1996 BMW E36 328i Coupe - we have history...
Discussion
There's quite a lot to report, but I don't have a great deal of time. If I don't write this up right now it's going to be at least a week before I get another chance, and potentially up to three. August has gone bonkers! Anyway, I thought I'd best get something down now, as it's better than nothing, but this will be a less full update than I would really want to give.
I was at Mallory Park over the weekend at Retro Rides Gathering 2023, including having a go at the Quick60 sprint race on the Saturday. I had a great time, however, I will come to that in a bit. First, some E36 things...
What's this?
Experienced E36 owners will probably be able to recognise it as the contents of an M52b25 cooling system adorning the road surface.
I was on my way home from visiting some friends on Friday, in the 323 convertible, kids in the back, and traffic on the A417 near Gloucester was at an absolute standstill. I tried a few detours but eventually realised there was nothing for it but to join the queue and wait it out. It was at this point, as I was waiting to rejoin the conveyor belt of doom, that poor old Derek lost control of himself and dumped his coolant all over the road, overheated and cut out. It all happened pretty quickly so I think/hope that there is no serious damage to the engine. The radiator expansion tank, however, is toast. It's got a big hole in it.
Fortunately I wasn't on the main road and I was just uphill from a field entrance so was able to roll back into it and off the road, with a bit of help from a friendly passer-by. The kids decided it was all a big adventure and spent the time waiting for the RAC man to fight his way through the traffic playing charades, adopting disabled ladybirds, playing tag, pretending to make films, and counting cars that looked like they had moustaches. When questioned later they said it was the most exciting part of the day! About five and a half hours into an hour and a half journey, I arrived back in my road ignominiously, with my fancy convertible being dragged behind an RAC patrol van.
As far as E36 cooling failures go, I've got away pretty lightly. It wasn't a fan blade through the radiator. It wasn't a water pump fracture sending fragments into the block. I know full well that the first thing anyone should do when taking possession of an E36 is to replace the entire cooling system, but I was a victim of my own hubris. I thought I'd at least get a summer of fun top-down driving out of it before doing the cooling system overhaul in the winter. I was wrong. I guess I'll be going on holiday in the Skoda instead, then!
So, with Friday gone to pot and the newer of my two toys now immobile in the garage, I packed up my tools and my camping gear for a dirty weekend away with Trixie the track car. It's about an hour and a half to Mallory from my house now, so I left bright and early on Saturday to get there in time to throw my tent up in the camping area and then go and sign on and get myself and the car sorted for the 0830 drivers' brief and the first practice runs at 0900. That preparation involved application of the snazzy Quick60 sunstrip and the slightly less snazzy vinyl wheelie bin numbers that I'd hastily ordered from Amazon Prime earlier in the week.
With it looking like a race car (sort of), I just hoped it would go like one. Being somewhat familiar with the track, I wasn't too nervous about doing the sprints, though on my first one I did get a bit carried away and did an extra lap. I was pleased to find out later that I was far from the only one! The format was a standing start from the pit exit, one full lap and then once more round Gerrards, finishing half way along the next straight. Timing was live and done by breaking beams at start and finish.
Having never done anything competitive before, I had no idea how I would stack up against any of the competition. Some of the other cars in my class looked a lot more sorted and serious than mine. I think I might have been the only one without a rollcage. As it was, after the first practice run I was sitting 7th out of 26 or so in the class, although one or two didn't do the first practice run. After the second I was 13th. My times were 91.13s and 90.76s. Consistent at least.
I went into the elimination runs in the afternoon feeling relatively confident that I'd at least get past the first round, as it was the top 16 in the class who went through, then the top ten from Round 2 into Round 3. I didn't get a great start in my first elimination run, spinning the wheels far too much off the start, and as I went quite early in the order I then had the agony of sitting watching the other competitors' times come in and my name keep dropping down the order. With four times left to come in I was sitting 14th, and fully expected to drop below 16th and out in the first round. Fortunately I stuck at 15th, with one of the favourites having a bit of a mare and ending up just below me in 16th. I breathed a sigh of relief as I'd at least get two bites at the competitive stuff. My time for Elimination 1 was 90.67s, so even with the bad start it was consistent with my practice runs. I hoped if I put a good run together in Elimination 2 I might scrape under 90s, but didn't hold out any hope of making Round 3. As it was I did put a good run together. I was happy with it, felt good and I was hopeful for a good time... 90.64! Seven hundredths of a second quicker. If there was a prize for the most consistent...
But there wasn't. I was out, as expected, but had very much enjoyed my first foray into competitive driving. For anyone interested, the full results of the competition are here:
https://www.tsl-timing.com/file/?f=SPRINT/2023/233...
The livestream is here:
https://www.youtube.com/watch?v=WFi0aO-QEzg
My runs are from 29.16 to 30.54 (Practice 2), from 2.35.00 to 2.36.36 (Elimination 1), and from 3.02.20 to 3.04.40 (Elimination 2). Practice 2 is worth a watch, if only because the commentator describes my 328i as 'gorgeous'
Being there by myself I needed to make some friends, which I managed to do with my paddock neighbours in the rather fetching red mk1 Transit and matching Triumph 2000.
