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Ex LOCUTUS the fun and pain begin

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TBM
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Re: Ex LOCUTUS the fun and pain begin

Post by TBM » Sun Dec 30, 2018 3:47 pm

baders wrote:
Sun Dec 30, 2018 6:57 am
Hey TBM. I'm heading to the hospital to catch up with my daughter and new grand son but will post more tomorrow. I had the box custom made by Christian Opitz in Germany. His email is; [email protected] He was great to deal with and this was the second airbox I had made by him. The first (pictured page 3 ?) was simply too wide and would have taken major mods to fit. The second is an M88 version that he modded up for me with larger S38B36 ITB ports and inlet.

CF airbox01.jpg
Firstly, Congratulations on the addition to the family! May he see only Health and happiness.

I've emailed him before.. I didn't want to take a chance being that he was in Europe and it was a custom piece that I need. I actually went through with all the custom work you are referring to. Thanks for the heads up! This looks good. Getting the same amount of air to the 6th cylinder on our cars is a challenge with that plenum design.... Keep up the great work.
'84 M635csi
'86 Lotus esprit Turbo (sold)

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Mon Dec 31, 2018 1:22 am

No problem. I did find him very easy to deal with and responsive.

I've got to tackle flushing the coolant system today possibly. This means jacking the front end up and removing the block drain plug, which looks like a right bitch to get out.
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

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Mon Dec 31, 2018 4:43 am

MrE wrote:
Sun Dec 30, 2018 7:01 am
Nice work Baders. Its all tidy, impressive stuff. Looks good.

Good to see the gauges up & running too.

Congrats on the grandson mate, Happy New Year!
Thanks Ellis. She'll never be concourse but that doesn't matter.
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

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Re: Ex LOCUTUS the fun and pain begin

Post by Shipper 01 » Fri Feb 22, 2019 7:07 am

How goes the build? Any updates??

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Sat Feb 23, 2019 5:40 am

Hi mate. Yep some progress. I bought a Quikjack which I was waiting on arriving. I've set it up now and have easy under car access. I finally did that coolant flush but the block drain plug was a mutha#$##$$%@#$$$##%$!! bitch. I could remove it easily enough with 2 universals, extension bar and socket but could not get it back in. Lucky my son brought his very long piano playing fingers with him and could reach in from the top to replace the plug after flushing. Took a while to get air locks out but I think its good now. Next break I hope to install the A/C compressor and maybe remove and flush the evaporator. Still need to complete the harness but the coolant temperature gauge isn't working so need to trace that. Also need to get a serious wheel alignment as I did lots of suspension work.
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

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Thu Nov 28, 2019 8:13 am

Hey you lot. Wow, last time I posted was February :shock: Real lifetm got in the road this year. Time is starting to free up and looking to get back to the project.

You might recall I had what appeared to be a low oil pressure problem. This was backed up by the reading from Roland's digital gauge I installed. Oil pressure would be fine for about 60 seconds after starting but would then drop away. This had me stumped for a while but I think I now have the answer. And this is really important to those using a B34 oil filter housing on a later block such as a B35 or B36 (mine).

There is an oil drain passage in the block of the above later variants that drains straight back to the sump. This was designed so that during an oil filter change, excess oil drains back into the sump. With the later variant oil filter housings, this passge corresponds to a dead end within a separate divided section. When you install an earlier B34 oil filter housing, there is no divided section so in effect, the oil from the pump shoots straight back to the sump ! Some images below;

My B36 block, red circle on the drain passage;
B36_oildrain.jpg
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Image of B35 (and B36) oil filter housing vs B34;
filterhousing.png
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So.....I need to block that passage with an M10 x 1mm plug. Hopefully this will be the project next break from work.
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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Thu Dec 05, 2019 1:32 pm

Its 44 degrees C here today, but had to carry on with this job. Dismantled the carbon fibre plenum (once again) to gain access to the oil filter housing. Removed the housing to expose the block. Confirmed yes indeed there is an oil passage back into the sump that would have been short circuiting oil :oops:

I searched high and low for a M10 x 1mm screw plug but nothing available locally. I did find a fastener shop that had an M10 x 1mm x 25mm cad coated bolt in 8.8. Only option so grabbed a few plus crush washers and scurried back home. Not enough room inside the block side for a bolt head and it was also too long. Ground the head down, cut it shorter, and cut a screwdriver slot into the bolt head. It fitted very nicely indeed as you can see. Put everything back together and fired her up. Success !! A solid 4.5 to 5 bar oil pressure. I can't tell you how relieved I am about that !
plug installed 01.jpg
The offending oil passage
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plug installed 02.jpg
Modified bolt
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plug installed 03.jpg
Installed
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plug installed 04.jpg
Success !
plug installed 04.jpg (557.76 KiB) Viewed 4550 times
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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Thu Dec 19, 2019 8:39 am

