BikealarmBlair's V8 Powered E46 BMW

BikealarmBlair's V8 Powered E46 BMW

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bikealarmblair

Original Poster:

1,085 posts

208 months

Tuesday 16th August 2011
quotequote all
I thought I'd share my little project that's been keeping me busy for the last few months...

I do some wiring work for Craig Taylor @ www.dynotorque.co.uk apart from running a motorcycle dyno Craig is also an expert fabricator/engineer & puts LS 1/2/3 engines into different cars, I do the wirirng on them for him & the V8 rumble/torque has finally got under my skin so he's making me one biggrin

I bought a 2001 325 M Sport Coupe for the conversion into which is going an LS1 5.7l GTO engine & 6 speed box, it's not 'just' an engine swap tho it'll need hand made header pipes, prop, steering rod etc & while we are it were installing the rear end from an E46 M3 to give the car an LSD, upgrading the suspension & brakes as well as sorting all the niggles with the car.

The Car...



M3 LSD Diff & rear end


LS1 5.7l GTO Engine & box smile


Laser cut widgets for the custom headers


The Carbon cube trim was worn out on the drivers door & needed replacing as I had to the door trim off to fix the CDL I decided I'd have a go at painting the trim & see what it looked like




Rear AP calipers being sized up for brackets onto M3 read discs



I sourced an M3 propshaft from a local breakers for £95 biggrin

Put my old black MV1's on still not sure on what to do about wheels unlike most I really like MV1's but this is 3rd car that's had them,,,,








Well the scales say 1421KG lets see how much it gains when it's finished.

Craig measuring up for the mounting brackets for the AP Calipers & bigger discs biggrin



Brakes




It needed a small spacer to clear the wheel but I'd intended to run spacers as the wheels sit to far in anyway so I popped next door & pinched some from driftworks....

Next up is the AP rear calipers



While I was @ driftworks I got Phil's old H&R anti roll bar off him for mine, my pile of stuff in the corner is getting bigger



Ready for bodyshop





Rear brakes are done




Car is back from bodyshop & Driftworks brought round a load of boxes (HSD's anti rollbars brakelines & loads of powerflex bushes.
The new radiator, engine mounts & fuel pressure reg/filter have been delivered too.

Shiny things B)




Complete back end removed so Craig can stiffen up the subframe mounting points




Good job we were planning to stiffen the back end up.... the trained eyes will see the crack starting & the movement on the spot welds





Removed the 2.5 engine/gearbox/wiring & front suspension.





There isn't a lot of the car I bought left...... More shiny stuff arrived today too smile



The DynoTorque subframe kit waiting to be fitted







Craig has had a look at the engine & the clutch is fubar'd frown It seems clutches are a weak point on LS1's & the clutch of choice is an LS7 but to fit an LS7 clutch you need an LS7 flywheel too all in about £700 ish frown Why did I buy that cam LOL after a bit of surching I found a brand new one that's been taken off a new engine for £300 biggrin

Ive put the new front shocks on




Craig busy making a racket grinding & then welding in the DynoTorque subframe strengthening kit








Painted the repair




Subframe poly bushed



& then got it back into the car



Got the rear suspension & brakes on & ran new braided brake lines to the front



I'm so sad!!!!



Craig's made an new steering arm & relocted the ABS




When I ordered the engine I ordered it with a certain type of sump unforttunately the breaker didn't have one so he fitted a different one thinking it would be ok so after a quick measure up it defo won't fit with this sump & I've not been able to source one in the UK so the sump he's fitted is being sent back & a the correct sump is being sent out to me, so just a case of being patient which is something I fail at!!!! The frustraiting thing is had he asked we'd have told him the sump he fitted wouldn't work.... until the sump is in Craig can't mount the engine, so he can't make the headers or get the propshaft modded & I can't start the wiring etc....




I've made a start on the wiring....




& pushed it outside for a wash



The black wheels look better clean & in the sunlight




Done most of the engine loom



As I said not much can be done until the sump etc turn up but I've been doing my best to keep it moving along...

