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Re: My henna 84
Posted: Tue Mar 13, 2018 12:44 am
by TBM
Happened to make a visit to my fabricator today...
We looked at the condenser mounting that Ken has been talking about and Spent a few minutes discussing changes that would make sense for ease of mounting (read adjustability) and reach. Trying to make it easy to fab a "kit" for you guys that are interested.. Once the changes are made I will post again what was done and what the fabricator's cost for said kit. As I mentioned it will have to be made in enough numbers to lower the cost so that it's not a "prototypical" in price.
Hope this helps anyone interested.
Re: My henna 84
Posted: Sun Jun 03, 2018 5:29 am
by TBM
Little update...
Yet to do anything on the car lately.. Life is getting in the way (read: no spare time)...
BUT.. Did get the MK-60 abs unit. Took off the OEM piece and I need to fabricate all new lines as the Mk-60 unit requires a slight change in mounting height (one of the first reasons I switched to it in the first place as it make tins more room for a bigger plenum in the works).
In the pic below is the master cylinder and the NEW much narrower right hand drive reservoir(worked out beautifully as its dead on flush with the master on the right side, again more room for the plenum). And the "S" run of brake lines I will be removing and replacing with more direct lines from all four wheels..
Once I re-wire the Engine loom to the Emtron I'll be able to run traction control through this particular unit as its an early piece the BMW hadn't burned all the programing into for the E46 M3.. So its eprom is programable.
Also in anticipation I've already purchased a trigger and wheel for the cam position sensor a la S38B38
- New Resevoir.JPG (1.54 MiB) Viewed 15490 times
- Trigger and wheel apart.jpg (1.2 MiB) Viewed 15490 times
- Trigger and wheel together.jpg (961.51 KiB) Viewed 15490 times
Re: My henna 84
Posted: Mon Jun 18, 2018 3:55 am
by TBM
Hey there..
So for Father's day I worked on making progress on the car..
Extracted the full engine wire harness.. Marked it all up as a very knowledgeable fellow (Douglas) will be replicating it and making a new one for all the Emtron KV-8, new sensors, electric water pump, and ABS unit..
Speaking of the ABS unit.. I've tried to mock it up in the OEM location and it doesn't sit low enough in the bay to allow me to clear the size of plenum I am planning.. So I decided to ...GULP.. cut out the bracket (pressuring it in case I want to go back to OEM one day) and create a custom bracket that will look like a factory piece.
- Harness exposed.JPG (1.44 MiB) Viewed 15423 times
- Glove box.JPG (1.62 MiB) Viewed 15423 times
- Relay 1.JPG (1.38 MiB) Viewed 15422 times
- Wiring Harness out.JPG (1.24 MiB) Viewed 15423 times
Re: My henna 84
Posted: Mon Jun 18, 2018 4:01 am
by TBM
- MK-60 ABS 1.JPG (1.31 MiB) Viewed 15422 times
- MK 60 ABS 2.JPG (1.28 MiB) Viewed 15422 times
Re: My henna 84
Posted: Mon Jun 18, 2018 2:01 pm
by ericono
Awesome stuff. Making good progress there. I have a few questions:
1) where did you get the Mk60 ABS parts? I have pondered doing the same thing. Are you swapping teeth rings and abs sensors at the hubs? Besides the wiring harness work, what else are you modifying to make this work?
2) Did you get the Spoon collars installed? Did you end up using them all?
3) Do you have a hand sketch or something that shows your electronic water pump routing? I am looking at a similar plan except using the e60 style ewp. Are you eliminating the e24 thermostat? Adding another one, or just using the controller to regulate the ewp and act as a thermostat?
Thanks and keep up the great work!
Eric
Re: My henna 84
Posted: Tue Jun 19, 2018 5:10 am
by TBM
ericono wrote: āMon Jun 18, 2018 2:01 pm
Awesome stuff. Making good progress there. I have a few questions:
1) where did you get the Mk60 ABS parts? I have pondered doing the same thing. Are you swapping teeth rings and abs sensors at the hubs? Besides the wiring harness work, what else are you modifying to make this work?
I got the ABS unit through Doug.. He has more. I will be making tone disks. You can just work off of the ABS internal brain but you can also employ DSC (need the E46 streering collar and yaw sensor) and traction control via this unit if you run it through a good standalone
2) Did you get the Spoon collars installed? Did you end up using them all?
Not yet.. I'm planing a rack conversion so there's not reason to touch anything right now..Especially since I am waiting for the Group A uprights
3) Do you have a hand sketch or something that shows your electronic water pump routing? I am looking at a similar plan except using the e60 style ewp. Are you eliminating the e24 thermostat? Adding another one, or just using the controller to regulate the ewp and act as a thermostat?