I ended up hanging out with them and their friends on the Saturday evening, including at the tat auction.
This was quite entertaining, but I couldn't believe the amount of money people were throwing around. It was for charity I suppose, though which charity was never specified!
After a lovely night's sleep in my tent I was awoken by the Retro Rides dawn chorus as a smorgasbord of exhaust notes rumbled their way into my eardrums. It was a fitting way to start the day. I packed up and drove round to the show area. I couldn't be bothered to find a space in the retro parking area so I just abandoned it near the track entrance and went for a wander. My main concern at this stage was to confirm a conversation I'd had with B'stard Child in person (that's not his actual name believe it or not) the previous day where he'd said there was space in the late afternoon track time slot on the Sunday and I'd whipped out my phone there and then to make an application. I eventually managed to catch up with him in the afternoon (he was a bit busy, understandably) and confirmed my slot. I'd enjoyed wandering around looking at cool retro cars and having the odd chat about E36s, but I definitely prefer being involved in some sort of action rather than being a passive bystander so my track time was the definite highlight. I don't imagine it was anyone else's highlight mainly because most people had gone home by the time I was thrashing my old beemer round Mallory once again!
Anyway, as B'stard Child had predicted, the attrition rate was high. Those of us who were prepared to stick it out to the end got loads of track time, and it was enormous fun chasing various things around the track, particularly a clio and some sort of S13/14 drift rocket, whose driver was very obviously straining every sinew NOT to drift it all the way round Gerrards. I ended the weekend on a massive high and drove the old bucket home happy and tired. Also, I think I'm getting used to the silly exhaust. It didn't bother me much at all really on the way home even though I had the windows down most of the way.
I've probably missed lots of things I wanted to say, but it was a bit of a rushed account of things. A big thank you to B'stard Child for prompting me to go and get involved, and for his part in organising and enabling the event.
I was at Mallory Park over the weekend at Retro Rides Gathering 2023, including having a go at the Quick60 sprint race on the Saturday. I had a great time, however, I will come to that in a bit. First, some E36 things...
What's this?
Experienced E36 owners will probably be able to recognise it as the contents of an M52b25 cooling system adorning the road surface.
I was on my way home from visiting some friends on Friday, in the 323 convertible, kids in the back, and traffic on the A417 near Gloucester was at an absolute standstill. I tried a few detours but eventually realised there was nothing for it but to join the queue and wait it out. It was at this point, as I was waiting to rejoin the conveyor belt of doom, that poor old Derek lost control of himself and dumped his coolant all over the road, overheated and cut out. It all happened pretty quickly so I think/hope that there is no serious damage to the engine. The radiator expansion tank, however, is toast. It's got a big hole in it.
Fortunately I wasn't on the main road and I was just uphill from a field entrance so was able to roll back into it and off the road, with a bit of help from a friendly passer-by. The kids decided it was all a big adventure and spent the time waiting for the RAC man to fight his way through the traffic playing charades, adopting disabled ladybirds, playing tag, pretending to make films, and counting cars that looked like they had moustaches. When questioned later they said it was the most exciting part of the day! About five and a half hours into an hour and a half journey, I arrived back in my road ignominiously, with my fancy convertible being dragged behind an RAC patrol van.
As far as E36 cooling failures go, I've got away pretty lightly. It wasn't a fan blade through the radiator. It wasn't a water pump fracture sending fragments into the block. I know full well that the first thing anyone should do when taking possession of an E36 is to replace the entire cooling system, but I was a victim of my own hubris. I thought I'd at least get a summer of fun top-down driving out of it before doing the cooling system overhaul in the winter. I was wrong. I guess I'll be going on holiday in the Skoda instead, then!
So, with Friday gone to pot and the newer of my two toys now immobile in the garage, I packed up my tools and my camping gear for a dirty weekend away with Trixie the track car. It's about an hour and a half to Mallory from my house now, so I left bright and early on Saturday to get there in time to throw my tent up in the camping area and then go and sign on and get myself and the car sorted for the 0830 drivers' brief and the first practice runs at 0900. That preparation involved application of the snazzy Quick60 sunstrip and the slightly less snazzy vinyl wheelie bin numbers that I'd hastily ordered from Amazon Prime earlier in the week.
With it looking like a race car (sort of), I just hoped it would go like one. Being somewhat familiar with the track, I wasn't too nervous about doing the sprints, though on my first one I did get a bit carried away and did an extra lap. I was pleased to find out later that I was far from the only one! The format was a standing start from the pit exit, one full lap and then once more round Gerrards, finishing half way along the next straight. Timing was live and done by breaking beams at start and finish.
Having never done anything competitive before, I had no idea how I would stack up against any of the competition. Some of the other cars in my class looked a lot more sorted and serious than mine. I think I might have been the only one without a rollcage. As it was, after the first practice run I was sitting 7th out of 26 or so in the class, although one or two didn't do the first practice run. After the second I was 13th. My times were 91.13s and 90.76s. Consistent at least.