All the brake lines are now connected to the moved ABS pump



Done as much of the wiring as I can for now



What do you do when you can't buy a big enough back box? Well if your Craig Taylor you just cut/weld/bend one till it's the right size....







And then this morning Fedex handed me a package....



Just waiting (still) on the sump despite lots of assurances from the place I bought my engine (Calspeed & Performance) from were still waiting for them to sort their mistake out.

A minor update

Sump has finally tuned up late today biggrin so things should start moving forward, not that we've been idle while waiting for it..

Craig has fitted the new cam, cam chain, pushrods, uprated valve springs & collets





The engine just waiting for the correct sump.....



We've been able to do a bit on the exhaust & some of the pipework under the bonnet






A friend of mine has been over today looking at the canbus side of things & it's quite involved & going to take some work to do so as temp quick fix I'm going to install a set of E36 clocks I have while Rob works on the can bus.

This morning Craig fitted the LS7 clutch & T56 gearbox together & then poked the engine into the hole.....




& the he made some engine & gearbox mounts



& it's in smile



That's a very long difficult day made to sound very easy.... it's not trust me!

I've dropped the prop off to be shortened & have the correct end fitted for the T56 box & in the morning I'm off to Jetex to collect the bends & pipe/parts so Craig can start making the headers

It's been a busy few days for Craig @ DynoTorque he,s made the exhaust headers & connected them to rear section along with sorting power steering lines.

This



+



=













Waiting for the t**t that's borrowed efi live to bring it back so I can unlock the ECU then it will start smile





It runs smile





Still plenty of work to do before it's finished if a car like this is ever finished.....

Seems like I've got a faulty brake master cylinder as I no pressure to the rear brakes, not ideal wink
Needs to have the wheels aligned etc & still quite a bit of wiring/interfacing to sort out so still a few late nights left in it yet!!!!

But I'm a happy chap Craig's work is amazing I can't thank him enough for the work he's done & the endless advice & use of his workshop for the last month or two, I honestly wouldn't trust anyone else with car/van/bikes

Oh yeah it's gained a bit of weight..... It's 1499kg so 78kg heavier not all of that is engine tho, it's down to bigger brakes/wheel spacers/anti roll bars/diff/boot floor mods etc so it's about the same weight as a STD M3

I taxed it earlier & have done 5-6 miles in it, it's fast.... I love the way when you rev it the car rocks side to side, it's as quite as I could make it but you can still hear the V8 rumble it's almost wrong in a BMW. I've got lots to sort out before it's really roadworthy at the moment the brakes aren't working correctly, no abs, speedo or any gauges apart from fuel I think the can bus is connected to more of the car than I first thought. Lots to do but I can already tell this is going to be a fantastic car

I've got to the bottom of some of my issues today I've refitted the BMW engine ecu with hindsight I should never have removed it.... & now have a working temp gauge smile & I've been able to scan the car & the reason (or at least one of) I have no abs or speedo is because the car is not seeing the rear wheel sensors the M3 rear end is from a later 2004 car with DSC & it looks like the sensors are not compatible with my ASC unit so tomorrow I'm going to try & get some older sensors & fit them, with a bit of luck that will sort my brake issues too only leaving to decide which way to resolve the tacho either machine my front pulley & fit the BMW sensor or source a convert box from the chevvy crank sensor to the BMW one.

Todo list is very small indeed, aircon pipes/gas, bleed clutch, fit trigger ring for rev counter & clean it



The last few days have been a blur!!!! I'd say the car is 90% now my todo list is almost empty smile I think all that's left is to have the aircon gassed, alignment done & tweak the map when it's got a few more miles on it, oh & fix it.....

Obv you just can't buy aircon lines for chevvy in a bmw off the shelf so at DynoTorque that means Craig makes them....