So I can give the big <finger> to Photobucket, I'm going through and re-upping what images I can on Imgur.
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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Sun Dec 22, 2019 9:03 am

On a whim, I installed wheel spacers yesterday. 15mm front and 20mm rear. Bit hard to see here but it does look good.
spacers_before.jpg
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spacers_after_02.jpg
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spacers_after01.jpg
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Oh, and I just have to say. I love my Quickjack and I love my air compressor :D
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

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Sun Jan 05, 2020 9:30 am

Last couple of days I rectified the non reading coolant temperature dash gauge. The problem was that the BMW mechanic had installed the S38 B36 sender and this was obviously the wrong range to the dash gauge. They had also wired it wrong. I obtained an FAE M30 sender from FCP Euro (once again those guys came through, it arrived in 5 days from the US :shock: ). Installed this, corrected the wiring, and readings are nominal (as SpaceEx would say).
coolant temp dash gauge sender.jpg
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coolant temp dash gauge.jpg
coolant temp dash gauge.jpg (532.82 KiB) Viewed 4313 times
Next. My windscreen washer squirters have stopped working. Looks like blocked non return valves so have ordered an original T piece item plus new OE style 4.5mm braided hose.
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

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Fri Feb 07, 2020 7:41 am

After repeatedly asking an Ebay supplier if their hose was a continuous length, I received 5 x 1m lengths :roll: Asked for a refund and got it. Went with another supplier for a roll of 20m so see what eventuates here. The hose you need is currently manufactured by Cohline in Germany, and has an ID of 4.5mm and OD of 7.5mm. It is clear with a braided webbing like the original. The Cohline part number is 2032.0308 under the pneumatic hose section. Catalogue here;

http://www.cohline-uk.net/AFHC_2013_Teil_21.pdf
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

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Re: Ex LOCUTUS the fun and pain begin

Post by jps635 » Tue Feb 11, 2020 6:03 am

IF you want, and you're not concerned about replicating whats there, you can radically reduce the plumbing
- delete the headlight washers
- delete the main washer tank
- utilise only the intensive washer bottle - delete the other pump and modify wiring, ie connect the old washer pump wiring to the intensive.
- run a single hose up inside the hood with a single tee/check valve fitting

Not for everyone but, having a black car, I very seldom use my washers.

This will give you a ton of room to add a catch can

Can post some pics if interested.
'85 635csi JPS (RA2-66)

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Re: Ex LOCUTUS the fun and pain begin

Post by TBM » Tue Feb 11, 2020 11:14 pm

jps635 wrote:
Tue Feb 11, 2020 6:03 am
IF you want, and you're not concerned about replicating whats there, you can radically reduce the plumbing
- delete the headlight washers
- delete the main washer tank
- utilise only the intensive washer bottle - delete the other pump and modify wiring, ie connect the old washer pump wiring to the intensive.
- run a single hose up inside the hood with a single tee/check valve fitting

Not for everyone but, having a black car, I very seldom use my washers.

This will give you a ton of room to add a catch can

Can post some pics if interested.
Yes please please! :D
'84 M635csi
'86 Lotus esprit Turbo (sold)

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Wed Feb 12, 2020 4:29 am

Yes I'd be interested in seeing details jps. The headlight washer/wipers are already gone.
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

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Re: Ex LOCUTUS the fun and pain begin

Post by jps635 » Wed Feb 12, 2020 8:15 am

Here you go.

Check valve Tee connector https://www.pelicanparts.com/More_Info/ ... 374-978-M9

( I can't figure out how to gt the photos to load as taken)
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'85 635csi JPS (RA2-66)

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Re: Ex LOCUTUS the fun and pain begin

Post by jps635 » Wed Feb 12, 2020 8:23 am

3 more

I did use the proper clamps and crimping tool - very much like standard pincer pliers but narrower jaw and beveled both sides.

Use the old hose to pull through the new. (I guess this is obvious)
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'85 635csi JPS (RA2-66)

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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Thu Feb 13, 2020 2:36 am

Thanks for that the job looks original ! Waiting on my hose to arrive so I can progress this job.
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

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Re: Ex LOCUTUS the fun and pain begin

Post by GRNSHRK » Fri Feb 14, 2020 6:48 pm

jps635, could you please post info regarding that hood pad :-k

Did a quick search but did not turn up anything :-?