I went into the elimination runs in the afternoon feeling relatively confident that I'd at least get past the first round, as it was the top 16 in the class who went through, then the top ten from Round 2 into Round 3. I didn't get a great start in my first elimination run, spinning the wheels far too much off the start, and as I went quite early in the order I then had the agony of sitting watching the other competitors' times come in and my name keep dropping down the order. With four times left to come in I was sitting 14th, and fully expected to drop below 16th and out in the first round. Fortunately I stuck at 15th, with one of the favourites having a bit of a mare and ending up just below me in 16th. I breathed a sigh of relief as I'd at least get two bites at the competitive stuff. My time for Elimination 1 was 90.67s, so even with the bad start it was consistent with my practice runs. I hoped if I put a good run together in Elimination 2 I might scrape under 90s, but didn't hold out any hope of making Round 3. As it was I did put a good run together. I was happy with it, felt good and I was hopeful for a good time... 90.64! Seven hundredths of a second quicker. If there was a prize for the most consistent...
But there wasn't. I was out, as expected, but had very much enjoyed my first foray into competitive driving. For anyone interested, the full results of the competition are here:
https://www.tsl-timing.com/file/?f=SPRINT/2023/233...
The livestream is here:
https://www.youtube.com/watch?v=WFi0aO-QEzg
My runs are from 29.16 to 30.54 (Practice 2), from 2.35.00 to 2.36.36 (Elimination 1), and from 3.02.20 to 3.04.40 (Elimination 2). Practice 2 is worth a watch, if only because the commentator describes my 328i as 'gorgeous'
Being there by myself I needed to make some friends, which I managed to do with my paddock neighbours in the rather fetching red mk1 Transit and matching Triumph 2000.
I ended up hanging out with them and their friends on the Saturday evening, including at the tat auction.
This was quite entertaining, but I couldn't believe the amount of money people were throwing around. It was for charity I suppose, though which charity was never specified!
After a lovely night's sleep in my tent I was awoken by the Retro Rides dawn chorus as a smorgasbord of exhaust notes rumbled their way into my eardrums. It was a fitting way to start the day. I packed up and drove round to the show area. I couldn't be bothered to find a space in the retro parking area so I just abandoned it near the track entrance and went for a wander. My main concern at this stage was to confirm a conversation I'd had with B'stard Child in person (that's not his actual name believe it or not) the previous day where he'd said there was space in the late afternoon track time slot on the Sunday and I'd whipped out my phone there and then to make an application. I eventually managed to catch up with him in the afternoon (he was a bit busy, understandably) and confirmed my slot. I'd enjoyed wandering around looking at cool retro cars and having the odd chat about E36s, but I definitely prefer being involved in some sort of action rather than being a passive bystander so my track time was the definite highlight. I don't imagine it was anyone else's highlight mainly because most people had gone home by the time I was thrashing my old beemer round Mallory once again!
Anyway, as B'stard Child had predicted, the attrition rate was high. Those of us who were prepared to stick it out to the end got loads of track time, and it was enormous fun chasing various things around the track, particularly a clio and some sort of S13/14 drift rocket, whose driver was very obviously straining every sinew NOT to drift it all the way round Gerrards. I ended the weekend on a massive high and drove the old bucket home happy and tired. Also, I think I'm getting used to the silly exhaust. It didn't bother me much at all really on the way home even though I had the windows down most of the way.
I've probably missed lots of things I wanted to say, but it was a bit of a rushed account of things. A big thank you to B'stard Child for prompting me to go and get involved, and for his part in organising and enabling the event.
Loved reading this whole thread (over the last two days!)
I've gone through a similar journey with a (rather less pretty) E46 325ti (Compact). I respect the agile approach you've taking to using and fixing it... I very much took a "fix almost everything before daring to take it onto track", and as a result it has seen one (faultless) track day in the last 3 years...
I do have a couple more booked for later this year, though...
I've gone through a similar journey with a (rather less pretty) E46 325ti (Compact). I respect the agile approach you've taking to using and fixing it... I very much took a "fix almost everything before daring to take it onto track", and as a result it has seen one (faultless) track day in the last 3 years...
I do have a couple more booked for later this year, though...
Diesel_Nick said:
Loved reading this whole thread (over the last two days!)
I've gone through a similar journey with a (rather less pretty) E46 325ti (Compact). I respect the agile approach you've taking to using and fixing it... I very much took a "fix almost everything before daring to take it onto track", and as a result it has seen one (faultless) track day in the last 3 years...
I do have a couple more booked for later this year, though...
Yes… agile… that’s definitely what it is I've gone through a similar journey with a (rather less pretty) E46 325ti (Compact). I respect the agile approach you've taking to using and fixing it... I very much took a "fix almost everything before daring to take it onto track", and as a result it has seen one (faultless) track day in the last 3 years...
I do have a couple more booked for later this year, though...