Not really. No need for thermostat since the pump will run off of temp sensor and through standalone
Thanks and keep up the great work!
Thanks Eric!
Eric
Re: My henna 84
Posted: Sat Jun 30, 2018 2:09 am
by TBM
Re: My henna 84
Posted: Sat Jun 30, 2018 2:11 am
by TBM
I also removed and cleaned the alarm horn, but to be honest, as I'm after losing weight I'm considering removing it since it works on the OEM DME and I wont use it any more... Any thoughts?
- IMG_6256.JPG (1.77 MiB) Viewed 15312 times
- IMG_6257 2.JPG (1.49 MiB) Viewed 15312 times
Re: My henna 84
Posted: Fri Aug 03, 2018 2:08 am
by TBM
Re: My henna 84
Posted: Fri Aug 03, 2018 2:09 am
by TBM
I am planing to relocate the dip stick to an area between the first and second intake runners. I hope I can find someone to make a new tube that I will bend up...
and finally I am planing on making an exact model of the OEM airbox so that I can use the OEM sized ITG filter, except I will make the opening to the headlights much larger but shaped like to opening behind them for more air intake as well as a much much larger feed to the plenum because I plan to run a MAP/TPS (Variohm)/Dual Lambda system.
- plenum test bottom clearances .JPG (1006.16 KiB) Viewed 15177 times
- Plenum test fit front .JPG (1.22 MiB) Viewed 15177 times
Re: My henna 84
Posted: Fri Aug 03, 2018 3:46 am
by GazM3
Looks ambitious and interesting. So variable trumpet length not variable plenum volume.
What are u going to use for an ecu?
Re: My henna 84
Posted: Fri Aug 03, 2018 6:21 am
by TBM
GazM3 wrote: āFri Aug 03, 2018 3:46 am
Looks ambitious and interesting. So variable trumpet length not variable plenum volume.
What are u going to use for an ecu?
Plenum volume is basically the same but I think much more involved. I have access to a sophisticated 3D printer and hoping that some of my connections will help me figure out the mechanisms. The control is very easy..In fact an E46 M3 throttle motor can do the trick and be totally controlled by the standalone
One must figure out:
Bore
Stroke
Compression ratio
INtake valve size (and 2V or 4V chamber)
Target RPM at peak power
Target RPM at peak torque for
shortest runner scenario (usually 1500 +/- 250 or so RPM lower than peak power RPM)
Target RPM for peak torque in
longest runner scenario
I'm limited to about 179mm total space from butterfly and therefore movement maybe limited to about 88mm in total.. But still significant when tuning.
Emtron KV-8. Already purchased
layout planing
Posted: Sun Aug 05, 2018 3:29 pm
by TBM
A graphic showing some changes implemented and future of plenum. It wont be easy for sure, but I've spent a lot of time to try to keep everything looking oem in a sense by using as many OEM parts as possible on the peripherals. The size of the plenum is important but also the resonance as it relates to the pulses created but the motor. Its all in the details but in this case complicated ones. Just to give an idea of the complexity, there is a book that was written about plenum and intake design that is 500 pages long and costs almost $300...
As I'm having the engine torn down and rebuilt we are also considering Rod ratio, making custom cams and looking at exhaust design as it pertains to scavenging. Its the sum of all the parts and quite tedious and make work in unison without overspending.
- future layout reference.jpg (1.11 MiB) Viewed 15115 times
Re: My henna 84
Posted: Mon Aug 06, 2018 10:06 pm
by Jono B good
Very cool, but my question is why do this? Our cars are becoming more and more rare everyday, why not leave it stock? As to retain its' resale values. And retain BMW's rich history. I feel honored to drive a historical car. Just my curious monkey mind asks WHY?
Re: My henna 84
Posted: Mon Aug 06, 2018 11:30 pm
by TBM
Jono B good wrote: āMon Aug 06, 2018 10:06 pm
Very cool, but my question is why do this? Our cars are becoming more and more rare everyday, why not leave it stock? As to retain its' resale values. And retain BMW's rich history. I feel honored to drive a historical car. Just my curious monkey mind asks WHY?
Sure resale value is good.. But after all I'm not doing anything that isn't reversible. And I bought the car to drive and enjoy. So if I'm spending so much money on BMW parts why not get more out of it as I see fit? The goal is more usable power throughout the rev range..and its a challenge.
Re: My henna 84
Posted: Tue Aug 07, 2018 3:19 am
by GazM3
This direction sounds exciting. I been collecting parts to eventually do my built engine. Iām even thinking using 13.5:1 comp with flex fuel e85 and pump fuel combined with water/meth port injection (all hidden under trumpets). Iām using another s38 with either 86mm or 90mm crank, as keeping the original engine as this will retain value if prices go into the stratosphere with our m635csi cars in the future.