Agreed, looking great, nice work =D>
:mrgreen:
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1980 633 CSi Cypress Green/Pearl Beige
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Re: Ex LOCUTUS the fun and pain begin

Post by jps635 » Sat Feb 15, 2020 6:19 am

Hood Lining

http://www.classic9leathershop.com/bonn ... -3-pieces/

I have the 1/4" stuff. Use 3M 90 high strength spray contact adhesive
'85 635csi JPS (RA2-66)

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Re: Ex LOCUTUS the fun and pain begin

Post by GRNSHRK » Sun Feb 16, 2020 8:41 pm

Thank you very much =D>

Hmm, now what color Roundel to go with :-k
:mrgreen:
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1980 633 CSi Cypress Green/Pearl Beige
2017 X5 M Sport Xdrive 35i Carbon Black/Ivory White
2005 330 Ci ZHP Cabrio Imola Red/Bone/Black
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Mon Feb 17, 2020 1:52 am

I got the white roundel as jps has. Haven't installed it yet as other higher priority jobs for the car beckon.
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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Thu Feb 27, 2020 8:59 am

Made some progress today ! Removed the worst of the old hood liner in preparation to install the Classic 9 liner. Going to take the hood off to do this to make it easier to remove the remaining adhesive;
hood liner removal.jpg
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Next was the long overdue installation of the A/C compressor using the adapter brackets Jay sent over. Went in great but was difficult holding the entire unit up to get a bolt in #-o Just as well I've been hitting the gym this year \:D/
compressor installation.jpg
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Lastly was the install of the Ed Raether steering box re-inforcement bush sent by Ron;
reinforcement bush.jpg
reinforcement bush.jpg (602.09 KiB) Viewed 3661 times
All in all a good day ! When I get the hood off i'll be attacking the liner but also the windshield washer hoses. After that possibly look to remove the A/C evaporator to flush and install new expansion valve.
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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Sun Mar 01, 2020 1:19 pm

Today I took the hood off and replaced all the windshield washer hoses. Plumbed up the intensive washer bottle which had been removed from the circuit. Just as well I did as found this;
rust under intensive bottle.jpg
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Make sure you look under the intensive washer bottle folks !! For now, I've ground back and treated the rust but will need to address this properly in future.
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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Mon Mar 30, 2020 4:57 am

So today I got the hood back on the car with renewed washer hoses etc. I decided to stick with the main tank plus intensive tank. My lack of plumbing knowledge showed however because I forgot to put a one way valve in the intensive line :oops: When the main bottle washer was operated, the fluid dribbles out of the squirters but back fills the intensive bottle. Will rectify that.

I also cleaned up the main bottle as was discoloured.

Took the chance to test the A/C clutch +12vDC signal which confirmed that the A/C circuit is working OK via the evaporator temperature regulator. Still need to pull the evaporator to flush and clean it plus replace the expansion valve. When things return to some normalcy I'm taking the car to a local A/C mechanic to manufacture hoses and gas up !

What else did I do ? Ahh yes, installed the Xpel protective films on my new fog lights.
washer hoses 01.jpg
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washer hoses 02.jpg
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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

baders
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Re: Ex LOCUTUS the fun and pain begin

Post by baders » Fri Apr 10, 2020 6:14 am

Yesterday and today I got stuck into removing the A/C evaporator assembly for refurbishment. Fairly easy job which is well documented elsewhere. The evap was a little crusty but only minor surface rust in a couple of places. Decided to run with it instead of trying to find a new replacement. Cleaned it up and flushed it with acetone using my air compressor. Replaced the expansion valve with new and moved on to the A/C blower transistor. I had purchased a 2N3771G which is twice the current rating (30a) as the original 2N3055H (15a) with the intention of uprating this troublesome component. Well, what a bitch. I pride myself in being able to fix almost anything electronic but this had me beat. It's nowhere near as easy as replacing the heater blower transistor as it is part of a pre-assembled circuit board with a capacitor and resistor. When I attempted it, the capacitor and resistor disintegrated, specifications unknown ](*,) :twisted: Anyhoo, about this time I crumbled and bought a new transistor assembly from FCPEuro at exorbitant cost :shock: I'll need to wait for this to arrive now to continue.
evap.jpg
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evap crusty.jpg
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evap flush.jpg
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evap new tx valve.jpg
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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

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