Glad you enjoyed reading it. I’m hoping there’ll be more action over the winter months (subframe and bodywork type action) and less musing. I’ll try and keep the musing to a minimum. More pictures of rust and broken parts, less misty-eyed philosophical thoughts.
I’ve been away for a while. Meanwhile, Derek’s been languishing in the garage with a knackered radiator.
I had a bit of time this evening, so, having ordered a new radiator last night, I thought I’d whip out the old one. As I couldn’t figure out how the undertray was fixed on, I ended up taking the bumper off to have a better look. It’s not exactly difficult, and I had an ulterior motive anyway.
Interestingly, when I drained what was left of the contents of the radiator, it appeared just to be water. I applied the powers of my eyes and my nose to determine that, as far as I can tell, it was in fact just water. No coolant/antifreeze in sight (or smell). Weird.
Out came the radiator, and the damage was plain to see. It had blown a big old hole in the plastic expansion tank.
Hopefully my new one will arrive in the next few days and I’ll be able to get out with the roof down before this spell of hot weather passes. I bet it tips it down as soon as I get the car back together though!
I know I ought to replace the water pump,thermostat housing, hoses, fan and fan clutch while I’m in there, but… I still don’t know whether I’m keeping it yet, and I want to get it done quickly to take advantage of the weather. So I’ll stick a new rad in it and continue playing Bavarian roulette with the rest of the system!
Ooh, a game of spot the difference:
The top one is the 323, the bottom one the 328. At some point the 323 appears to have lost its fan cowl, assuming it had one. I’ll check on RealOEM, but can’t imagine why it wouldn’t have had one originally.
What about the bumper?
You may remember that I put a cheapo reproduction lip on it, which ended up all wrong, pointing up at the sky in the middle
I thought I’d have a go at re-fixing it further back so that it sits properly. It had enough flex/movement in it that I could adjust it, drill new holes, and put it back together. I think it looks better, but will confirm with pictures when the car is all back together and on the ground.
Just waiting for that new radiator now…
I had a bit of time this evening, so, having ordered a new radiator last night, I thought I’d whip out the old one. As I couldn’t figure out how the undertray was fixed on, I ended up taking the bumper off to have a better look. It’s not exactly difficult, and I had an ulterior motive anyway.
Interestingly, when I drained what was left of the contents of the radiator, it appeared just to be water. I applied the powers of my eyes and my nose to determine that, as far as I can tell, it was in fact just water. No coolant/antifreeze in sight (or smell). Weird.
Out came the radiator, and the damage was plain to see. It had blown a big old hole in the plastic expansion tank.
Hopefully my new one will arrive in the next few days and I’ll be able to get out with the roof down before this spell of hot weather passes. I bet it tips it down as soon as I get the car back together though!
I know I ought to replace the water pump,thermostat housing, hoses, fan and fan clutch while I’m in there, but… I still don’t know whether I’m keeping it yet, and I want to get it done quickly to take advantage of the weather. So I’ll stick a new rad in it and continue playing Bavarian roulette with the rest of the system!
Ooh, a game of spot the difference:
The top one is the 323, the bottom one the 328. At some point the 323 appears to have lost its fan cowl, assuming it had one. I’ll check on RealOEM, but can’t imagine why it wouldn’t have had one originally.
What about the bumper?
You may remember that I put a cheapo reproduction lip on it, which ended up all wrong, pointing up at the sky in the middle
I thought I’d have a go at re-fixing it further back so that it sits properly. It had enough flex/movement in it that I could adjust it, drill new holes, and put it back together. I think it looks better, but will confirm with pictures when the car is all back together and on the ground.
Just waiting for that new radiator now…
It's been a little while. I have been doing car stuff but lost the motivation to write about it at the time. So I'll summarise for now, which will probably turn into a gargantuan epic anyway as I ramble on. Let's see...
So, Derek. The 323i convertible. Last update was that I was waiting for a radiator...
The old blown radiator had a coolant level sensor in it, which was not plugged into anything. I couldn't see that the loom had any provision for it. This is not surprising as the car doesn't have an OBC and therefore no way of communicating a low coolant signal to the driver. I thought 'no need for a sensor, then,' and left the plastic blanking cap that came with the new radiator screwed onto that hole. I'm a frickin' genius.
This was after fitting the new radiator. I rather optimistically thought, 'maybe I overfilled it and it's just shedding some excess coolant.' Obviously that wasn't the case, and I ended up pulling over on the way home with all my lovely new coolant pissing out all over the road. Rather than calling the RAC (again), I thought a better bet time-wise would be to call my parents, who don't live too far away. They went and bought a brand new tow strap to mark this auspicious occasion, and towed me home. While we were waiting, my son (8) asked me why we kept breaking down. I said it was because I buy silly cars, which prompted him to ask if I could just buy normal cars from now on. I can see I have some educating to do.
When my parents arrived on the scene we reminisced about the last time my dad came to tow me home, which was when I crashed my old mini into several other cars on the A44 when I was 17 and he had to rescue me and my twisted lump of mini. Fun times.
To be fair, Derek is still gorgeous even when he's broken down.
