Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Document your Sixer project here.

Moderators: GRNSHRK, ron, bfons

Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

tschultz wrote:Great, thanks for clarifying. To fit the later model subframe, does this mean you have reinforced the subframe mount, or is tearing no longer an issue with the new design? I imagine it is a custom setup you guys used...
We reinforced it. Stiffener plates and a solid square bare welded through and into the entire transverse beam. Then the bomb proof diff mount. There was also a tear in the floor which we welded up. Go back to page 1 and top of page 2 and you can see a bit of this work. (wait, wrong forum for those pages. Go here http://www.bimmerforums.com/forum/showt ... s-d-633CSi

With 430nm of torque I wanted to be sure. Car is 39 years old this year.
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

Update, all parts in for final build.

Parts to go on;

1. Complete head re-build. Will run CATCAMS 293/279 cam with 12.45mm valve lift - http://catcams.co.uk/acatalog/1301008.pdf . Cams now here to install.
2. Will run performance valves, springs, seats, retainers, the lot. Here to install.
3. Will run the megasquirt MS3-PRO stand alone ECU. Here to install.
4. Will run PLX multi-gauges (2 of) and water temp/pressure, oil temp/pressure and A/F direct live stream to the gauges. TNT'ing across now. http://www.plxdevices.com/Automotive-Ga ... -s/108.htm
5. Will run 135i turbo front 6 piston calipers with hopefully 338mm by 28mm discs. Purchased, pick up Thursday. Rears are already 540i's.
6. New used un-cracked dash to go in.
7. Twin age correct recaros to go in.
8. internal under dash fan and evaporator to come out. To lighten her up a little (and it does not work!).
9. Large case 3.71 LSD now in.
10. New carpet to be sourced. Have 6sqm of Alpina Cloth so will re-upholster the car when carpet is done (next year).

So, over the next 4 weeks of completing the above build she should be close to 390hp, under 1480kg, 338mm 6 piston big brakes front, and well on her way to being the fastest NA 633 in Aus. Hopefully dyno and then first test drive in 4 weeks time.

Image

Image

Image
baders
Platinum Member
Platinum Member
Posts: 1084
Joined: Sun Nov 23, 2014 7:38 am
Location: Perth Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by baders »

Great news Josh. Also adding MegaSquirt to the list, though mine will probably be MS3 Assembled because I can't be bothered with the hassle of coil on plug.
1986 635csi LOCUTUS / Arktis Blau Metallic / Pearl Beige / S38B36/ Close ratio dogleg 5sp
2002 E46 M3 / Topaz Blau Metallic / Black Nappa / 6 speed SMG software tuned / Bilstein PSS10 Coilovers / CMP RACP reinforcement
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

CatCams have arrived in the office along with the hight strength valves, retainers, caps, springs etc.

Off to mechanic today.

Image
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

Update- VAC sent the wrong valves sending B36. B38 valves arrived yesterday and head off to machine shop today.

Hopefully together and running early next week. Then off to dyno shop to have megasquirt ms3 pro installed and tuned. Only issue is whether or not my dyno shop is booked out prior to Christmas.
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

Catcams in and engine back together. Needs fnalising over the coming two weeks and a change to the S50 timing chain tensioner. Hopefully to the dyno late Jan.

Image
baders
Platinum Member
Platinum Member
Posts: 1084
Joined: Sun Nov 23, 2014 7:38 am
Location: Perth Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by baders »

Nice work Josh. I'm still intrigued as to your cooling solution used ? Is there an electric pusher fan in front of the radiator ?
1986 635csi LOCUTUS / Arktis Blau Metallic / Pearl Beige / S38B36/ Close ratio dogleg 5sp
2002 E46 M3 / Topaz Blau Metallic / Black Nappa / 6 speed SMG software tuned / Bilstein PSS10 Coilovers / CMP RACP reinforcement
User avatar
ericono
Posts: 500
Joined: Fri Mar 23, 2007 1:51 am
Location: Spartanburg, SC

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by ericono »

Curious about more info on the brakes. What size wheels are you running again? 17"? Will those calipers properly fit inside them and still grip the rotor? I ask becuase I thought the original wheel size these were designed for was 18 or 19" wheels. Also, are you changing the master cylinder? Do you know the piston diameters in those 6 piston calipers?

