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Old Sun, Sep-13-2009, 07:03:33 PM   #1
M3_MadBimmer
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Location: Homer Glen, IL

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Default Mad Bimmer's build thread

I've been a member for a while, but never posted. Calvin (99mpower) got me interested to start browsing this forum.

The car is finished, but i'll just copy/paste the whole progress as it happened.



Little backround story,

I had my 98 estoril/mullberry m3 and never drove the damn thing, always wanted to boost it. I was away at school and the car was just sitting in the garage so i decided to sell it. When i sold it shortly after bassmaster from bimmer forums was selling his 95 turbo m3. I though man, pretty good price, i have no time to do a build at this time, why not buy it. So i flew out to NC and drove it back. Put a few thousand miles on the car and needless to say, everything on the car was sloppy and the motor gave out, windowing the block with the number one rod.

I've always stayed in touch with the buyer of my estoril and he actually was telling me that he might be selling the car. I cam up with the perfect plan...

I bought the estoril back, yanked the motor out of it and threw it in the 95 which is now my daily driver. I also replaced ALL of the suspension, brake lines, and brakes on the car, it was very poorly maintained by the NURSE bassmaster haha. and i went to town on the estoril.

Out of all the parts that were on the 95 when bass master boosted it, i only used a few to go into the estoril. PWR radiator, ebc, aa DSB, FPR, oil distribution block, crankshaft, stewart water pump, and aa 90* TB elbow.

I’m now finally doing what I wanted (and should have) to do initially. And that is make a completely custom and proper turbo setup on my estoril/mulberry sweetheart using all new/quality parts. I’ve spent roughly about $25-28,000 on parts for this car. Only labor I paid for was for tuning, cylinder head work, block machining, and getting camshafts reground.




engine:

- M50 block machined to 84.5mm, decked/honed
- S50 crank
- Eagle rods
- CP 8.5:1 pistons
- ARP main stud kit
- OEM main/rod bearings
- New oil pump, welded nut
- New cam/crank/kncock sensors
- UUC underdrive pullies
- A/C delete
- All new seals


Cylinder head/Valve train:

- .080” 85mm MLS headgasket
- ARP 2000 head studs
- Head Pressure tested
- Decked to very smooth finish
- Ported
- TB coolant supply port with a custom made adapter used for water temp gauge sensor
- Ferrea competition +1mm intake/exhaust valves
- Ferrea high performance valve springs
- Ferrea titanium retainers
- Ferrea spring seats
- Custom ground camshafts by Elgin Cams
- New OEM lifters
- New timing chains, and guides
- All new seals


Fuel System:

- 60lb injectors
- Bosch 040 in-tank pump, modified hanger with a modified -8 bulkhead fitting
- Bosch 044 in-line external pump -8 inlet/outlet
- Both running on direct wired relays using 10ga wiring, and 30amp fuses
- -8 supply line with a inline filter come to a Y and then two -6 lines going into the fuel rain
- -8 dual feed fuel rain with a -6 supply on each end, and a -6 return in the middle
- -6 return to BMP adjustable fuel pressure regulator, then -6 back to the tank with a modified -6 bulkhead fitting going to through the stock hanger.
- all stainless braided hoses and AN fittings used.


Intake/Cooling:

- Stewart water pump
- Euro expansion tank with factory lines/hoses
- PWR 57mm aluminum radiator
- 16” spal pusher fan with a custom aluminum fan shroud
- Irleland Engineering oil cooler cap with -10 lines going to a oil cooler with a in-line thermostat
- M50 intake manifold tapped for vacuum source
- AA 90* TB elbow
- 803 MAF
- New idle control valve
- Tial Q BOV (might switch to recirc)
- CXRacing 31x12x3 intercooler with 3” inlet/outlet
- Welded 3” intercooler piping
- All silicone couplers and t-bolt clamps
- Deleted EVAP system


Lubrication:

- Amsoil 15w50 racing oil being used
- -4 turbo oil supply from the IE cooler cap
- -10 oil return to oil pan
- BMP oil distribution block foil oil temp/pressure gauges


Exhaust:

- Tubular T4 top mount exhaust manifold
- 3” exhaust all the way back with a vibrant performance resonator and muffler
- Tial 44mm wastegate
- Wastegate piping tied back into the down pipe
- Turbine housing, manifold, DP, and WG piping all ceramic coated
- All v-band connections


Turbo/Tuning/Electornics

- Turbonetics T66 ball bearing turbo
- Converted to OBDI and using TRM tuning
- Aquamist HFS-5 water/meth system using two jets (aquamist system is for sale)
- Custom 8 gallon meth tank
- Blitz sbc id III electronic boost controler
- PLX wideband
- Stri-Racing boost/vacuum, oil pressure, oil temperature, and water temperature gauges
- Aquamist gauge in the headlight switch location, A/F ratio and boost/vac gauges mounted on the steering wheel column pod, oil press/temp, water temp gauges and EBC mounted In a custom sunglass holder


