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

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

Post by Shipper 01 »

Gertie is near complete. My 1977 633CSi with a 5 speed manual, race sway bars, 40% stiffer springs that are 40mm lower, e28 rear subframe with a 3.45 LSD. Just 2 to 3 weeks away from hammering the streets!

What a shoot fight to get this done.

After 16 months with the last mechanic and such a shoot fight to get anything done (good quality work, very intelligent guy who knows is stuff but, horrid communication and client attention and horrid time frames) the latest team have made great headway. This week we will be ready for exhaust back on and then a week of testing. So, where are we?

1. Rear subframe in. The e28 rear subframe swapping out the e12.
2. LSD in.
3. E34 540 rear brakes in. Got the fronts but they can wait.
4. Engine in. Needs auto electrician to finalise and mechanic to hook up missing hoses, lines. But apparently starts and runs. So 370hp plus hear we come.
5. Car now sits level in stead of nose in air.
6. rear floor strengthened.
7. New drive shafts to go in with correct bolt pattern.
8. New cables for hand brake going in.
9. New rear brake lines for bigger brakes.
10. Battery to the boot/trunk.

So hopefully we are;

a) finished this week and ready to go to the exhaust shop to get the high performance exhaust put back on.
b) once exhaust is on, late this week or early next week, a week to clean up engine bay. Testing for say 200 miles to iron out the bugs, oil change from start up oil, tuning and then final hot day run. Final check and then interstate for 1100km.

Wish me luck. Did I mention "what a shoot fight"? Note how I'm not swearing?

Image


Image


Image


Image


Image


Image

Year she needs a good wash. And she'll look great with that M6 front spoiler! Must get that uncracked dash in as well and the 1970's Recaro's!
GazM3
Posts: 1791
Joined: Wed Oct 26, 2011 12:55 pm
Location: Melbourne, Australia

Post by GazM3 »

Nice.
Did u contact the exhaust shop as I forgot to swing past this morning. Got sidetracked.

The rear sits much better. No rediculus -4+deg camber anymore.
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

Post by Shipper 01 »

GazM3 wrote:Nice.
Did u contact the exhaust shop as I forgot to swing past this morning. Got sidetracked.

The rear sits much better. No rediculus -4+deg camber anymore.
Called 3 times. Rang out each time. Will try again in the morning.

Yeah the old rear camber was an ass. It sat low with legs spread. Now I think it sits all right.
baders
Platinum Member
Platinum Member
Posts: 1084
Joined: Sun Nov 23, 2014 7:38 am
Location: Perth Australia

Post by baders »

That's fantastic Josh. Reminds me I have to get back on to my BMW mechanic to get this S38B36 into LOCUTUS started. I now have all the parts required.

Interested to see how Gertie gets up and boogies !!
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

Post by Shipper 01 »

I think she'll go great. The 5 speed over drive box should accelerate at least as fast as the 5 speed dogleg does given the straight gate from 1st to 2nd.

She only weighs 1495kg stock and has no aircon (not a thing) and now will have light weight recaro's replacing the old flat-beds.

All new military grade bushes should help handling and a 3.45LSD must be better than the old open 3.25 slippery for acceleration. Performance springs, lower ride, Bilstein shocks and performance sway bars should keep her firmly on the road at speed.

Now I've committed to E34 replacement brakes and the rear set are on (although the disks are nearing replacement), I'm tossing up whether or not to drop the E34 540 302x28mm fronts for the E31 840 324x30mm fronts with calipers. I can use the E34 540 fronts on my E3 racer as they are the largest that will fit a 15 inch wheel. The 840 fronts are the largest for a 16 inch wheel so should be fine for my 17's. They are also 4 piston (4x45mm) where as the E34's are single piston (1x60mm).

Here's that big brake to wheel diameter link again viewtopic.php?t=2137&

The engine runs 250kw stock with a cat. The previous owner had it running at 296kw before he melted a piston triggering a complete rebuild (using the Alpha-N chip that when it runs lean, melts things). Less cat and with small increases in compression and capacity (head decked and slightly larger forged pistons) plus race extractors and race exhaust it should run somewhere between 275kw to 290kw, with the Landzer chip I have for the engine. It runs to 275kw on a stock setup with a Landzer chip. Less cat and with performance exhaust the engine should pull somewhere between 370hp to 390hp should be achievable.

So what should this mean re acceleration times? A stock M635CSi has a power to weight ratio of 141kw/tonne. Gertie will run 184kw/tonne to 194kw/tonne. Additional to this is the M635CSi has 333nm of torque where as Gertie will have around 420nm+ of torque and far more torque lower down the rev range. So honestly, she'll eat M635's for breakfast!


Given M635CSi acceleration times of 6.1s for 0-100km/h, I'd expect low to mid 5's but more importantly, with V8 levels of torque I'd expect serious rolling acceleration on road and track.
TrevorB

Post by TrevorB »

Hey Josh, glad Gerties Blue not Black. I can see you disapearing in the distance and the cops booking me by mistake!
Looking forward to catching up soon.
User avatar
ericono
Posts: 500
Joined: Fri Mar 23, 2007 1:51 am
Location: Spartanburg, SC

Post by ericono »

Very cool project. Can't wait to see more.

I actually like the look of the front spoiler you have on now. It's nice and clean.

Keep up the great work.

Eric
'85 M635, '00 528iT, '98 Z3
User avatar
Finally6
Posts: 181
Joined: Sun Mar 10, 2013 6:01 pm
Location: Stafford, VA

Post by Finally6 »

Awesome build, impressive results are sure to follow when on the tarmac!!
Northern VA, I-95 drone...
RHD 81 635
02 530i
00 528iT
91 535i
User avatar
jps635
Platinum Member
Platinum Member
Posts: 872
Joined: Sat Feb 27, 2010 10:50 pm
Location: NZ

Post by jps635 »

Should be a weapon.

