BMW Touring build with Saab power

Thread in 'Project Cars and Builds Threads' started by oldroydsr4, Jan 30, 2009.

  1. oldroydsr4

    oldroydsr4 Member

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    BMW Touring build with Saab power -(now with a SR)

    The Below info is taken from my document i've been writing since i started the project ,so with my slow progress this is 2 years of work but i have replaced or upgraded every component with new items , I have loads more pics and step by step write ups but can't really be bothered to post it all.
    Also alot of the pictures are crap quality due to my phone
    Some of you may know I have now sold all my Bmw M20 turbo equipment and are now in the process of purchasing a post 1993 Saab 9000 aero for the engine. I juct couldn't justify spending 7k on an engine.
    PS You don't know how many times iv almost sold every thing a bought something else to abuse.
    Enjoy.


    Before I get into the project I’ll explain the story which leads me to the point I’m at now (and thousand of pounds worse off)
    In October 2005 I was at university in Swansea and was in serious need off a run around and craved some sideways action (I currently had a very special VW Polo G40 at home and didn’t want to take it to the car crime capital of Wales). Several of my friends had E30 325i’s and this is what I decided on. Ebay was my next port of call and a 169k 325i SE was purchased
    [​IMG]

    After a few weeks it was clear that the 20 year old E30 could be so much better with an input of cash, however being a broke student I didn’t have any and as a result the G40 was sold to fund the initial project
    The spec was planned and purchased
    SPAX PSX kit -60
    Strip the interior
    LSD
    DS2500 pads and Black diamond disks
    Braided hoses
    Sparco steering wheel
    Powerflex bushes through out
    6 Point cage.
    15” split wheels
    [​IMG]
    I was happy with this for a few months and did a few track days/drifting. However it soon be came clear that the 325i isn’t that quick and is in desperate need of some more power.
    I wanted to create an e30 that was as much fun in the dry as the stripped 325i with LSD is in the wet. With little research it was clear that Turboing the M20 was the way to go and while the engine was out the 2 door shell was going to be resprayed (September 2006)
    So the engine was taken out and the plan was to respray the shell.
    At this point I purchased some goodies with the below spec and said good buy to a student loan

    Engine:
    Fully rebuild: rebored block, lead copper big end and main bearings etc
    Polished Crank
    8:1 C:R with JE forged pistons and total seal rings
    O-Ringed + decked block by 0.1mm
    Head Spec
    PPF valves + springs with high accuracy cut valve seat
    Welded water jackets (where appropriate)
    New valve stems
    Standard Cam (possible change before completion)
    Other components
    750cc injectors
    Large Intercooler
    Spec 3 clutch

    However once the strip down started, the shell was past its best and an alternative was found in the shape of a recently resprayed and derusted rolling touring shell.
    Saying buy buy to the original
    [​IMG]

    Here is a pic after I got rid of the rusty old running gear, the outside had been sprayed very well in brilliant red, although the interior was still the original alpine white, this didn't bother me as the cage and chassis mods would have damaged the paint anyhow.
    [​IMG]

    The next stage was to start planning a spec list, due the exchange rate at the time I bought a lot of stuff from Ireland engineering in the us.
    Which included
    E30 front coilover conversion kit
    Urethane rear Subframe mounts
    Urethane engine mounts
    Urethane gearbox mounts
    Adjustable camber top mounts
    Adjustable rear camber and toe kit
    Billet rear anti roll bar mounts
    Billet rear top mounts
    Eibach 550Ibs / 600Ibs coilover spring kit

    Front strut Conversion
    The below pic shows the front struts after sandblasting with the ring welded on for the coilover perch
    [​IMG]

    Here the strut assembly shown once sprayed and assembled with the top mounts
    [​IMG]

    Rear Bean Conversion
    When ordering the suspension parts the camber and toe adjustment kit was chosen, this will in the future allow the car to be setup as necessary for drift or track use and also give the option of reducing the excessive negative camber produced when lowering the e30.
    Outer pick up points are for toe and inner are for camber, hence why the outer bracket slot is horizontal and the inners are vertical.
    A dye grinder was used for the slots
    [​IMG]

    [​IMG]

    The New bushes being installed
    [​IMG]

    Rear beam Finalised with the brackets welde and whole beam painted
    [​IMG]

    Front Subframe Reinforcement
    To prevent flex in the front cross member due to big power reinforcement brackets were purchased from UWEM3
    Below of subframe after sandblasting
    [​IMG]
    Subframe with bracket welded on.
    [​IMG]
    Subframe painted
    [​IMG]

    Shell Work
    Now work started on the shell.
    First, I wire brushed the underside and waxoyled it.
    [​IMG]

    [​IMG]

    Following this work started in side, the first step was to remove the nasty/ heavy sound deadening.
    [​IMG]

    This is a horrible job, Ive learnt recently that te easiest method is using dry ice. Not chipping inch by inch with a screw driver and hammer
    [​IMG]
     
    #1 oldroydsr4, Jan 30, 2009
    Last edited: Apr 4, 2013
  2. oldroydsr4

    oldroydsr4 Member

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    Sunroof removal

    To save further weight i decided to remove the sunroof and replace it with a cabon fibre panel.

