1983 BMW E24 635csi Track Car Turbo Build
Discussion
Really good write up and a fascinating project.
Just a personal opinion of course, but if the trim was put back on the front bumper it would look almost factory, a real Q car....apart from the side exhausts of course !
Your engine installation looks great, very well finished and unlike modern cars, there seems to be plenty of space under there.
Just a personal opinion of course, but if the trim was put back on the front bumper it would look almost factory, a real Q car....apart from the side exhausts of course !
Your engine installation looks great, very well finished and unlike modern cars, there seems to be plenty of space under there.
1602Mark said:
Fingers crossed for your repair.
Such a nice car.
Took it for a good drive up the A10 to help my mate with his E34 M5 3.8 LE (now THAT'S a nice car!) today. It ran perfectly, it remains to be seen how long the gaskets hold up for, though. If it happens again the situation may have to be re-though - possibly a fire ring type fix instead of the gaskets..Such a nice car.
Paul S4 said:
Really good write up and a fascinating project.
Just a personal opinion of course, but if the trim was put back on the front bumper it would look almost factory, a real Q car....apart from the side exhausts of course !
Your engine installation looks great, very well finished and unlike modern cars, there seems to be plenty of space under there.
Thanks, mate. The trims aren't in great repair, I was considering a GRP one-piece bumper that eliminates the trims. There is a small company that makes them in UK. It's all money, though..Just a personal opinion of course, but if the trim was put back on the front bumper it would look almost factory, a real Q car....apart from the side exhausts of course !
Your engine installation looks great, very well finished and unlike modern cars, there seems to be plenty of space under there.
A little update. I dropped the car off at my mate Steve's again as we have a few more plans. These include:
Diff ratio swap
Turbo manifold adapter fire ring/seal
Check turbo play
Manifold/downpipe heatshield /ceramic coating?
New wastegate spring
Fit bumper
Cage
Oil cooler thermostat
Exhaust additional silencer
Install Emerald K6 and modify upper timing case to accept cam sensor
Fit bonnet pins/boot straps
New turbo v-band
New turbo blanket
MOT
I ended up pruchasing the GRP bumper, it will save some weight and will save me buying new trims for the original bumper. I was never happy with how it looked, naked.
It has been painted but I haven't any pics. Probably the wrong way to do it as I'm not even sure it wont need a bit of editing but it was easier, logistically.
Also Steve has already been busy with his mangle grinder, cutting the cage up for a test fit. it is actually a half-cage for an E36 coupe with doorbars etc. welded on later. Some of these welds are suspect...however, it was a bargain for the £250 I paid.
Diff ratio swap
Turbo manifold adapter fire ring/seal
Check turbo play
Manifold/downpipe heatshield /ceramic coating?
New wastegate spring
Fit bumper
Cage
Oil cooler thermostat
Exhaust additional silencer
Install Emerald K6 and modify upper timing case to accept cam sensor
Fit bonnet pins/boot straps
New turbo v-band
New turbo blanket
MOT
I ended up pruchasing the GRP bumper, it will save some weight and will save me buying new trims for the original bumper. I was never happy with how it looked, naked.
It has been painted but I haven't any pics. Probably the wrong way to do it as I'm not even sure it wont need a bit of editing but it was easier, logistically.
Also Steve has already been busy with his mangle grinder, cutting the cage up for a test fit. it is actually a half-cage for an E36 coupe with doorbars etc. welded on later. Some of these welds are suspect...however, it was a bargain for the £250 I paid.
rob0r said:
I love this project! Are you getting a cage for it? Anything else planned? When's the next outing?
I wanted to do something similar with my old E23 728i manual (also owned by Mark above!) though I sold that project in the end. I have a rolling shell E3 3.0si I want to track at some point and I think the same BC coilovers (E28?) will go straight on (well maybe not the top mounts...).
Your 3.0Si, isn’t Fjord Blau / navy interior and L registered is it ? Stupidly sold my 3.0 Si a few years ago.I wanted to do something similar with my old E23 728i manual (also owned by Mark above!) though I sold that project in the end. I have a rolling shell E3 3.0si I want to track at some point and I think the same BC coilovers (E28?) will go straight on (well maybe not the top mounts...).
She's down off the ramps and seems to be running well! MOT on Friday and then some tweaks to the map to accommodate the extra boost. There seems to be a slight issue with traction in any gear at the moment, hopefully the longer diff will fix that but it'll have to wait until the autumn!