I've gained control of most of my gauges, I made this really hard work for myself by taking out & selling the bmw ecu with the engine I didn't realise how much of the car was connected to the DME, heater, aircon, abs, speedo instrument cluster with the help of my mate rob & a bentley manual, bmw tis, bmw laptop software, chevvy laptop software, digital volt meter & a lot of time we refitted what we needed of the bmw DME & wiring and had a trigger wheel made to so the DME still thinks the bmw engine is fitted.....



All of which gives it



Took a couple of pics before I drove home in it last night




Unfortunately the bmw expansion tank has sprung a leak so I'm off to try & source one or there will be UBMW for me frown

Not really an update more just an excuse to post a pic or two




Wideband sensor controller



Craig made me an adaptor to put the sensor in the exhaust




Still a few bits to to make it 100% finished but its getting close

Edited by bikealarmblair on Tuesday 16th August 23:25

bikealarmblair

Original Poster:

1,085 posts

208 months

Wednesday 17th August 2011
quotequote all
Thanks for all the positive comments smile

V8mate said:
Awesome! Now bring us some video; with sound! smile
There are two in the first post but here they are again laugh

First run


First drive



Stig said:
Dare I ask what this is going to stand you cost wise? Would have been a hell of a lot cheaper just to go and buy an 05+ 4.6l GT Mustang smile
Aprox £11k It may have been cheaper to buy something else but whatever I bought would have had tired suspension/brakes etc & would have been the same as everybody else's I love E46's this is my 3rd one, I had a 56 reg 120d MSport & hated it so did the maths & realised for similar money I could have the car I really wanted

ManOpener said:
Cracking car. One question- I always though that the M3 rear had a wider track than the 3xx one? Doesn't appear that way from the images...
Nope they are the same it's the rear wheel offset that's different, mine has 20mm spacers at the rears to make the wheels fill the arches

mig25_foxbat2003 said:
That is wicked - I love the standard-ish look. Really really cool project. That badge will confuse some Americans though, as it's technically a 345ci engine...!
Ahh your not first to mention this BUT it's a German car fixed in Birmingham so

3 cause its 3 series, 57 cause it's a 5.7l, C cause it's a coupe & I cause it's injected stuff the yanks laugh

Somnophore said:
What sort of bhp is it putting out?
It's not been mapped yet so it's 'only' revving to 6100rpm instead of 7000rpm but when it's sorted it should no it had better make 400+bhp

M5cheaper Tom said:
Would it not have been to get an E39 M5? They rock side to side as well mate. smile
I don't know?? I don't think so, also M5 lumps are probably much harder & dearer to tune

Tonberry said:
So when are you adding the supercharger?
I'm not!!! I wasn't even going to put a cam in it but bowed to peer pressure! I wanted a car that was really nice to drive & has that factory feel rather than a monster I'm scared to let the better half drive.

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 19th August 2011
quotequote all
fishman said:
Wicked project m8! So what sort of BHP is this actually producing? I assume its around the 350bhp mark.....whats the next step? supercharging?
err....

BikealarmBlair said:
Somnophore said:
What sort of bhp is it putting out?
It's not been mapped yet so it's 'only' revving to 6100rpm instead of 7000rpm but when it's sorted it should no it had better make 400+bhp

Tonberry said:
So when are you adding the supercharger?
I'm not!!! I wasn't even going to put a cam in it but bowed to peer pressure! I wanted a car that was really nice to drive & has that factory feel rather than a monster I'm scared to let the better half drive.

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 19th August 2011
quotequote all
Bladez said:
Looks fantastic.
Love the second vid.... That orange RX7 looks pretty tasty too.
The Orange one is another of DynoTorque's V8 conversions it's 6.2 LS3, it's owned by a mate of mine.....

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 19th August 2011
quotequote all
Superhoop said:
Lovely car, and I love the wasy it looks completely standard - It must suprise a few people!!

Eddited because my iphone decided to post something in the wrong thread!!

