retoropak

Members BMWs · June 14, 2023

Chassis harness is done and 99% functioning. There are small things to correct, like fogs and low beams control wiring is wrong and I need to move some pins around in the bulkhead connectors.

Fuel lines, flex sensor etc is done i just need to mount the fuel filter.

ECU is mounted and one of the bulkheads is terminated.

Will finish second bulkhead and engine harness sometime this and next week. The goal is to start the engine this month.

I cleaned the motor, slapped new gaskets including a headgasket and it should be ready to go. This thing sat for 4 years behind my shed. Damn chipmunk lived in the motor and stored bunch of chipmunk food in the head port.

Hopefully everything cleaned fairly ok. I will pull this motor anyway and drop some forged goodies over the winter.

I welded drain plug and turbo drain and oil pan is now ready to go.

My arp flywheel bolts from bmw m10 are a bit too short. I will need to replace with 28mm bolts.

Also the tilton hydraulic throw out is 2mm too long and I will need to swap the TO piston for the shorter one.

I got the steering shaft mocked up with some woodward u-joints. Will finish it once i get the e36 column in final position.

I decided to not run the motor NA and go for boost. I got the intercooler setup and i have a log manifold from my friends Volvo. The cylinder spacing is spot on i just need to redrill the flange for m42 bolt pattern. I got some green top injectors that should support 200-250whp which should be more than enough to test the chassis.

I also pondered the idea of running e90 cluster in my car. I got the arduino setup with can shield and was able to control most of the cluster. Cluster talks at 100kbs and maxxecu supports 500kbs i will need to setup arduino with dual can to translate the messages from maxx to BMW but that should not be a big issue.

Members BMWs · March 17, 2023

Electrical work is progressing well. I decided to abandon the Littlefuse integrated fusebox and build my own using TE fuseboxes. It allowed me to bus the power to the components the way I wanted.

I left the original rear harness and terminated it with the 20 pin deutsch connector. It will connect to the front harness.

Body harness is 90% complete. Almost everything under the hood is done. I am still adding some wires under dashboard for gauge power, glovebox lights or radio power and finishing up some grounds. It should be ready this week.
I get the set of cheapo rock auto parts e28 axles , brake discs and some pagid brake pads. I also got the gasket set for the m42.

I got a set of cheapest VAG coils of amazon to see how they fit. I think i will whip something to retain the coils. Once that thing moves out of garage under it own power and suspension aligns I will replace all el cheapo parts with something of better quality.

I spent some bucks on the Radium FPR and it fits beautifully with the nuke fuel rail.

Finish the steering: I ordered woodward u-joints and will need to whip a steering shaft. I still have to mount the column in final position. And lastly will need to sort the tie rod situation. I am thinking shorted e90 inners and e36 outers?

Engine: I have a second m42 which was sitting (covered) outside for almost 3 years. Damn squirrel lived in that thing for two years before I chased her out of there and sprayed 2 cans of pb blaster into the motor. It made very interesting, kind of crunchy noises when turning so I am pretty sure that it will work great. I got a gasket set for it and I am ready to dingleberry the shit out of the cylinders if needed and re-ring the pistons.

Who knows maybe it will make it to the Vintage

Beginning of the new fusebox

New fusebox

And the guts : power first

And the outputs

Radlok for incoming power: This thing is well........... very rad. Possibly best power connector I've seen so far

Finished product with chassis harness attached. Still need to shrink the boots but first will need to test and verify all circuits. I already found horn connected to the radiator fan output and vice versa. Hooooooonk you overheated

FPR. works really well with Nuke rail. Looks like this part was meant for m42 with my manifold

Chinesium coils

Members BMWs · January 17, 2023

h my that is what happen when you have 4 other projects ehm ehm. kids, wife and house and poor bimmer had to wait again. Oh well I got a bit of motivation so I will try to keep the momentum going. Vintage 2023 I am coming

It is wiring time. I ordered bunch of tefzel wire a while ago but could not get myself to start the wiring process.

And of course when i started checking circuits and what wires I will need I found that I forgot to order roughly 20-30% of needed wires.
I fixed that and I am getting the remainder tomorrow.

Since I could not continue wiring for about a week focused on other things. Fuel tank was partially modified (read cut but not welded), so i tackled that. I will run just the right side tank (measures roughly 7.5 gallons). Range will be amazing escpecially on e85. Space left after the left tank will be occupied by the exhaust.

Don't mind my ugly welds it doesn't leak and its temporary until I get the fuel cell

I also got the main power feed done. It is 1/0 splitting into 3x 4 gauge. Black thingy is the main 70A relay that will power up the "run" bus of the fusebox

I painted front calipers black and inspected rear e28 calipers that I sourced from the lemons e28. Rears will need rebuild which will be done as soon as I get my rebuild kit from rockauto.