Sorry for all the questions and thanks for sharing,

Eric
'85 M635, '00 528iT, '98 Z3
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

ericono, the wonderful thing about BMW wheels is that the Aussie Holden Commodore uses the same 5 bolt, 20mm offset 120mm bolt spacing layout. So over here, we have plenty of wheels to fit our beemers. That also means that we have plenty of disk brakes.

So;

The 135i uses a 333mm disk. The Holden Commodore v6 and v8 from around 2006 uses a 328mm diameter disk. The 5mm difference has zero impact.

The hat height and diameter are important as there is no way on earth a 135i disk will fit an e12 or e24 hub.

So this is probably what I'll use. http://www.dba.com.au/dba-part-finder/? ... L36/_147KW

We have completed a dummy fit and it all works (with wheel back on with clearance). We used a ply brake adapter plate.

I may need to replace the master cylinder and brake boosters. Again once the car is running on song and driven in we'll turn to the brake upgrade. Would love to remove the twin master cylinders and boosters from my car for something far more modern.
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by GazM3 »

I'm pretty sure the e46m3 disc is around the 325mm and will probably go close to fitting behind a 17" rim and have a friendly hat offset. This is what I used for the 840ci brake upgrade.

What is the centre spacing on the bolt holes on the 135i caliper. Is it the usual BMW 120mm?


Also if doing a mega upgrade on the fronts you may need to consider upgrading the rear. Not sure if the e34 540i brakes fit the early e24 hub but they are a bolt on for the late model e34 hub and reasonably easy/inexpensive to purchase still.
BMW’s
84 E24 M635csi
90 E34 M5 3.6
94 E34 540i/6 SC E85
97 E36 M3 euro SC U/C
97 Z3 2.8 widebody

OTHERS
11 Audi S5 3.0 SC
19 VW Amarok V6
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

The 135i has a much larger hub diameter and a completely different hat height, so just cannot be used. I'm pretty sure the e46 disk works as well but will go the HSV route.
User avatar
tschultz
Posts: 2515
Joined: Wed Jul 07, 2010 10:54 pm
Location: Colorado
Contact:

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by tschultz »

Can you send your MS2 tune over? Looking for settings for S38B36/38 to get started with on MS2 unit.
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

Bimmerforums has the entire write up for this build.

Long story short, finally endurance race S38B38 on the dyno and ready for tune prior to going back in. At the same time we will;
  • place new front recaro sports seats.
  • place new uncracked dash.
  • place new M Sport stearing wheel.
  • place new 6 speed from an E39 M5.
  • place new 300km/h 8000rpm M Power gauge cluster from Ivo.
The race exhaust is already on as is the bomb proof diff mount and the large case 3.73 LSD. I then need to do the interior and repair two small rust bubbles. Those can wait a year or two. Want to drive it first with the 5 speed and have some fun.

here's the link to the Bimmerforums updates: https://www.bimmerforums.com/forum/show ... CSi/page10
Shipper 01
Posts: 791
Joined: Mon Nov 03, 2008 5:26 am
Location: Sydney Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by Shipper 01 »

After years and years, (May 2014 to be precise) we are finally on the last leg of completing the engine install. The engine is in and on the weekend we did the cold tune and the road ECU auto tune. The auto tune was limited to 1st to 3rd and to 3000rpm. But the car is now running well enough to take to the dyno for power tuning.

Latest photos here; https://www.bimmerforums.com/forum/show ... CSi/page17
baders
Platinum Member
Platinum Member
Posts: 1084
Joined: Sun Nov 23, 2014 7:38 am
Location: Perth Australia

Re: Gertie Nears Completion -S38B38 with 370hp+ now in my 633CSi

Post by baders »

Nice work Josh. You did the KMac rear suspension too yes ? How did that go ?
1986 635csi LOCUTUS / Arktis Blau Metallic / Pearl Beige / S38B36/ Close ratio dogleg 5sp
2002 E46 M3 / Topaz Blau Metallic / Black Nappa / 6 speed SMG software tuned / Bilstein PSS10 Coilovers / CMP RACP reinforcement
Post Reply