1983 BMW E24 635csi Track Car Turbo Build

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Might be a bit of a nothing post this but I took photos of it anyway. Basically, I'd lost most of the original floor as it was replaced with fresh metal and so there was no accelerator mounting bracket (this is usually spot welded to the floor). It's not a part you can buy from BMW so I removed one from my mates E36 breaker with the intention of using this along with a new e24 pedal (the original had snapped). Unfortunately, they are mounted in a different fashion so it wasn't compatible with the new pedal. I ended up just modifying the e36 bracket to fit (the height was all wrong). Anyway, here's some pics, I ended up just bolting it to the floor as it was easiest.













Some pics I took afterwards.

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e30m3Mark said:

Throttle pedal looks like a perfectly good solution. If ever it lets you down, this might well work OK?

https://www.vinkmotorsport.com/shop/bmw-e30/bmw-e3...

That's a nice bit of kit, thanks. It may be something I end up getting when everything else is paid for!

Makes me want to paint the interior white too..

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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...).

Cheers. Cage will be the final thing I do, I have a whole boot full of parts including the new diff, ARB's, strut braces etc, just waiting on a mate to help with a few of the hard bits (ie diff) and I should have some more updates!

I love the e3, I should imagine you could get the BC's to fit, if not I'm sure GAZ can sort you something out. I know they do a set for the E12.

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shalmaneser said:

I love this thread.

I've been seriously considering getting into a 635csi for a while now and this isn't helping!

I think I'd go down a more resto-mod route though, although I'd have to junk the auto gearbox. You planning on putting much interior back in?

Get it done! Would love to see it. Nope, that's it for interior, they're not the lightest cars and she needs all the help she can get!

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Managed to get the manifold gaskets replaced today, what a PITA - of course they'd all come out fine except the one at the back above the steering box. Lots of blood and swearing..

All done now though, heat-shields are toast so about to order some new ones.

Few pics






Doggo keeping a watchful eye..

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Braided brake hoses fitted, BC's welded in and now on, strut braces bolted in.

New stat housing also

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Good shakedown on the East Anglia run today. Coolant level dropped a bit but that's it! Bit slippery though..

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Turbotechnic said:

Sounds like fun, what does it go like?

Tbh, I'm surprised by how rapid it is. I suppose it must be fairly quick as they were 7.1 seconds to 60mph as standard and this thing is now empty! The only downside is how long geared the diff is (3.07). You can't even think about 5th until 50mph. It should make it a lot more driveable when I get the 3.64 gearset in.

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Notanotherturbo said:

Mine has stainless headers and system from Fritzbitz.

Yes, I put those on mine too. Not before I'd been told that I hadn't got a real B10. Have delt with them since and wouldn't deal with them again.

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Bit of an update

540i brakes, HEL lines, 60% LSD, 3.73 rear end, adjustable ARB's, coilovers, and Powerflex Black Series bushes all fitted.

Did a track day a few weeks ago and she performed flawlessly. This was before the bushes however so should be alot tighter for next time (7th June).

I have also started accumulating a few parts to turbo the car, so far I have Nuke Performance BOV and fuel rail, Turbosmart 50mm wastegate, Rapid Spool Industries turbo manifold, colder plugs and Emerald K3 ECU and map sensor. Once I've collected everything else it should all be bolted on this winter.

Edited by e28525e on Sunday 27th May 18:45

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Buff Mchugelarge said:

I bet that turns a few heads on a track day?! Very cool

It does, mate. Cheers!

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e30m3Mark said:

Love it.

Cheers, boss!

Another track day today with my mate, Sam. Car felt great although the diff wasn't locking up as well as I wanted.

Still, after playing with the front coilovers we got the front to bite alot better and the back started to be a little more drifty on the limit, just what we wanted.

I started to get into the swing of things and managed to get fairly consistent times; 2:30, 2:29, 2:29, 2:28.

Sam managed a couple of 2:27's so it gives a good benchmark for future mods.

Cheers!.

Edited by e28525e on Thursday 7th June 20:14

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Quick update!

After having fun in the car on track with the few mods I've done I've found it really does need more power in the straights so, as I've mentioned previously, I'm going to turbocharge it. I'd love to go NA but the cost is prohibitive..

I had a decompression plate made by Ferriday Engineering but I came to the conclusion I could knock out the timing or have problems getting the chain to fit I scrapped that idea and am going for an 0.120 MLS gasket and ARP studs. I've bought a B35 engine (fitted to later e24) that used a lower compression head and I'm going to use that with the gasket and should achieve around 8.4:1 compression. I'm going to trial an e34 M5 clutch and see if it will handle the torque. Loom for the Emerald has arrived, I just need to buy the big whooshy thing!

Anyhow, will keep you updated. Cheers

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rallycross said:

this is a great project and nice to see your car at Snetterton, a friend used to race these when they were current models.
I took this photo at the willhire 24 hr at the bomb-hole ! check out the roll on this production spec' racer.



I've had a couple of road E24 would love to have a drive on track in one.

That's a great picture! Cheers for that. You are more than welcome to have a clutch. Are you local to Cambridgeshire?

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Upon taking the head off the b35 engine, we found many of the rockers to be worn, along with the cam lobes. This is fairly common on m30 engines as the oil spray bar can either work lose or the holes in it can become blocked. The b34 head that's already in the car has done nearly 180k so the decision was made to buy a new cam and rockers and install them in the b35 head. This will be carried out over the next couple of weeks. I did briefly consider upgraded rockers but the cost was prohibitive and we aren't revving the engine anyway.



Holset HX35 has been bought. This one has a 12cm housing, hopefully this will be just enough to reduce lag but not enough to choke the engine at higher revs.

Have also purchased a remote expansion tank and 70mm throttle body

Edited by e28525e on Wednesday 24th October 10:37

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Managed to get the engine out on Saturday. Wanted it to come out with the gearbox attached but there was just not enough room. We had to take the front pulley off as it was.




Once out, a liberal application of Gunk was applied and then washed off. Couldn't resist doing the obvious..





Then it was all taken off and Steve took the head off on Sunday ready for the B35 head. Interestingly, the original head was a carburettor casting and the cam had a lobe for fuel pump. All ready apart:





New chain guides were thought to be a good idea so these were bought. Should all be here by Friday, ready for a bit more progress on the weekend!

Cheers

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Thanks for the replies, guys.

Bit more done. Steve took the head to work and it's been skimmed and cleaned up. He lapped the valves today and got them all in place.





Meanwhile, I prepped and painted the block



Hopefully get the head fitted next week and we can get on to the fun stuff!

Cheers for now

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Update time.

Steve wanted to create an angled throttle body adapter that would sit correctly in the engine bay whilst also increasing common plenum volume. He milled this out of a solid block of aluminium today. It will all be coated the same colour as the intake manifold so should look pretty smart!