Edited by Superhoop on Friday 19th August 18:03
Thank you smile

Did it post a rant about mazdas??

bikealarmblair

Original Poster:

1,085 posts

208 months

Sunday 21st August 2011
quotequote all
Craig! said:
Awesome thread, nice work... i'm deciding what to do for a power plant for my e36 so this has gave me some good ideas!
http://www.dynotorque.co.uk/index.php/2011/07/colins-e36-m3-ls2-v8/ that should give you some more ideas!!!

bikealarmblair

Original Poster:

1,085 posts

208 months

Sunday 21st August 2011
quotequote all
Thanks for all the positive comments glad everyone likes it smile

I've been offered a set of genuine BBS LM's but I don't think they will clear my brakes frown

warwick hunt said:
superb work well done...

ps.how the hell did craig donate so much of his time...confused
Maybe something to do with me paying him!! That & that fact that I've re wired his twin turbo LS3 V8 turbo for him.....

bikealarmblair

Original Poster:

1,085 posts

208 months

Monday 22nd August 2011
quotequote all
RobCrezz said:
bikealarmblair said:
That & that fact that I've re wired his twin turbo LS3 V8 turbo for him.....
Rewired his what? How many turbos? wink
Touché!

Try again Twin turbo 7L LS3 V8 RX7

bikealarmblair

Original Poster:

1,085 posts

208 months

Wednesday 24th August 2011
quotequote all
That's what mine owes me inc the car, obv I've done a lot of the work myself & as much wheeling & dealing on parts etc but I've done loads more than just an engine conversion on this car. You'd have to speak to DynoTorque yourself for prices etc but you should be able to buy an engine & have a conversion for £7-10k then again you could easily blow £12k+ on an engine.....


Couple of workshops shots from the other day prob the 2 most modded E46's next to each other one designed to look very subtle and the other to look very modded & Craigs RX7 LS7 7L twin turbo.....



bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 9th September 2011
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[quote] Over the coming weeks/months time & money permitting I'll be:
Sort ABS/brake issues, still have a long pedal & odd ABS performance I really don't want to remove the ABS but it's becoming an option & fit rear AP's
Sort Air bag faults (passenger seat pad override)
Connect oil level sensor from LS1 sump to BMW DME
Find/sort irritating noise from rear seat/shelf area
Get air con gassed
Replace front tyres
Decide how high/low I want the car & get Alignment sorted
Make front strut brace & mod tower so camber can be adjusted easier.
Fit Parrot hands free kit
Make it quieter
Map the fuelling
Drive it like I stole it
[/quote]

So over the last month I've been a bit lazy/unfocussed but I have done a couple of bits to it....
Brakes: I'm hating brakes at the moment! I found that the ABS module was faulty so finally gave in and ditched it another set of new braided lines were made up and fitted, I have brakes..... Well kinda it now stops in a straight line but pedal feel travel is still the same frown So it must be a master cylinder ratio issue even tho the maths say it's all fine.... So I replace it with a bigger one & also put the rear AP calipers back on & the difference is minmal frown Without Craig pushing me at this point I'd have just parked it up & sulked! Craig modified the pedal pivot but still no real difference it seems that everything makes it a 'little' better but nothing fixes it 100% we also changed the servo as we had one but no difference... I'm beaten!!! Craig isn't tho he checks the internal diameter of the pipes & it's dash 4 not the dash 3 he specified (means nowt to me either) so yesterday I made new front lines with dash 3 and the pedal is 75% better!!! Going to change the rear lines too & fingers crossed I should have the amazing brakes this car needs! Craig your a hero without you this would be just another unfinished project.

I've made a sensor pad bypass for the passenger seat airbag mean the pass airbag will always trigger now, these are on eBay for £15 but I made mine using 2 100ohm resistors & a diode so about a £1

I've replaced the front tyres with some awesome Dunlops (well Craig treated me to them as a unneeded thank you for getting his website up to date smile ) they have transformed the car the grip & turn in is fantastic wet or dry very impressed this is the first E46 I've had that doesn't understeer

I've been twiddling with the HSD's & have a decent compromise between looks & bottoming out getting to the garage, I've also backed the front camber off from 3degrees to 2degrees since fitting the Dunlops but will still get it aligned at some point if only to see how close to correct I've got it.

