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First hurdle. The engine mounts on my M30 are apparently the later type and in no way will we be able to install the OEM S38B36 headers. My BMW guys seems to think the earlier version (11811175592) will allow the correct clearance. Trying to track one down. Looking to source one here and have a couple of feelers out. Ralph would you have one of these in case I can't find one here ?

Second hurdle. I took a gamble on the carbon fibre airbox but the one I purchased will foul the ABS unit and brake fluid reservoir. Got the following options;

1) I can remove the ABS block, re configuring the brake lines and relocate the reservoir, but this is a major task and cost.
2) I can sell the airbox I have and purchase one for an M88/3 which should fit.
3) I can ditch the airbox altogether, run trumpets and aftermarket ECU deleting the MAF.

Mmmmmm, what should I do BC hive mind ?

I'd never want to run a car without a proper air cleaner and cold-air duct, so I'd go with the M88/3 setup.

No Brainer - Options 2 + 3
Ditch the distributor and leads too, you already have the cam sensor somebody else set up for you. Just think of the aural pleasure.

I've ordered this airbox, from the same supplier;

http://www.ebay.com.au/itm/BMW-M5-E28-C ... 2060771329?

The supplier Christian is very responsive and answers questions quickly. He sent me dimensions and it should fit OK. Minor adjustments like moving dip stick and re-route brake regulator hose will be needed, but not show stoppers. BMW mechanic guy has offered to reduce price of the conversion by the cost of the original carbon air box and he will keep it. Win, win.

Option 3 will come later. Well, running an aftermarket ECU, 6 post coil pack and wasted spark firing that is. Just want to get her running for now so dizzy and OEM ECU it is.

Here's a progress shot from today. Lots to do. Next is sorting out engine harness while we wait for carbon air box and engine mount. BM Autohaus has an eclectic mix of cars in at the moment. A lovely arctic blue 2002 undergoing full sports suspension mods and the racing Fiat. I've been getting my hands dirty with all of them, helping where I can.

No doubt the carbon airbox looks fantastic... But may I ask why you are installing it? Do you feel the plenum is so much better it will yield a real performance gain? Thank you

You need to be more precise. Compared to what ? An OEM E34 M5 plenum ? Non existent.Open trumpets ? Heat induction problems.

Read thread on engine mount and what you are doing, it's clearer now :)

francoid wrote:No doubt the carbon airbox looks fantastic... But may I ask why you are installing it? Do you feel the plenum is so much better it will yield a real performance gain? Thank you

The S38B35 plenum box has the 3"air entry at the front. The S38B36 engine has the 4" air entry in the centre with a 90 degree elbow facing forward. This was designed for the E34 and when you try and put it in the E24 it fouls on the ABS unit. BMW went a lot of trouble with the design of the B36 plenum to improve torque spread across the rpm range, when you change over to the carbon airbox you lose this feature.

But boy do they look and sound good

Nice progress happening.

The OEM m88 plenum is pretty small. The trumpet entry is also very close to the wall of the plenum. Not sure of the OEM s38 plenum. The carbon one looks a good option if it can fit.

Most big power m88 and s38 seem to run open trumpets. You could fab up a heat shield to seperate the engine and radiator heat from the intake. I like the idea of running a bigger cf plenum as you are.

Thank you for the clarification. Much appreciated.

Currently at the "what the hell am I going to do for the exhaust headers" point. OEM S38B36 RHD versions foul the;

1) RH side engine mount. OEM braket was swapped for an earlier rectangular type. Clearance issue on this solved. Photos 1 and 2. 2) Steering Box. No solution for this. It would run straight through the middle of the box.

3) Thrust arm chassis pick up point. It fouls this by about half a pipe.

To get around this problem, I looked at standard M88/3 RHD stove pipes. There is a set for sale in the UK. Too expensive at 600 GBP. Fortunately, I have access to a very skilled exhaust guy who believes he can do it by modifying the OEM headers I have. Car goes in the exhaust shop 14th November.

Modify the oem headers. If he is skilled he should be able to do it without bastardising them.

Also took care of a couple other little projects. Installed the oil temp/pressure read out manufactured by Roland into the cluster. Fixed a previously bodged job on the SI batteries and circuit board (hot joint). Soldered in wires to two separate half AA battery holders, so I can replace SI batteries with ease in the future.

GazM3 wrote:Modify the oem headers. If he is skilled he should be able to do it without bastardising them.

Yes Gaz that's the plan. The guy was pretty confident he could do it. Gonna send you a PM mate for some advice on another matter.

Well, here they are, and I'm pretty pleased. Never going to get the smooth factory look but Andrew from Hyperdrive http://www.hyperdrivems.com.au has worked some magic and re-engineered those problem headers. It's still mighty tight in there though and I may have to wrap them. This was the initial fit up and a bit more tidy up work required.

I'd definitely put some sort of heat shield over that motor mount.

Wow that's tight.

Wrapping them can make them prone to rusting out. Perhaps one of those high tech coatings will be in order. I'm sure u can get the equivalent of jet hot coatings here in Victoria. It doesn't make financial sense to shop headers to Victoria and back.

We do. CIC High Performance Ceramics may be just getting a visit from me :)

http://cicceramics.com.au/coatings/exha ... -coatings/

Hi Baders
Haven't been on here for ages. Would definitely go with ceramic coating, inside and outside. A potential issue with wrapping is if they become oil impregnated, they can be difficult to extinguish, in the event of a fire.

Also see the RHD headers on the S.A. Jagermeister replica - but not sure if for the 24V.

I've booked the headers into CIC Ceramics for outside/inside "stainless" coating on 11th January. After this, well, it's time to engine harness up, bolt up, move ABS, and fire up !

Headers are back and have installed them. Came up pretty good I think, considering the options I had for this engine in a RHD car;
I have re-installed the instrument cluster complete with digital oil temp/pressure read out. My mechanic is altering the positioning of the ABS unit as it slightly fouls the new carbon fibre air box. Dropped the new Wizard radiator into place and am going to have to cut off and shut the coolant overflow bottle off take on the front of the thermostat housing as this fouls the radiator a bit. Progress !!

The headers look good. Hope they stay shiny like this.

Yeah, I reckon they look really cool. Nice & tidy job when it's all chromed up like that.

Show us that digital read out when you can please...

Coming on very nicely and those manifolds (sorry, headers) look great.
Keep up the very good work.
Any more news on the CF Intake installation? Pics?

Kev