This week I will try to finish fuel lines (6AN ptfe for that corn juice power) and continue the wiring challenge.

Members BMWs · July 26, 2022

On 7/24/2022 at 12:59 PM, YoungCR said:

This is the same one Eastwood sells and I highly recommend it, perfect flares every time. There are few other brands listed on amazon with the same thing a well and available with prime shipping but I got the K Tool years ago.

K Tool International Brake Line Flaring Tool, 45 Degree Set. Single, Double, and Bubble Flares, Vise-Mounted, T-Handle Screw Clamp

Yup just ordered it from amazon it is a TGR brand but otherwise looks the same.

What is the preferred way of doing fuel lines?

I got enough -6AN PTFE hose to run both supply and return but I thought that maybe going with stainless hardline would be a better option.

Members BMWs · July 24, 2022

Pedals are done.

Dual master ready to be plumbed. I am using stok e36 325i front brakes and stock 528i e28 rears. Front master is tilton 0.7" and rear is .75". Clutch is wilwood .75" I must say that Tiltons look much beefier and beter quality than wilwoods.

I bolted front and rear suspension and set the car on jenga blocks. I need to order new brake line flaring tool since cheapo amazon one crapped out on the second try.

Members BMWs · July 6, 2022

I were going to build one then i figured that I can set up the canopy thing outside but I got some stupid neighbors who would certainly call code enforcement cops so decided to move it inside.

Paint came out great. Engine bays are not my favorite thig to spray. There are bunch of angles, crevices and spots that are hard to get. I got couple of spots with that dry spray texture. I did not bother using a tack cloth after I preped the bare metal so there is bunch dust spots. Its good enough tho for the engine bay.

The floor around the drivers side torque box rusted out so this will get fixed next. I need to paint the driveshaft center bearing supports and diff mounts. Also will get the rear fender lips touched up since they cracked pretty badly when I pulled the fenders.

Members BMWs · July 5, 2022

After couple of weeks of engine bay paint prep. I am ready to paint it. I build a beautiful spray booth in my garage with two box fans and shoot some epoxy primer followed by some seam sealer and more epoxy. Today i will finish it with single stage urethane in original safari beige.

I got the intercooler figured out. Wiring is next on the list.

Members BMWs · May 7, 2022

I got a monstercooler today. I think it is a bit too much @ 24x12x4" core. It fits though but I think I will swap it for something a bit smaller. It will take an hour for the turbo to fill this thing with air. I think transient response may suffer a bit. It might require some pie cutting to connect to throttle body.

Members BMWs · April 28, 2022

I got my fleabay Intercooler it supposed to e 3" core. Well it is not. Its a 2.5" and has some shitty spoolgun welds.. I am not even mad I will just return it and get another cheapo intercooler hoping it will be a bit better. Anyone know ebay sellers/brands that might have decent 3" intercoolers? My 12x12 ebay intercooler that i got couple years back look much better with decent welds and nice looking 3" core.

I made upper radiator mount/ shroud/ intercooler mount.

Front frame rail brace might come handy. The e21 chassis flexes a lot. I will most likely use this brace as a mounting point for the skid plate

Strut tower brace will be next.

I also got my e90 gas pedal. It should work really well.

I started designing chassis electrical harness with my new fusebox. I got the inventory of all circuits including wire lenghts, colors, gauge and approximate splice locations.I will be ordering some tefzel wiring sometime next week.

I had a bit of an issue with clutch master fitting in the bay, So I had to expand the bay a little bit. Half a pound of seam sealer and some epoxy primer and it will look beautiful

Members BMWs · April 22, 2022

Pedal box is done.

I got my throttle body flange. I use 68mm Bosch motorsports TB. Its funny that you cant get that flange in the states. I had to order one from Sweden.

I ordered my eBay intercooler. 12x18x3" core. Should be plenty to support my power goals.

Next week will be finishing some bracketry and I should be ready to prep it for paint.

Members BMWs · April 3, 2022

I welded up the manifold. It was a pain. My 200amp tig had some trouble welding 1/4" plenum with the trumpets. Trumpets were quite thick with some sections close to 1/2" or more. I could use 50amps more.
I added fuel rail brackets and end cap. I also ordered bosch motorsports 68mm DBW throttle. I still need to get the weld-on flange for this throttle.

I ditched floor mounted pedals and get hanging pedal setup. I whipped new firewall plate and added the e36 column mount

Members BMWs · March 29, 2022

2 hours ago, P_Roloff said:

Holy smokes, this is cool. That intake looks awesome, super excited to see that come to fruition. How is the throttle body going to be mounted, out the end of the manifold towards the front of the car or out of the side like an OEM one?

Throttle will be in front of the manifold.

Members BMWs · March 28, 2022

And intake is almost done. All tack welded and ready to be finished. I got some 1/4" plate to do the end cap and to add some reinforcemnt for vacuum fittings.