Hoping to make Helmingham Hall on Sunday. I'm coming from Ely way if anyone fancies a convoy.
Hoping to make Helmingham Hall on Sunday. I'm coming from Ely way if anyone fancies a convoy.
Helmingham was great, as always. Got stuck on the grass though!
After that it was a few tweaks to the fuelling by Steve and off to the dyno!
Not before a weight in:
Pleased with that! Weight from factory is anywhere from 1420-1480kg for the 5 speed.
I chose Emerald for the power run and I'm glad I did. They were most helpful and did a fair bit of mapping while she was on the rollers.
Injectors were at 95% duty with 0.8 bar of boost. 385bhp at 5400rpm and 403lb ft of torque at 4500rpm. Full boost at 2750rpm, turbo prob wants another 0.5 bar before its running at full efficiency. Super driveable at present with great response. Pleased with that! Bigger injectors, some more chuff and another tune and I think I'll leave it there. Somewhere between 1.2 and 1.5 bar so as not to over spin the turbo. Current power to weight is 300bhp/tonne.
After that it was a few tweaks to the fuelling by Steve and off to the dyno!
Not before a weight in:
Pleased with that! Weight from factory is anywhere from 1420-1480kg for the 5 speed.
I chose Emerald for the power run and I'm glad I did. They were most helpful and did a fair bit of mapping while she was on the rollers.
Injectors were at 95% duty with 0.8 bar of boost. 385bhp at 5400rpm and 403lb ft of torque at 4500rpm. Full boost at 2750rpm, turbo prob wants another 0.5 bar before its running at full efficiency. Super driveable at present with great response. Pleased with that! Bigger injectors, some more chuff and another tune and I think I'll leave it there. Somewhere between 1.2 and 1.5 bar so as not to over spin the turbo. Current power to weight is 300bhp/tonne.
Hello, all
Another little update. I've found some Siemens 875cc injectors for a decent price so these will be getting ordered in time for the next tuning session on November 1st. Boost will be turned up to approximately 1.2 bar (currently 0.8).
I have also ordered a new AFR sensor as the one fitted had done it's time and the oil temp gauge has also given up so I have another one of those to fit as well. I am currently using the oil pressure to figure out when everything is up to temp!
Installing an aftermarket M30 "turbo" cam or hotter Schrick was also considered but these tend to alter the torque delivery and you lose the early shove you get from the stock B35 cam. This stock camshaft was used in the e23 745i and the Alpina B10 Bi-Turbo, so you'd think it would be a decent compromise!
Vernier pulley was also considered but as the cam operates both the inlet and exhaust valves, playing with this would simply move the power band up or down the rev range and, as you set it and then button it all up and see what happens, it's a bit of a risk when you're paying for a full tuning session without the ability to alter timing..
A new exhaust will be made up for the run, the single side exit box has had a kicking and it's now too loud to pass track limits and also is very uncomfortable in my right ear! Going back to a 4" with rear exit and two silencer boxes is the order of the day.
Here is some footage of the power run:
https://www.youtube.com/watch?v=vy2nWTfQTPA&li...
Cheers!
Another little update. I've found some Siemens 875cc injectors for a decent price so these will be getting ordered in time for the next tuning session on November 1st. Boost will be turned up to approximately 1.2 bar (currently 0.8).
I have also ordered a new AFR sensor as the one fitted had done it's time and the oil temp gauge has also given up so I have another one of those to fit as well. I am currently using the oil pressure to figure out when everything is up to temp!
Installing an aftermarket M30 "turbo" cam or hotter Schrick was also considered but these tend to alter the torque delivery and you lose the early shove you get from the stock B35 cam. This stock camshaft was used in the e23 745i and the Alpina B10 Bi-Turbo, so you'd think it would be a decent compromise!
Vernier pulley was also considered but as the cam operates both the inlet and exhaust valves, playing with this would simply move the power band up or down the rev range and, as you set it and then button it all up and see what happens, it's a bit of a risk when you're paying for a full tuning session without the ability to alter timing..
A new exhaust will be made up for the run, the single side exit box has had a kicking and it's now too loud to pass track limits and also is very uncomfortable in my right ear! Going back to a 4" with rear exit and two silencer boxes is the order of the day.
Here is some footage of the power run:
https://www.youtube.com/watch?v=vy2nWTfQTPA&li...
Cheers!
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