1983 BMW E24 635csi Track Car Turbo Build

[e28525e]

Set about stripping and cleaning the engine bay yesterday, the e24 was fitted with a booster that's combined with the power steering system. Rather complex, heavy and unnecessary for track so it had to go. It will be replaced by an e34 vacuum servo. Sorry the pics are a bit fuzzy, they're screenshots from video





All removed and cleaned :







Meanwhile, Steve continued to assemble the engine:

Edited by e28525e on Sunday 18th November 08:47

[e28525e]

More progress

Spent the morning ridding the bay of brackets that won't be needed and painting with rust convertor and primer.





Intake manifold modified to accept the throttle body adapter





Oil return spot welded, test fitted and ready for final weld and paint



Cheers

[e28525e]

Output Flange said:

You can use the electric PAS pump from a Merc A Class, if you want to lose some of the parasitic load on the engine.

I think parasitic loss would be an issue on an na engine but I'm not worried about it on this. It will have a lightweight flywheel which should help with response. Thanks anyway!

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Not a huge amount of progress recently due to a combination of weather and Steve being snowed under at work. Intake manifold is currently at the welders and should be ready by tomorrow so that we can take it, the strut brace and this to the coaters.

[e28525e]

Part one

https://youtu.be/PSCiXTrJgvY

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Turbotechnic said:

Coming along nicely. That’ll certainly wake you up when it comes on boost! I work with Steve, that engine will be awesome. Keep up the good work.

Thanks, mate. Steve is a great bloke

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rallycross said:

Good work will be great once finished!

Thanks and hope so!

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sdotmac]28525e said:

"Set about stripping and cleaning the engine bay yesterday, the e24 was fitted with a booster that's combined with the power steering system. Rather complex, heavy and unnecessary for track so it had to go. It will be replaced by an e34 vacuum servo. Sorry the pics are a bit fuzzy, they're screenshots from video.."

Did you complete the E34 vacuum servo mod? Hate the brakes in mine - E32 master/lines/big caliper/disc combo on way and will see if this does the job but the general setup, link and hydro, offends me and have been teapotting about to see what could fit. Keen to hear how you're going.

Its all there and bolted in. Not tested yet but i will report back. Just pm me if i forget

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rallycross said:

some inspiration for you to keep going, these cars are something special

Great shot

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aaron_2000 said:

It's a waste of a build if you don't call it the TurboShark.

I'll have to get a badge made up..

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Picture of progress so far

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Part 2 of the build:

https://youtu.be/eX_nuAlW9UI

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1602Mark said:

That's a few weeks pocket money you've invested there fella! Is looking great though. The guy that looks after my cars built an M30 turbo'd E30 recently, that made well over 600 brake with enough torque to raise the Titanic! I know yours is a little more reserved but it should still move along nicely.

Yeah, can't be doing these things on the cheap!
It is incredible what these lumps will stand, I've seen builds that are making that figure with a stock bottom end! Not bad for an engine designed in the 60's..

[e28525e]

rallycross said:

wow love the quality of your work that looks fantastic! Adjustable top mounts look nice on the struts..

Cheers. I have a great friend who is helping me. Got to look the part as well hasn't it!

[e28525e]

shalmaneser said:

what was the deal with the tubular manifold? was the fit really that bad - i guess being RHD makes things a lot tighter!

this is a great project btw!

I changed my mind with it as i didnt want to be dealing with cracking and warping, such is the nature of 304 ss, the fit was actually pretty good - better than the cast one. We shouldn't be limited by the log manifold as we're not making 600bhp plus or anything..

[e28525e]

Another day on the 6er with my mate Steve. Fuel system now 95% done. Just got to connect the fuel lines under the car to the swirl pot/pumps and then to the rail itself. Should have the fittings needed by next weekend. Hopefully we can get most of the exhaust finished next weekend. After that, the turbo and downpipe can be removed, wrapped and bolted on for the last time and then work can start on the wiring.

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Output Flange said:

Is that a custom fuel rail?

Yes and no! It's a Nuke Performance rail that's designed for M88/S38 but needs a bit of 'editing' to make fit along with injector extenders.

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1602Mark said:

Cracking job you've done there. Looks a really nice install.

Cheers!

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Sorry about the long time between updates! We've made a good deal of progress and hopefully we can start it this Saturday. At the moment we just have to remove the downpipe, weld a boss in for the EFR and heatwrap it ready to bolt it all back up for the final time. Compressor housing needs drilling and tapping for the wastegate and the sump needs tapping for the oil temp sensor. Should be a good half days work.

My friend Andy has sent me the map file from his Alpina E12 B7S that's also on Emerald which is very kind and should give us a good starting point.
Part 3 here: https://youtu.be/_kyG9SKLNvAere And here are a few pictures

Edited by e28525e on Tuesday 8th October 08:47