Been logging the fuelling/mapping & it was being restricted by the MAF/throttle body so before an E46 forum dyno day I decided I'd change the MAF with one we had just before I left for the dyno.... Car felt flat as a fart frown and made shockingly low 326bhp on the dyno, on my return to DynoTorque after some of the piss take had stopped Craig told me the MAF I'd put on was from a car that had been written off in floods..... No wonder it felt flat!!! So I took it off & Craig got busy porting the throttle body for me & also persuaded Pinhead to remove the LS2 MAF from his ute (he's had a mafless tune) so I could use it on mine a few new pipes later & it feels like a new car the bottom end is now so sharp the pick up is much faster smile much more mapping/tuning is needed but I can't believe the difference it's made so far.







So my to do list now looks like:
Replace rear brake lines again
Interface LS1/BMW oil sensor
Fit/gas aircon compressor
Front strut brace
Fit Parrot
Fix rattles
Mapping
And more destroying rear tyres smile

Blair

bikealarmblair

Original Poster:

1,085 posts

208 months

Saturday 10th September 2011
quotequote all
400/400 has always been in my mind but that might be a bit optimistic after last weekend.....

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 16th September 2011
quotequote all
lordf said:
bump, just really curious on this
They have been done in -3 braided hose now & they are amazing zero fade even when standing on them repeatedly from 100+ on a private test track of course....

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 16th September 2011
quotequote all
Bought the braid & ends from listers motorsport

bikealarmblair

Original Poster:

1,085 posts

208 months

Tuesday 27th September 2011
quotequote all
bikealarmblair said:
So my to do list now looks like:
Replace rear brake lines again
Interface LS1/BMW oil sensor
Fit/gas aircon compressor
Front strut brace
Fit Parrot
Fix rattles
Mapping
And more destroying rear tyres smile

Blair
Sorted the brake lines
& rear tyres..... wink

http://www.youtube.com/watch?v=mCbg2CLWl50

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 21st October 2011
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bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 21st October 2011
quotequote all
gsd2000 said:
Looking good, I would have expected more towards 450hp with a cam only ls1, but it does have a lot of torque.

What's the spec of the cam?
I guess that depends on the dyno, we were expecting 390-410, there is still some more to come as the intake is slightly restrictive above 4800rpm

The cam is quite mild http://www.thunderracing.com/shop-by/category/Cyli... it's the LS2 cheater.

bikealarmblair

Original Poster:

1,085 posts

208 months

Friday 21st October 2011
quotequote all
Glad you guys like it, it's amazing to drive smile

bikealarmblair

Original Poster:

1,085 posts

208 months

Saturday 22nd October 2011
quotequote all
I love this car B) I needed to go into brum earlier & left it parked in a side street, when I walked back to the car it just looked aggressive I walked past it & then back from the other way just so I could look it some more.... Not sure if it makes me a bit odd tho? I wanted to take a pic but felt like a tt so didn't lol

Popped into DynoTorque on the way back for a cuppa & cause the car keeps leaving lines.... Craig thinks it may be impossible to fix.....


http://www.youtube.com/watch?v=IQ6KdOJJi1w&fea...

Any ideas on how I can fix this problem.... wink

Took a few new pics & never being one to miss a chance to post them enjoy






My fav pic of the car to date smile



bikealarmblair

Original Poster:

1,085 posts

208 months

Monday 24th October 2011
quotequote all
Maf has been ditched already, can't see any obvious improvements to the intake but willing to take your advice when your at DynoTorque Richard.

Cam spec 215/230 .629/.592 117 LSA. Off Idle-6800

It was done on a dyno dynamics RR and the figures are about what we expected & compatible with other similar spec ones we've run on SRR.

bikealarmblair

Original Poster:

1,085 posts

208 months

Saturday 5th November 2011
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