I have since ordered and fitted a coolant level sensor in that hole, which is not plugged into anything but should at least provide a decent seal to stop the coolant falling out again. I haven't done much mileage in it since, but it seems to be holding up ok as far as I can tell.
One drama I had with the new radiator (apart from all the fluid falling out of it) was that the bleed screw appeared to be made out of cheese. Either I'm stronger than I thought I was, or this thing was as soft as fresh snow.
Fortunately, because it was so soft, I was able to sink a screwdriver into what was left and get it out without too much trouble.
This led me to an unfortunate discovery after I tried the screw from the old radiator and the one from the track car in the hole. Radiator bleed screws for the radiators available for these cars have different thread pitches. This is annoying to say the least! I even ordered a new brass one, and did it fit? Of course it bloody didnt.
Oh, I mentioned the front lip. I did re-drill the holes and pulled it back a bit in the middle, and I think it looks much better.
He has now gone into hibernation, but is still really, really, ridiculously good-looking.
Meanwhile, Trixie the track car has gone into the garage for major surgery...
So, Derek. The 323i convertible. Last update was that I was waiting for a radiator...
The old blown radiator had a coolant level sensor in it, which was not plugged into anything. I couldn't see that the loom had any provision for it. This is not surprising as the car doesn't have an OBC and therefore no way of communicating a low coolant signal to the driver. I thought 'no need for a sensor, then,' and left the plastic blanking cap that came with the new radiator screwed onto that hole. I'm a frickin' genius.
This was after fitting the new radiator. I rather optimistically thought, 'maybe I overfilled it and it's just shedding some excess coolant.' Obviously that wasn't the case, and I ended up pulling over on the way home with all my lovely new coolant pissing out all over the road. Rather than calling the RAC (again), I thought a better bet time-wise would be to call my parents, who don't live too far away. They went and bought a brand new tow strap to mark this auspicious occasion, and towed me home. While we were waiting, my son (8) asked me why we kept breaking down. I said it was because I buy silly cars, which prompted him to ask if I could just buy normal cars from now on. I can see I have some educating to do.
When my parents arrived on the scene we reminisced about the last time my dad came to tow me home, which was when I crashed my old mini into several other cars on the A44 when I was 17 and he had to rescue me and my twisted lump of mini. Fun times.
To be fair, Derek is still gorgeous even when he's broken down.
I have since ordered and fitted a coolant level sensor in that hole, which is not plugged into anything but should at least provide a decent seal to stop the coolant falling out again. I haven't done much mileage in it since, but it seems to be holding up ok as far as I can tell.
One drama I had with the new radiator (apart from all the fluid falling out of it) was that the bleed screw appeared to be made out of cheese. Either I'm stronger than I thought I was, or this thing was as soft as fresh snow.
Fortunately, because it was so soft, I was able to sink a screwdriver into what was left and get it out without too much trouble.
This led me to an unfortunate discovery after I tried the screw from the old radiator and the one from the track car in the hole. Radiator bleed screws for the radiators available for these cars have different thread pitches. This is annoying to say the least! I even ordered a new brass one, and did it fit? Of course it bloody didnt.
Oh, I mentioned the front lip. I did re-drill the holes and pulled it back a bit in the middle, and I think it looks much better.
He has now gone into hibernation, but is still really, really, ridiculously good-looking.
Meanwhile, Trixie the track car has gone into the garage for major surgery...
Sammo123 said:
How’s the track car doing? Anymore outings planned for this year?
I’ve finally started back on my E36 getting the rear axle rebuilt. It’s only taken me three years
You asked, so I shall answer. Probably at great length...I’ve finally started back on my E36 getting the rear axle rebuilt. It’s only taken me three years
First of all, what a coincidence!
The SS Rear Axle has been recovered from the sea bed after lying there for several decades. Or that's what it looks like anyway.
It's horrific. Despite the crustiness levels being off the charts, it was actually not that hard a job to get the whole assembly off the car. The rattle gun was my friend. The hardest part was getting one of the handbrake cables to pull back through its tunnel. It was clinging on like a toddler to a doorframe when you're trying to get them to go to bed. I managed to persuade it out in the end though.
I briefly contemplated cleaning up all the parts, painting, re-bushing (with poly bushes) and putting it all back in. Then I thought, 'screw that for a game of soldiers,' and sent A LOT of money to a guy on Facebook, who I'm very much hoping will send me something like this very soon.
It comes (if it comes at all...) fully poly bushed, with wheel bearings fitted, and an uprated ARB. Given the amount of money I was going to spend on bushes alone, let alone the money, time and effort involved in cleaning and painting everything, I thought it well worth spending a little more for the privilege of not having to do all that soul-destroying de-rustification.
The diff was just as dirty/crusty.
That was just after a fairly cursory hack at it with a screwdriver. I've now drained it (DON'T LET ME FORGET I'VE DRAINED IT) and taken it to a local engineering place for them to stick in their parts washer. I'll then give it a rub down and a coat of Hammerite or something. I can cope with doing that to one part. I can't cope with doing a full rear axle!