Suspension/Drivetrain/Brakes

- Ground control coil overs with DA front struts, rear schock mounts and GC camber plates
- UUC swaybars with soild front/rear links
- Understeer short shift kit with heavy selector rod
- AA front, racing dynamics rear strut bars
- New front control arms with delrin offset bushings
- New tie-rods
- Power flex rear subframe/trainling arm bushings
- Rouge engineering rear camber arms
- X-brace
- New front and rear wheel braings
- New euro floating front rotors, brembo blank rears, new pads
- Stainless brake and clutch lines
- UUC motor and transmission mounts
- ZF 5-speed transmission with amsoil fluid
- ClutchNet light weight flywheel, 6 spuck unsprung clutch and stage 3 pressure plate
- 3.15 LSD
- Modified subframe to limit differential movement and a AA DSB installed.


Exterior:

- LTW’s
- 30% tints
- Clear corners/tails/side markers





Pictures (sorry for crappy i-phone quality)


Both the beasts sitting side by side getting A LOT of treatment












S52 pulled and put in the 95, converted to obdI








Carnage pictures














Engine all assembled waiting to get dropped in the freshly cleaned engine bay



















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2003 ZHP

Last edited by M3_MadBimmer; Sun, Sep-13-2009 at 07:43:39 PM.
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Old Sun, Sep-13-2009, 07:04:24 PM   #2
M3_MadBimmer
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Sensors for gauges








Manifold/DP/WG piping construction
































Gauges, the headlight switch is now located right under the foglight switch














Methanol tank











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Old Sun, Sep-13-2009, 07:04:59 PM   #3
M3_MadBimmer
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Fan Shroud










Misc.


















Few of the car
















Big thanks to JT for being a huge inspiration for me to even start welding, and putting together my motor.

Mike Radowski for supplying me with parts and answering a ton of questions.

George at ICS

TRM, hopefully you guys will bring me to the promised power goals that I have!
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Old Sun, Sep-13-2009, 07:06:32 PM   #4
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installed fuel tank and mounted the bosch 044 inline pump.










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Old Sun, Sep-13-2009, 07:07:27 PM   #5
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4/23 12:15 AM - made some decent progress tonight after work.


first i drilled a hole for the level sensor in the tank. Then i had my father (machinist) make me a little weld on bung that i could weld on the tank, and he tapped it for the fitting. So i drilled a 1/2" hole for that and welded it on.











then i decided to weld on my drain fitting on the oil pan. welding a bung directly on the oil pan and having a 90* hose end go into that was not acceptable by me because i feel that with the angle of the oil pan that will create a low spot. Probably not a big deal, but with only a bit of more work i cam up with this. I had my dad machine me a little pipe with a perfect od/id for the weld on fitting, and then i cut it on a angle, welded the bung onto that and then, welded the pipe onto the oil pan.

end result

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Old Sun, Sep-13-2009, 07:08:14 PM   #6
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finished up the tank and leak tested. To the BRIM of the filler neck, it took 8.3 gallons and there appear to be no leaks what so ever. All i have to do is figure out how to secure it now.






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Old Sun, Sep-13-2009, 07:09:26 PM   #7
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cut/assmebled hose/fittings going from 044 outlet to inline filter to Y junction.


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Old Sun, Sep-13-2009, 07:10:17 PM   #8
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- paint the euro tank mounting brackets
- welded the strut tower bracket on, touched up the welds with paint
- rivited the firewall mount on and painted the rivit heads
- made a boost controller solenoid bracket to go under the exp. tank, tacked on washers/nuts for proper fit and easy assembly.
- cut and installed engine bay heat insulation (i may do some more)












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Old Sun, Sep-13-2009, 07:11:33 PM   #9
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Meth tank is now 100% complete. Decided to drill some holes through the plastic trunk support piece and have bolts go through it. Then i welded on little brackets to the tank. Holds down firmly, will most likely make a small rubber wedge to tap in between the top of the tank and the top of the trunk so it doesnt rock or possibly crack the plastic support under heavy cornering.










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Old Sun, Sep-13-2009, 07:12:06 PM   #10
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Mckinney Racewerks with the supplied mounting hardware, self tapping screws? I dont think so...








i cut/bent a simple L shape bracket for the FPR




Cut a short piece of pipe, and cut it so it would be spread apart, and then with a clamp, it would tighten down on the can










Welded it on to a straight bracket














Twisted the FPR L bracket and made a few adjustments, and welded it on the main bracket.








Smoothed it out







Put together










All installed using the intake manifold bracket bolt.












Then shot it with a coat of black (drying now)



Note, i decided not to use the catch can
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Discussing Mad Bimmer's build thread in the Forced Induction (F/I) Forum - Discuss the ever growing F/I options here! at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)