    [​IMG]


    I had to leave a lip for the panel to be bonded/ riveted to

    [​IMG]


    Once that was tidied up, I used Proflex for the bonding and screwed the carbon panel in place.

    [​IMG]


    Rear Diff hanger Modifications

    With some research, it became clear that the weakness in the e30 shell when running a large increase in torque/power was the rear differential hanger and after viewing the picture below it was decided that thorough reinforcement was required

    [​IMG]


    While Chatting to Ant @ Atech he gave me a few ideas and i knocked up a drawing on Solidworks,

    [​IMG]



    [​IMG]



    [​IMG]

    When sourcing a diff, i contacted Kevo and he built me one to my specification.

    E36 back plate and trigger wheel
    Sand blasted casing
    50% Lockup LSD
    Tightened plates
    new seals
    3.46 ratio


    At this point the Cage was also welded in

    [​IMG]


    Once the fabrication was complete the inside was sparyed.

    Inside Respray

    The inside was complete degreased and rubber down usin 600 grit sand paper.

    Then red oxide primer was applied.

    [​IMG]


    following this that coat was rubbed down using 1200 grip and the brilliant red first coat was applied.

    [​IMG]


    This coat was then rubbed down with 1200 grit and another coat was applied. Following this a clear coat was added.

    [​IMG]


    In the above pic the colour looks a little orange but this is due to my crap camera phone.

    With the car sprayed the running gear was bolted on

    [​IMG]


    Suspension and driveline spec so far


    Here it is the progress to date, still lots to do but most is bolting bits on so progress will be fast.

    [​IMG]


    [​IMG]


    Suspension

    Coilover fronts with eibach 600ibs springs and spax adjustible dampers
    Rear Eibach 650ibs springs and spax adjustible dampers
    Adjustible top mounts
    Adjustible rear beam with ireland engineering bushes othrough out
    M3 control arm bushes
    H&R roll bars
    Billet rear anti roll bar pick up points
    Ireland engineering rear billet top mounts
    Ireland engineering Front strut brace
    6 Point OMP FIA roll cage

    Steering

    Z3 1.9 steering rack
    Solid Steering Guibo
    Every bolt /bracket /bush replaced


    Brakes

    Wilwood 310mm brakes
    25 mm master cylinder

    [​IMG]


    Transmission

    50% lock up and rebuilt LSD
    E36 diff back plate
    Modified diff hanger and reinforced rear end

    Wheels

    BBS LM replicas (wanted the real ones but cound't spend 2k on wheels :mad: )
    Toyo T1r tyres

    Ive also installed my Fuel cell today, helps with space around the rear beam when changing setup and hepls with the front heavy e30.
    IMO it also looks ace.

    [​IMG]

    Heres the pic of the recently installed front intercooler the front was cut away for this to be installed.

    [​IMG]


    Some other Bits that need to go in.

    [​IMG]


    Group A carbon mirrors :cool:

    [​IMG]
     
  3. oldroydsr4

    oldroydsr4 Member

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    b]Jobs to do to Finish[/b]


    Brake lines through car
    Install perspex windows
    Install wiring loom and cut down
    Install fire extinguisher and cut off
    Find omega gear box and prop
    Fabricate mounts


    Iv started installing the loom today :cry: , which if you read my posts from above will know that i didn't mark any thing up. However i did sort of remember where every thing went so wasn't to bad.

    [​IMG]

    [​IMG]

    As the car doesn't need the electric windows , mirrors, heater, abs, clocks, check computer etc from before , iv also started to unrap the loom and cut the bits out that aren't required. Following the Bently wiring diagrams is great fun :eek:

    [​IMG]

    Heres what i have cut out already
    [​IMG]

    Thats the progress on the loom so far.

    Got my flocked dash back this week :cool:

    [​IMG]
    [​IMG]

    Here is the compay that did the work,(they had some stunning mk1 and 2 escorts there)
    CBC Services

    The quality of the flocking is awesome and I'm over the moon with the results. Does any body know how durable the flocking is?

    On the donor car front, iv been looking at every possible website for the right car but nothing yet.



    The Donor

    Picked up the Saab 9000 aero this morning and paid just £650 for it.

    The body is rough as a bears arse (perfect) but the engine is mint and clearly had a bit of cash spent on it.including saab flight stage 3 ecu, dump valve, induction kit, silicon hoses, new radiator and electric fan with switch on dash, boost gauge, poly engine gearbox mounts etc etc

    Also have a Dyno chart stating 304bhp and 320nm of torque. She felt bloody quick in the saab body which weighs 1438kg, so i think the 1000kg e30 will be great fun especially with the 50% locking lsd.

    Heres a few pictures
    [​IMG]

    [​IMG]

    [​IMG]

    And the important part

    [​IMG]

    [​IMG]

    [​IMG]


    Hi All, Just a little update of the progress i have made since last time i posted. Although it might not seem much, motivation has been low and with it being soooo cold staying outside allday is always a challenge.