I contemplated getting an LSD, rather than sticking with the standard open diff that came with the car in the first place (when it was an auto). I just don't think the extra enjoyment I'd get from an LSD would be worth the money they cost though. I quite like the ratios on mine, it works quite well for track work, and the open-ness of it hasn't bothered me in the slightest. So I thought I'd save that upgrade for the future and stick with what I've got for now.
I've been ordering some new hardware to go with the subframe/axle. A lot of the nuts and bolts are ok, and just need a bit of a clean on the heads. Others are relatively new anyway because I've had to replace them in the last few years. I've ordered what I think I need to replace. Next is some new driveshafts because I think separating the old ones from the hubs would be a job for Thanos, plus they're horrible and crusty anyway.
I'm very much looking forward to getting the diff sorted, receiving my new subframe/axle parts, and starting to put it all back together.
Meanwhile, whilst it's off the car, I've had a mobile welder in. The spare wheel well and battery tray had rusted through badly, three of four jacking points are in a pretty bad way, both front wings have rusty holes through them, and the front left inner arch was quite bad too.
All nicely finished and he even undersealed the crap out of everything he could see, which saved me a job. Mind you, I haven't had the bill yet...
The jacking points and outer wings still need doing, but the wings need to come off for that to happen, and it needs to not be sitting on the rear jacking points (because there isn't much else for it to sit on back there at the moment). I'll get the welder back another time when I've made some progress.
I'm excited to get it back together and see how it feels, but I'm also a bit apprehensive. I like the feel and the balance of the car on the track days I've done over the last couple of years, and changing so much all at once (fully polybushing the rear and uprating the ARB) worries me just a little in case I make it too stiff and harsh and lose the handling characteristics. However, I'm committed, so we'll just have to see what happens!
skylarking808 said:
Ah the joys of a crusty E36 
Good write up as usual. At least the work is heading in the right direction. Funny how Deriks good looks mean you can forgive it for breaking down!
He is so pretty. I’ve been thinking quite a lot about what to do next year, whether I should keep him or not, but I think he’s got so far under my skin that there’s not much chance of getting rid of him now. I mean, giving him a name was probably a pretty big nail in that particular coffin! I’ll look forward to the first sunny days of spring when my cheap and cheerful convertible can ride again. Good write up as usual. At least the work is heading in the right direction. Funny how Deriks good looks mean you can forgive it for breaking down!
I suppose that means a full cooling system overhaul then…
Gallons Per Mile said:
I believe you can convert an open diff to an LSD fairly cheaply via the Racing Diffs website. Might be worth it especially as it's a track car!
Fascinating. I had no idea that was even a thing. Turn my diff into an LSD for £200? I think I’m going to have to have me some of that!It looks a bit like Christmas...
Most of the bits are here. They definitely look better than the barnacle-encrusted stuff that came out!
The ARB is on its way separately. Meanwhile, I've had the diff case cleaned and parts vapour blasted.
I've wire brushed and cleaned the main casing and now I'm giving it a bit of paint.
Once that's done I'll do the really exciting bit.
Thanks to GPM for pointing me in the direction of RacingDiffs. This conversion kit cost me £200 including delivery in their Black Friday sale. I then had to pay another £65 import tax, but even then it's a third of the price of a used LSD for one of these (I saw one advertised on FB Marketplace the other day for £750). The installation video makes it look eminently DIY-able, at least until the guy put his output shafts on a lathe to trim 4mm off each of them...
I looked all over my garage but couldn't find a lathe, so I had to get the guy who vapour blasted my parts to do it for me. That's added expense of course. With the cleaning, blasting and machining, I'm about £400 deep into this diff overhaul. I'm happy with my ratio and it'll look fine once it's tarted up, so £400 to turn it into an LSD isn't bad at all. As long as it does what it says it does.
Most of the bits are here. They definitely look better than the barnacle-encrusted stuff that came out!
The ARB is on its way separately. Meanwhile, I've had the diff case cleaned and parts vapour blasted.
I've wire brushed and cleaned the main casing and now I'm giving it a bit of paint.
Once that's done I'll do the really exciting bit.
Thanks to GPM for pointing me in the direction of RacingDiffs. This conversion kit cost me £200 including delivery in their Black Friday sale. I then had to pay another £65 import tax, but even then it's a third of the price of a used LSD for one of these (I saw one advertised on FB Marketplace the other day for £750). The installation video makes it look eminently DIY-able, at least until the guy put his output shafts on a lathe to trim 4mm off each of them...
I looked all over my garage but couldn't find a lathe, so I had to get the guy who vapour blasted my parts to do it for me. That's added expense of course. With the cleaning, blasting and machining, I'm about £400 deep into this diff overhaul. I'm happy with my ratio and it'll look fine once it's tarted up, so £400 to turn it into an LSD isn't bad at all. As long as it does what it says it does.
You should replace the polybushes in the trailing arm by the hub with ball joints if you can - better location and less wind-up. That's how the M3 comes from the factory. Cheap as well with lemforder parts.
