with my E30 with ITB.

However, I'd have to build a 2002 Turbo suspension and brakes to get the power of an M20 approved, then the tax authorities come along and demand a tax for a 2002 Turbo, which is quite expensive.

 

So, I've decided to use the original M10 and put a turbo on it. I can base it on a 2002 2.0 with about 100 hp and then tune it up to 100% without changing brakes or similar, as long as my 1502 can pass a brake and driving test.

So now the goal is about 200 hp in my M10. Then Ican always increase the boost afterwards (of course, ONLY when doing track days or similar ;) ). 

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As mentioned, my thoughts were to use the original M10 engine, provided it was in good condition. After all, it hasn't been running for 30 years and has been lying outside for the past few years, as I was very close to throwing it away.

But fortunately, it's in good condition. It's a 1.6 with an 84mm bore and 71mm stroke, and it has a 118 cylinder head with 34 & 41mm valves.

In the long run, I'm considering boring the block up to 89/90mm and getting the cylinder head ported and fitting larger valves, as I'm not allowed to replace the block and cylinder head in conjunction with approval and tax.

It will be fun to work with the M10, as I've only worked on M20s before. I can easily imagine achieving the 200hp mark without making any modifications - and in the long run, with an optimized cylinder head and bottom end, and possibly using E85 fuel, reaching 350-400hp certainly wouldn't be unrealistic.

Another advantage is that by using the M10 and  gearbox instead of the M20 and 260 Getrag, I save 57kg!

Good old M10 ready for some make up time
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Quite nice looking, taking the age in consideration

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128 kg ish. 
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172kg ish

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It's not easy to have a car hobby in Denmark. We have similar restrictions in Finland but I feel they are a bit easier than yours. Anyway that's why I moved on to build racecar years ago - less rules, or maybe as much but more simple and reasonable.

Funny, well maybe not funny but strange, that it's so different to Sweden. There's this guy driving around with a Lambo V10 in a 200 series Volvo and all kinds of crazy builds. Swedes are having all the fun 😥

Racing is Life - everything before and after is just waiting!

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  • 3 months later...

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