I will use bosh motorsports dbw throttle body. I am shooting for anything between 350-500whp. I think that 68mm throttle should do. The next size up is 82mm but I worry it will be too twitchy and drivability will suck.

Holesaw setup to cut 3" holes for trumpets

A little mockup with two runners to check the position of the plenum

All 4 runners in.

Fuel Rail

Members BMWs · March 28, 2022

First part of the manifold is tacked up. injector angle could have been a bit shallower but I don't think it will have significant negative effects on performance.

Members BMWs · March 24, 2022

I started putting together manifold. Just some mockups for now to figure out injector positions and angles.

I also got a set of wilwood floormounts that i am trying to fit. Looks like pedal position will be close to stock

Members BMWs · March 13, 2022

I finished transmission mount.

Stock fuel tank wouldn't fit with e28 rear subframe so I had to trim it a little bit.

I started mocking up intake plenum to see if it will fit with a stock booster. The verdict is: I need boosterless brakes. I will try to fit floor mount Wilwood pedals and if it wont work I might go with firewall mounted ones. There is just not enough room for a booster even e90 one with vert mounted motor.

Members BMWs · March 11, 2022

I tried honda B series manifold and it sat too low. Then I tried volvo whiteblock without one cylinder and it was a bit off spacingwise and also sat too close to the firewall.

I figured its time for some custom manifold. I got some trumpets, plenum and a bit of a runner pipe. Flange is also on its way.

In the meantime I started wrapping up some other bits.

I welded shock mounts for the trailing arms. I started working on oil pickup and also threaded some holes for the windage tray. That cheapo oil pan came with windage tray mounts without any threads. Also internal oil pickup passage has a burr that obstructed 40-50% of the opening.

Members BMWs · February 24, 2022

Since the engine sits upright the stock m42 manifold (e30) or ugly e36 one won't work anymore. Miata folks are adapting honda intakes with pretty good results. After some research I decided to get a Honda b series manifold and try to fuse it with m42 intake flange. Spacing is the same +/- 2-3 mm so it should line up fairly well.

It will get bosh DBW throttle body either in 68mm or ill go size up to 82mm if it fits.

Its a pro series so I expect some pro results . Sadly It will sit upside down so that beautiful logo wont be visible.

Members BMWs · February 14, 2022

3 months later............

I had to redo the whole subframe. There was not enough room for decent size sump. Engine is mounted to the frame rails anyway so the middle section of the subframe was cut and pushed towards the front of the car. Don't mind crappy welds, once I hit it with some pretty epoxy paint it wont look that bad anymore. It seems that I can tig aluminum better than I mig steel.

Here is the oil pan that I hat to cut a little bit to sit flush with the subframe.

I also put together lower radiator mounts. It uses stock e36 plastic mounts that sit on steel brackets welded to the frame rails. There is enough room in front of the radiator to fit 3" intercooler.

I also got a new daily driver. I got rid of my xc70 and got F32. That b58 and zf 8spd combo is amazing.

Members BMWs · November 20, 2021

2 hours ago, YoungCR said:

Is that just a universal fuse box?

It is LittleFuse EPC . https://www.littelfuse.com/products/dc-power-distribution-modules/configurable-pdm/epc.aspx

Two separate buses, 9 relays, 27 fuses should be more than enough. Uses ip67 TE connectors

I also thought about this busman/Eaton but it has relay on every circuit.

https://www.waytekwire.com/item/46065/Dual-SSVEC-12VDC/?gclid=CjwKCAiAs92MBhAXEiwAXTi25yWbJ6SQQpt_pXWnZg-UyW1xzr7SP_NbntmXLOg5mJaHZgv6zz3WnxoC-gUQAvD_BwE

Members BMWs · November 19, 2021

I finally found a driveshaft and test fitted transmission and motor. It came out that i made my oil pan 0.5" too long and will have to redo it.

A bit of CSB mount relocation will be required

I started some engine mounts. I also ripped the whole wiring harness and will redo it along with the new fusebox.

I cleaned up and painted rear inner fenders and applied some brush on seam sealer for some extra protection.

E36 steering column is a pretty good fit. I will gain a cruise control stalk which I will need for some dash display controls.

Initially I got garagistic e30/m20 mounts but they are bolt thru which I am not a big fan of. I ordered the revshift mounts.FCP shipped my radiator mounts and engine mounts and I should get em by Monday. I will finish the mounts next week and will modify the oil pan. Radiator and intercooler will be next.

September 10, 2021

Hi,

I am looking for e36 manual zf320 driveshaft with a 4 bolt flange or e30 manual (m20/g260) driveshaft. Or any other bmw driveshaft with a 4 bolt flange that is roughly 1480-1490mm (~58.375”) long.

Thanks.