    Here goes

    The first step was to remve the lump from the saab, i decided to do this with as much attached as possible to help when installing it into the e30

    [​IMG]

    [​IMG]
     
  4. oldroydsr4

    oldroydsr4 Member

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    The next stage was to find the GM omega gearbox, I contacted Megavaux and £80 (including postage) later it arrived. This is the big worry on the build, as the GM gearbox is rated at 280nm and in tsandard form the saab b234r makes 325nm, with the current spec its getting on 350nm. I'm hoping theres a large safety factor in the GM figure. However I'm going to purchase a second box and have it cryogenically treated to allow for future turbo and boost upgrades.

    Check out this link for the explanations

    1 Cryogenics, Cryogenic Treatment, Tempering, and Cryo Processing: Cryogenics International

    [​IMG]

    Following this i stripped anything of value on the Saab and sent her to the race track in the sky(scrap value is now at its lowest so the £100 i thought i was going to get never materialised) :cry:

    [​IMG]

    Gearbox and engine bolted together ready for the test fit

    [​IMG]

    While the engine was out i measured up the mounting points on the block and made some dummy plates from 2mm aluminium for a test fit.
    [​IMG]

    [​IMG]

    These were then measured and drawn on solidworks. the working drawings where then sent to be my former place of work and machined for free :D

    [​IMG]

    With this done the engine counld now be positioned int the engine bay. It was decided that the engine was to be loctaed central to the car with anough room to get to the bellhousing bolts incase a gearbox change was required :roll: , I think a little manipulating of the tunnel may be required for the shifter tho.

    [​IMG]

    Bloks of wood/ axle stands and jacks were used to hold the engine in place until the mounts were welded

    [​IMG]

    With the engine positioned I friend (with 20years of welding experience) came round to weld the mounts up.

    [​IMG]

    [​IMG]


    Engine is now bolted in place :cool: and ready for radiator +exhaust fabrication etc etc. Once this is done i will remove it all and give it a freshen up + new clutch etc etc

    [​IMG]

    [​IMG]

    [​IMG]


    Mean while Iv Started work on the interior, The dash panel has been started and the door cards are finished. Iv also started countinued work on the loom and have decided to use CBS fuse box and simply cut what is needed from the bmw loom and wire straight to this.

    [​IMG]
    Although it is not finished and needs tidying, the plan is to copy the old Group A M3 dash layout and then get all of the aluminium panels powder coated plack.

    Currently i have no real pictures of loom work but just imagine a plate of spagetti and your half way there :mad:


    Engine wise, i'm planning on keeping with the standard td04 and stage 3 saab flight ecu +3 inch exhaust and large front mount, for now. But once has had a shake down i will plan for the bigger injectors and turbo etc


    Sorry if it doesn't if the tread doesn't flow, i have simply copied and pasted from my thread on another forum. I hope you lads and lasses like it.
     
  5. jap-si

    jap-si Active Member

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  6. prisspringle

    prisspringle Member

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    nice work, someone else reads PPC then ? that shell looks like new

    chris
     
  7. xan_lee

    xan_lee Member

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  8. Silverfang

    Silverfang F**knuggets

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    Location:
    Some workshop / Milton Keynes
    Someone's been reading PPC :worthy:

    This will be a real weapon of a car , the suspension and brakes look perfect but with the addition of the Saab engine should make the weight distrubtion almost 50/50.

    Maybe worth getting it corner weighted after it's built :nod:
     
  9. OptiBull

    OptiBull > > > > > > > > > >

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    W0W, nice project my friend. Top work
     
  10. retro-ed

    retro-ed Flicks 'n' Kicks

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    Spot on mate!:thumbs: An obvious awesome quality of work going on there!
     
  11. Cyruz

    Cyruz Sell Out

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    Very awesome :D :thumbs:
     
  12. oldroydsr4

    oldroydsr4 Member

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    Cheers all.

    PPC is my bible, was in the process of building a supercharger 12v 325 engine but the costs were getting ut of hand, the saab lump made alot of sense

    Going to spend another day on the wiring tomorrow, if i do any thing worth showing you lot i'll stick up a few pics.
     
  13. chunk

    chunk Raging Alcoholic

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    Great stuff, keep up the good work.
     
  14. Desperate_Dan

    Desperate_Dan Member

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    Very nice...Great fab skills, keep us updated
     
  15. goose

    goose Member

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    very nice, well impressed
     
  16. griffo20022

    griffo20022 Active Member

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    holy shiznit this is amazing!

    Love the likes of the research etc into the axle setup etc! Legend!
     
  17. gonças

    gonças Member

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    fcuking brilliant!
     
  18. MJG

    MJG Active Member

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    Very nice work, like a simpler and more functional version of Bryn's car! lol. Look forward to seeing/hearing this drive
     
  19. Chunky Nugget

    Chunky Nugget honkeytits!!

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    Awesome mate!

    Have you got one of the adapter plates for the inlet manifold or you going to make one?

    Loving this!:thumbs:
     
  20. Papercutout

    Papercutout Active Member

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    So, with an adaptor, a vauxhall omega box bolts onto the 2.3 turbo saab engine? VERY useful thing to know! Especially when it comes to plans for the viceroy in years to come! (it'd be rude not to!)

    Keeping an eye on this!
     

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