I think you can do the same with the larger front bush but it's not such a big deal.
I think you can do the same with the larger front bush but it's not such a big deal.
Court_S said:
Pisser about the vice exploding - was looking forward to seeing the diff rebuilt as an LSD.
Do you think the 323 will stay? Hopefully it won't be too much longer until you can enjoy roof down motoring again.
I'll get to it. My new vice is waiting at home for me now. The first stage of inserting the plates into the diff is to put the springs between them and compress them together. You then secure them with little brackets that screw into the ends of the plates. The brackets then come off again once you've inserted the assembly into the diff.Do you think the 323 will stay? Hopefully it won't be too much longer until you can enjoy roof down motoring again.
I was surprised by the amount of force required to compress the springs, but not as surprised as my cheap bench vice was, apparently!
I think the 323 will be staying. I'm not realistically going to be in a position to get and properly look after an M3, and driving Derek doesn't half put a smile on my face. Besides, I gave him a name. I think after that the deal was sealed, really!
New vice mounted on the bench, enabled this:
Which then went in here:
Everything was liberally coated in diff oil, then I released the grub screws with some trepidation. I thought that once released there would be no moving it, given how stiff those little yellow springs are, and the chances of releasing the thing perfectly aligned with the hole for the pin were about zero. But actually after releasing the pressure, it was possible to nudge it one way or the other with a gentle tap with a lump hammer. So, springs released, holes aligned, and the pin reinserted, again with a bit of help from the lump hammer. It went back together more smoothly than I could have hoped really. Next will be reassembling the whole thing back into the case (including the input shaft seal which was a pain in the backside to get out and it turns out I didn’t need to remove. Story of my life really. I couldn’t find a seal exactly like the one that came out. I think the new one is a millimetre thicker (same internal and external diameter though) so I’m not sure whether I’ve given myself a headache there. I guess I’ll find out.
Which then went in here:
Everything was liberally coated in diff oil, then I released the grub screws with some trepidation. I thought that once released there would be no moving it, given how stiff those little yellow springs are, and the chances of releasing the thing perfectly aligned with the hole for the pin were about zero. But actually after releasing the pressure, it was possible to nudge it one way or the other with a gentle tap with a lump hammer. So, springs released, holes aligned, and the pin reinserted, again with a bit of help from the lump hammer. It went back together more smoothly than I could have hoped really. Next will be reassembling the whole thing back into the case (including the input shaft seal which was a pain in the backside to get out and it turns out I didn’t need to remove. Story of my life really. I couldn’t find a seal exactly like the one that came out. I think the new one is a millimetre thicker (same internal and external diameter though) so I’m not sure whether I’ve given myself a headache there. I guess I’ll find out.
I've been far too lax recently. At this rate I won't have the car back together to do any track days this summer. I finally got round to spending some time on it today though.
My main headache, and probably the sticking point that has prevented me from getting on with it, is what to do with the brake lines. Yonks ago I bought a whole set of braided lines. I put the front ones on, no problem. Getting to the unions on the rears was problematic, however. Especially given how rusted and seized up they are. So they've just been on the shelf since.
Well, now the rear subframe is off, I have unfettered access to all the rear brake line I could want. If I don't replace them now, then when? But... the things are rusted to buggery. I've spent months soaking them in penetrant, and completely mangled a nut or two with mole grips trying to get them to release. I was wrestling with the idea of just leaving them as they are. After all, they work fine. But I can't bring myself to leave them alone whilst I've got the rear in bits. They are exposed now. I have to do something with them.
I drained and dropped the fuel tank (only a bit, I don't really want to go pulling all the hoses and things out, so just enough to give me some space above it). I thought, if I could get the unions just in front of the fuel tank to undo, maybe I could replace everything from there backwards. But would they let go? Would they hell! So I'm a bit stuck. I don't really want to try heat, because I suspect the amount they would need would be extreme, and I don't have much experience of heating things, especially things next to petrol tanks. I'd either half-arse it because I'm scared of going up in a fireball, and still get nowhere, or go up in a fireball. Neither of which would be particularly productive.
But today I have settled on a strategy. I watched a YouTube video of Eric the Car Guy (I'm sure many of you will have come across him) flaring a cut brake pipe on a car using a tool similar to this:
So, instead of undoing anything, my plan is to cut the line, flare the end (without eating the grease), then connect to my nice new (several years old) braided lines. And then probably some new calipers because mine look like they've been under the sea with the old subframe.
I feel like I've overcome something of a mental block. I have a plan now. Once I've sorted the brake pipes, I can lego everything back together again. I'm sure it'll be as straightforward as just bolting it all back on. I can't imagine anything will go wrong, it never normally does.
Beyond having a cunning plan and ordering the bits and pieces I need to achieve it, I have also been putting things back together.
The diff, with the clever LSD plates in:
I have bought a gasket for it but couldn't find it, so used some of this stuff that I bought for something else and hadn't used. Because I'm impatient, and an idiot. No picture of 'in progress' because it looks like it was applied by a toddler. It's definitely going to leak.
