1983 BMW E24 635csi Track Car Turbo Build

[e28525e]

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

[e28525e]

[e28525e]

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

[rallycross]

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.

[e28525e]

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?

[e28525e]

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

[alabbasi]

Nice project. Here's my contribution

85 M635CSI



88 M5

[sixpistons]

alabbasi said:

Nice project. Here's my contribution

88 M5

Awesome car - love the plate!

[e28525e]

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

[e30m3Mark]

Looking forward to seeing how this goes.

[GreatGranny]

Loving this thread.

Have owned a few older Beemers including an E21 315 which I'm told by my Ex. forces B in L who sold it me, was a RHD import from Germany.
Not sure if this is true but was a great car but unfortunately rust got the better of it.
Wish I'd kept it and repaired it now.

[deadslow]

one of the few old beemers I have never owned/driven, so very envious! Looks great.

[e28525e]

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

[e28525e]

[e28525e]

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!

[e30m3Mark]

Nicely done.

[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

[Output Flange]

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.

[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!