If you go for the e31 brakes make sure you have a 17" spare, which will sit proud of the wheel well.

A few years ago now I weighed my car on a weigh bridge. I can't remember exactly but seem to recollect was under 1400kg ?

You know they raced at under 1100kg so plenty to throw away if you want a balls out drag car.
'85 635csi JPS (RA2-66)
baders
Platinum Member
Platinum Member
Posts: 1084
Joined: Sun Nov 23, 2014 7:38 am
Location: Perth Australia

Post by baders »

Nice work !! What were you going to do with the intake, run a cone filter or something more extravagant ? Still figuring this out myself.
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

Post by Shipper 01 »

baders wrote:Nice work !! What were you going to do with the intake, run a cone filter or something more extravagant ? Still figuring this out myself.
Cone filter. Ducting can be seen to the left of the wiper panel. Will move battery to rear to make more room for cleaner cooler air and run ducts from new spoiler to below air filter to keep cool air in engine bay. Also have a heat reflective box to go around it. Nothing worse than sucking in warm air from a hot engine.

And jps635, did not think of this but you are right. Old 14" spare just will no longer fit. Will track down a 17" spare.
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 »

New Update:

1. Speed Signal Simulator in and working.
2. Car test driven for about 1 hour too around 3500rpm (zero miles post rebuild of engine so taking it easy).
3. Scared the hell out of the guys at the car restoration business with its acceleration and speed and they loved the banshee wail that was building at 3500rpm.
4. Ran beautifully, no heat issues (although a cool day around 20 degrees Celsius and not an Aussie Roaster!) but a banging from the back.
5. The rear shock shaft had driven its way through the upper panel work (parcel shelf).
6. Being fixed now. Appears retention washer to top of shock missing.
7. Race extractors touching the steering box. Being fixed as we speak.
8. Brakes pulling to one side. 540 disks and callipers in the rear. Rebuild or rust may be an issue.
9. Maybe a bent wheel or very badly out of balance.
10. will get wheels aligned and re-balanced.

See photos below of the shock issue. It's only one side and an easy fix. The last mechanic did such a crap job with the wiring that although spending $1,250 just now with a qualified auto-electrician to stop our feet and pedals being tangled in the wiring and relays (it was that ruddy bad!!!), he now wants to completely remove the entire wiring loom and re-do it as his repair works are, in his own words, only masking the major issue at hand and in typical Aussie fashion notes that 'wires are running all over the bloody place'. Currently getting this priced.

So a few weeks? Well it runs.... and ruddy fast!!!!!!

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 »

Josh, what were they doing to fix No. 7 ? Which extractors are you running ?
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 »

A set of S38B38 hand made race extractors. Hand made to get around the steering box. The e12 has a bigger steering box than the e28 so it hits. Will wrap extractors, wrap steering box, separate with high temp HDPE bearing separator and ensure that it cannot vibrate away. So ensure is secure.

Image

Image
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 »

Great progress!

You need to share videos with us too :)
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
downforce22
Posts: 9
Joined: Sun Aug 24, 2014 1:27 pm
Location: Colorado Springs, CO

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

Post by downforce22 »

Nice swap! I wonder how it would compare to my s38b36 e30

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 »

The engine came out of an e30. There's a link to it going into that e30 if you want it. The complete build from memory. The e30 now runs a 500hp BMW 5.4 litre v12! I think I have that link as well.
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 »

Car now finished. Heading to a BMW specialist this week for final engine and chassis go over plus oil change. Registration now needed and then the 1100km drive home.
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 »

We need more photos and videos!!
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 »

Image

Image

Image

Image

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 »

Image

Image

Image

Image

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 »

Image

Image

Image

Image
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 »

Very nice-- so no electric fan?

How much customization work was it for you to get everything fitted properly? Did you use many BMW parts from other cars?

Are the brakes still vacuum boosted, or did you convert it? Speaking of brakes, did you upgrade them?

Is that an E28 rear subrframe? I can't recall if you mentioned what differential you decided to use...
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 »

tschultz wrote:Very nice-- so no electric fan?

How much customization work was it for you to get everything fitted properly? Did you use many BMW parts from other cars?

Are the brakes still vacuum boosted, or did you convert it? Speaking of brakes, did you upgrade them?

Is that an E28 rear subrframe? I can't recall if you mentioned what differential you decided to use...
1. Not a huge amount of customisation work to fit it, but plenty to fit ancillaries, about $3k worth of fabrication and hand made brackets and parts. The engine fits properly and just clears the fan. A lot of work fitting the exhaust that was a further $1.6k and the extractors soaked up an additional $2.5k of in/out/cut/weld and then try again. Took a week to get them around the old e12 power steering box. RHD issues me thinks.

2. Brakes are still vacuum boosted, for now. It runs 540 rears and I have 850 front callipers for 330mm disks for the front. I'll convert next year to a modern braking system.

3. E28 rear subframe. 3.46 LSD.

4. Runs a speed signal simulator to trick ECU into thinking it is moving and not running in limp mode.

Next to do;

a) Recaro sports seats for the front. Then;

b) Dash replaced with un-cracked. Then;

c) carpet sucks. Fix then;

d) Alpina cloth for rear seats, door cards.

c) roof lining is stained so this will be done.
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 »

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...
http://www.Drive4Corners.com
Image
'79 635CSi Revival
'80 635CSi
'83 633CSi Callaway Turbo continued as 1988 535is Turbo
SOLD: '81 635CSi/A
Post Reply