Slow burn 645CSi build

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Fedaykin633csi
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Location: Portland, OR

Slow burn 645CSi build

Post by Fedaykin633csi »

Carrying on where this thread stops: http://bigcoupe.com/phpBB2/viewtopic.php?f=25&t=31339

Back in the fall I picked up a pair of e24's, a '79 euro 635CSi with the 2.8 in it and a ton of issues, and a crusty but rust free '83 633CSi (sorry for the redundant pics):

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THEN I parted what I had time for from the euro (constraint being my apartment does not have off-street parking), and retained a pair of early manual Recaros and the euro bumpers front and rear. The '83 is on the road and running fairly well save a misfire on acceleration, still plenty of maintenance items to do.

MEANWHILE I picked up a complete M102 of unknown provenance (thanks Bill, Sharkski), an early air dam (the fogless one), and have a used Llama interior (thanks again Sharkski) in the works.

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THE PLAN is to euro-bumperify it, Llama it, paint it, then do the turbo. I'll be completing work as time and more significantly money allows. I have always and will continue to do all of my own mechanical work. In terms of turbocharging, it will be a long road with lots of learning, but my current thinking is to swap the M102 head onto the B32, thus starting with a nearly 9:1 compression motor, and going from there. Gnarly. Stupid, even. I am planning on starting with an air-to-water intercooler system, upgraded fuel delivery, and I don't know what yet for management. Would love to try no stand-alone first, but whether to use the B32 Motronic 1.0 or the L-jet from the M102, or even convert it to M1.1 with the e28 I'm parting, I don't know.

I feel a bit like a mad scientist, and very green in the forced induction department, but it will be fun, right? Meanwhile, while waiting for an injector to arrive I mounted up new rubber on my old Epsilons:

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I'll try to keep up to date with progress here. Cheers!
Last edited by Fedaykin633csi on Thu Apr 30, 2020 9:42 pm, edited 5 times in total.
1983 633CSi 5-speed Burgunrot, a slow burn 645CSi project
1984 528e Saphirblau
Fedaykin633csi
Posts: 36
Joined: Mon Nov 18, 2019 9:45 pm
Location: Portland, OR

Re: Slow burn 645CSi build

Post by Fedaykin633csi »

Very nervous about this:

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225/50 R16 on unknown offset wheels... we shall see once the car's running again.
1983 633CSi 5-speed Burgunrot, a slow burn 645CSi project
1984 528e Saphirblau
kylefav390
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Re: Slow burn 645CSi build

Post by kylefav390 »

I love those Epsilons, had two sets of them and I never ran either on the 6er (or any car for that matter). I'm here for this build though. Seems like you have a solid game plan. Can't wait to see where this goes.
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hornhospital
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Re: Slow burn 645CSi build

Post by hornhospital »

The wheels/tires will be fine. The travel of the suspension pulls the upper side of the tire inward. It will clear the fender by plenty.
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
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86_6series
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Re: Slow burn 645CSi build

Post by 86_6series »

hornhospital wrote: Fri May 01, 2020 7:30 am The wheels/tires will be fine. The travel of the suspension pulls the upper side of the tire inward. It will clear the fender by plenty.
I agree.
86-635CSi
96-MB C220 SOLD
98-740i
71-Continental MK3
Fedaykin633csi
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Joined: Mon Nov 18, 2019 9:45 pm
Location: Portland, OR

Re: Slow burn 645CSi build

Post by Fedaykin633csi »

Can't wait to see if they rub, but you've put my mind at ease.

In the meantime, I'm trying to figure out why it's running so rich won't really run. Wet plugs, smoke, stalling. I just replaced my injectors, and now this! Weird coincidence for the FPR to fail. I was running a 3.0 bar FPR (accidentally), and swapped an old 2.5 bar of unknown condition in with no change. FPR is passing fuel to the return, but I'm not sure if at the correct pressure. I can blow through the return, but I'm not sure how much effort it should take, it does take some. I'll pick up a pressure gauge this weekend, but I have a new FPR in the mail, I shall prevail.

While doing the injectors, I did lose a pintle cap down the intake. Did some googling, seems it happens all the time to no ill effect. Some noise, but the engine seems to have eaten it just fine. Yummy.
1983 633CSi 5-speed Burgunrot, a slow burn 645CSi project
1984 528e Saphirblau
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hornhospital
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Re: Slow burn 645CSi build

Post by hornhospital »

I did the same thing on the 635 right after I got it. Pulling the injectors to send them off for cleaning/rebuilding and OOPS one of the pintles went down the hole into the manifold. I bought a snake camera to try and find and remove it, but it wouldn't make the corner inside the manifold. After some choice pronouncements I bit the bullet and pulled the manifold, then dropped the pintle :evil:
while removing the intake. Never did find it, but it gave me an excuse to gussy up the manifold, and the valve corner while I was at it.
Ken Kanne
'84 633CSi "Sylvia"; '85 635CSi "Katja";'85 325e "Hazel Ann"; '95 M3 "Ashlyn"
Fedaykin633csi
Posts: 36
Joined: Mon Nov 18, 2019 9:45 pm
Location: Portland, OR

Re: Slow burn 645CSi build

Post by Fedaykin633csi »

Quick update, it's been running for a while now. Turned out to be the 'ol CTS resistor hack had gone bad. The car is still a little jerky under medium throttle.

Tires don't rub, and it feels great on those tires despite needing a suspension refresh.

I am getting impatient while I work through some other projects on the e28's so might throw the crappier euro front bumper on. I'm in the process of doing the Leatherique treatment to the rear seats and hope to get that in soon. I have a 3.25 LSD and shafts on the bench for some attention before I put that in.
1983 633CSi 5-speed Burgunrot, a slow burn 645CSi project
1984 528e Saphirblau
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zinnocoupe
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Re: Slow burn 645CSi build

Post by zinnocoupe »

Interesting thread here. I really love those epsilons. I've come close to buying a few sets of those but never followed through.
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1979 Euro 635ci no longer a basketcase, just a running rust bucket!
1977 530i Partially restored and running now!
1987 635csi 60K KM Garage Queen
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