The benifit of using high comp is u can use pretty agressive cams with a wider rev range. Should easily be able to make 450+bhp without having the engine too grumpy.
Urethane Foam plenum
Posted: Sat Aug 11, 2018 12:02 am
by TBM
Well, I ordered the foam and made the plunge so to speak...
I first tried to mix 2oz+2oz =4oz mix. As you can see in the pics. It yielded +/- 62oz by volume.. So quick math tells me how much to mix AND.. not really. Had to mix 4 batches to complete the plenum.
It wasn't too bad but I hate sticky messes.
When it all cures I'll peel the outside and start carving her up. Hopefully it all came out ok. Otherwise I'l give it another try.
- Experiment .JPG (1.36 MiB) Viewed 15031 times
- First pour.JPG (1.45 MiB) Viewed 15031 times
- not pretty but ok.JPG (1.41 MiB) Viewed 15031 times
- Side view.JPG (1.45 MiB) Viewed 15031 times
Re: My henna 84
Posted: Sat Aug 11, 2018 10:02 pm
by GazM3
Expandable foam is horrible stuff but souls make a good mould for the plenum construction. Fibreglass is not much better either
Re: My henna 84
Posted: Thu Aug 16, 2018 5:40 am
by TBM
Re: My henna 84
Posted: Thu Aug 16, 2018 5:41 am
by TBM
- final.JPG (1.25 MiB) Viewed 14920 times
- previous.JPG (1.02 MiB) Viewed 14920 times
Group A
Posted: Sat Aug 18, 2018 12:36 am
by TBM
I finally got these in!!!
I found a person that makes CNC aluminum versions (weigh the same as the original Magnesium cast pieces ) of the original Group A front suspension pieces. I always wanted them. Made in England
- Frint with stub axels.JPG (1.35 MiB) Viewed 14895 times
- back .JPG (1.61 MiB) Viewed 14895 times
- bottom.JPG (1.25 MiB) Viewed 14895 times
Re: My henna 84
Posted: Sat Sep 01, 2018 6:57 am
by TBM
Hi All,
We have been fast at work on the intakes. The first thing we are doing is making sure that the back plate will fit the ITB's perfectly and so a mock up of the openings needed to be done. I am posting a link to the video showing the piece being made. Also, I think we figured out how to collapse the Velocity Stacks and lift them at the higher RPM like the Yamaha YCCI system does. The biggest hurdle is the plenum and supplying enough air to make it all breath as it should. After reading a lot of tech articles about resonance waves and inertial waves I can tell you that it isn't easy to get it all right.
video link:
https://youtu.be/ggMYA2QBvlA
- Inner lattice structure.jpg (1.79 MiB) Viewed 14740 times
- Completed copy.jpg (1.66 MiB) Viewed 14740 times
Intakes
Posted: Sun Oct 21, 2018 7:38 pm
by TBM
Fast at work on the variable intake runners. They have been designed and are in the process of being finished on the 3d printer in Nylon X.
- Collapsed Stacks.jpeg (268.42 KiB) Viewed 14297 times
- Extended.jpeg (257.29 KiB) Viewed 14297 times
- Uppers in NylonX.jpeg (155.7 KiB) Viewed 14297 times
These will sit atop an aluminum back plate who's holes will have trumpet rings extending past the holes.. The design is so that the whole assembly can lift off and shorten the velocity stack at high RPM.
Like this
- Lifted.jpeg (40.88 KiB) Viewed 14295 times
Re: Group A
Posted: Mon Oct 22, 2018 2:37 am
by Shipper 01
TBM wrote: āSat Aug 18, 2018 12:36 am
I finally got these in!!!
I found a person that makes CNC aluminum versions (weigh the same as the original Magnesium cast pieces ) of the original Group A front suspension pieces. I always wanted them. Made in England
Frint with stub axels.JPG
back .JPG
bottom.JPG
Supplier info available? I'd be interested in a set as well.
Re: Group A
Posted: Mon Oct 22, 2018 3:36 am
by TBM
Shipper 01 wrote: āMon Oct 22, 2018 2:37 am
TBM wrote: āSat Aug 18, 2018 12:36 am
I finally got these in!!!
I found a person that makes CNC aluminum versions (weigh the same as the original Magnesium cast pieces ) of the original Group A front suspension pieces. I always wanted them. Made in England
Frint with stub axels.JPG
back .JPG
bottom.JPG
Supplier info available? I'd be interested in a set as well.
HI,
Hit me up by PM..