Strongflex bushes to match those on the subframe and suspension bits. And a label saying 'no oil,' again because I'm an idiot. I will forget to put oil in it. At least then it wouldn't leak, though.
The diff reassembled, and the cover bolts torqued to the limit of my bravery (which turns out to be almost certainly too much, but at least they didn't snap), I turned my attention to the subframe. There are some threaded holes for the diff to be bolted into, which had been powder coated. I had to break out my taps and got a sweat on.
Then I put some bits together.
Actually, another blocker to my progress was that I had allowed the garage to get into a bit of a state, with stuff everywhere. Now I've tidied and cleaned up, and made a bit of progress, hopefully I can stay in the groove and get on with it. The next update is likely to be when I've cut off the ends of my brake lines and made an absolute hash of flaring them. I'll almost certainly forget to put the nut on the pipe before I flare it. That will be hilarious. For everyone else.
I haven't even thought about track days yet. I'd like to do the Quick60 again if I can get it sorted (hopefully I can by August). That was fun last year.
My main headache, and probably the sticking point that has prevented me from getting on with it, is what to do with the brake lines. Yonks ago I bought a whole set of braided lines. I put the front ones on, no problem. Getting to the unions on the rears was problematic, however. Especially given how rusted and seized up they are. So they've just been on the shelf since.
Well, now the rear subframe is off, I have unfettered access to all the rear brake line I could want. If I don't replace them now, then when? But... the things are rusted to buggery. I've spent months soaking them in penetrant, and completely mangled a nut or two with mole grips trying to get them to release. I was wrestling with the idea of just leaving them as they are. After all, they work fine. But I can't bring myself to leave them alone whilst I've got the rear in bits. They are exposed now. I have to do something with them.
I drained and dropped the fuel tank (only a bit, I don't really want to go pulling all the hoses and things out, so just enough to give me some space above it). I thought, if I could get the unions just in front of the fuel tank to undo, maybe I could replace everything from there backwards. But would they let go? Would they hell! So I'm a bit stuck. I don't really want to try heat, because I suspect the amount they would need would be extreme, and I don't have much experience of heating things, especially things next to petrol tanks. I'd either half-arse it because I'm scared of going up in a fireball, and still get nowhere, or go up in a fireball. Neither of which would be particularly productive.
But today I have settled on a strategy. I watched a YouTube video of Eric the Car Guy (I'm sure many of you will have come across him) flaring a cut brake pipe on a car using a tool similar to this:
So, instead of undoing anything, my plan is to cut the line, flare the end (without eating the grease), then connect to my nice new (several years old) braided lines. And then probably some new calipers because mine look like they've been under the sea with the old subframe.
I feel like I've overcome something of a mental block. I have a plan now. Once I've sorted the brake pipes, I can lego everything back together again. I'm sure it'll be as straightforward as just bolting it all back on. I can't imagine anything will go wrong, it never normally does.
Beyond having a cunning plan and ordering the bits and pieces I need to achieve it, I have also been putting things back together.
The diff, with the clever LSD plates in:
I have bought a gasket for it but couldn't find it, so used some of this stuff that I bought for something else and hadn't used. Because I'm impatient, and an idiot. No picture of 'in progress' because it looks like it was applied by a toddler. It's definitely going to leak.
Strongflex bushes to match those on the subframe and suspension bits. And a label saying 'no oil,' again because I'm an idiot. I will forget to put oil in it. At least then it wouldn't leak, though.
The diff reassembled, and the cover bolts torqued to the limit of my bravery (which turns out to be almost certainly too much, but at least they didn't snap), I turned my attention to the subframe. There are some threaded holes for the diff to be bolted into, which had been powder coated. I had to break out my taps and got a sweat on.
Then I put some bits together.
Actually, another blocker to my progress was that I had allowed the garage to get into a bit of a state, with stuff everywhere. Now I've tidied and cleaned up, and made a bit of progress, hopefully I can stay in the groove and get on with it. The next update is likely to be when I've cut off the ends of my brake lines and made an absolute hash of flaring them. I'll almost certainly forget to put the nut on the pipe before I flare it. That will be hilarious. For everyone else.
I haven't even thought about track days yet. I'd like to do the Quick60 again if I can get it sorted (hopefully I can by August). That was fun last year.
To remove rotten brake unions I use my plumbing blow torch with MAPP gas which is apparently very hot. Just heat the union directly for a good 30 seconds and then get a spanner straight on to it and it should undo no problem. If not, rinse and repeat with the heat. It's not difficult to do but be sensible around any fuel lines. I had to do this on all four corners of the family A4 Avant last year and heat made it a simple job. Ideally you don't want extra unions and flares where you've had to cut pipes - it's more to go wrong and leak. Flaring lines on the car is also annoying and fiddly to do well.
Looking forward to knowing what you think about the diff upgrade. They seem to be good
Looking forward to knowing what you think about the diff upgrade. They seem to be good
Gassing Station | Readers' Cars | Top of Page | What's New | My Stuff