craigdiver
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| posted on 5/8/17 at 11:51 AM |
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Just got my 2nd hand wishbones back from fabrication shop (to tidy them up), shot blaster (to strip previous paint job) and powdercoater. £100 all in
and they look fantastic (photos to follow). Started fitting polybushes and crush tubes - quite tricky, going to have to chamfer the crush tubes so
they slip into the second section of poly bush.
Looking forward to getting wheels on!
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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Simon
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| posted on 5/8/17 at 09:42 PM |
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Have you tried a bit of washing up liquid - works wonder.
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craigdiver
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| posted on 6/8/17 at 06:57 AM |
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quote:
Originally posted by Simon
Have you tried a bit of washing up liquid - works wonder.
The pile of crap silverline vice I bought stripped the screw so have sourced a record vice and am picking that up this morning. Will use washing up
liquid, can I use that for the polybushes into the bush tubes as well (as ive been putting these in dry)?
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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Schrodinger
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| posted on 6/8/17 at 07:14 AM |
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When I put mine in, some time ago, they came with sachets of silicone grease to aid insertion.
Keith
Aviemore
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craigdiver
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| posted on 6/8/17 at 07:22 AM |
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quote:
Originally posted by Schrodinger
When I put mine in, some time ago, they came with sachets of silicone grease to aid insertion.
I was under the impression that the silicone grease goes between the polybush and crush tube (supposed to move) and the polybush to bush tube should
be dry (so doesn't move)?
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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David Jenkins
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| posted on 6/8/17 at 07:47 AM |
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quote:
Originally posted by Simon
Have you tried a bit of washing up liquid - works wonder.
The trouble with washing up liquid is that it contains a lot of salt - liable to cause corrosion in the future, maybe.
Plain old bar soap is probably better - just moisten the soap and smear it on.
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rusty nuts
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| posted on 6/8/17 at 08:15 AM |
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Some of the stretch C.V gaiters use an aerosol spray of boot lube which apparently very much like KY jelly, it works a treat . If you haven't
already seen it check out "crush tube issue"
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craigdiver
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| posted on 6/8/17 at 02:15 PM |
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Wisbones assembled and fitted :-)
Good job done today with help from my son Matthew, got the wishbones assembled and fitted, do they look ok?
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 6/8/17 at 02:18 PM |
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The polybushes I bought were a very rigid polyeurothane compared to the softer ones that came with the wishbones. Made it difficult to fit the
wishbones but suspension will be nice and tight.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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rusty nuts
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| posted on 6/8/17 at 02:39 PM |
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While fitting the crush tubes did you ensure that the wishbone rotated around the tubes easily when clamped in the vice?
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craigdiver
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| posted on 6/8/17 at 02:52 PM |
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quote:
Originally posted by rusty nuts
While fitting the crush tubes did you ensure that the wishbone rotated around the tubes easily when clamped in the vice?
Wouldn't say easy as any silicone grease I put on the crush tubes was wiped off whilst being inserted, however, they did move and not the
polybush. Still to tighten up the bolts holding the wishbones to clamp up the crush tubes. That will be the real test!
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 11/8/17 at 06:24 PM |
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Brake/fuel lines
Planning on getting the front brake lines in tomorrow (from the MC to tee anyway) so I can get engine in. Also going to copy this for the fuel/brake
lines through the transmission tunnel (if this is your car, great work);
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 12/8/17 at 03:31 PM |
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A productive day
Got front brake line in - getting the brake pipe flares done was a piece of cake after buying the Sykes Pickavant flaremaster 2
Put engine back in for the final time and found pulley on crank a bit close to brake pipe. The front pulley was for the power steering / aircon which
is no longer there so will cut off the pulley giving more room. Still need to work out how to remove the surplus viscous cooling fan hub.
Fabricated aluminium strips to hold the clips for the fuel and brake lines - really pleased with the job, just need to add a couple of clips at the
front and I'll be able to run front to back brake / fuel lines.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 13/8/17 at 07:38 PM |
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Another productive morning
Managed to scour the BMW forums and find out to remove cooling fan viscous hub - easy when you know how, removed and binned. Removed crank pulley that
was connected to power steering and air con pumps - no longer needed and was quite close to my front brake line - plenty of clearance now.
Made up blank for port left over from removing BMWs monsterous exhaust gas air purge pump. Fitted new spark plugs, old ones were quite tight but came
out ok and new ones went in well. Ordered oil for engine and ordered new throttle cable.
Going to try to get my fuel tank welded up this week and then won't be long before I can get the engine fired up.
[Edited on 13/8/17 by craigdiver]
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 22/8/17 at 07:22 PM |
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Fabricated aluminium supports for the brake/fuel lines.
Fitted propshaft, bit of a pig to get in but relieved it fits well.
Worked on OBP universal pedalbox, set bias bar centrally and locked in place with supplied nylocs. Fitted microswitch for brake lights. Installed in
car and ran front to back brake pipe.
Fabricated and welded in rear wheel arch infill panels. Also fabricated brackets to take the roll-bar supports gudgeon pins. Think these will need
some bracing once I see what room I have after fitting fuel tank.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 24/8/17 at 09:36 PM |
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Fuel lines in. Designed fuel tank on solidworks, cut out the aluminium and had it welded - delighted with the results.
Just need to fabricate some mounts for the tank. Going to mount the tank off-set towards the N/S to balance weight out a bit (shown on wrong side on
photo). Also leaves room for a little 5ltr reserve green unleaded fuel container.
Need to mount fuel pump, level sender, breather valve in tank, then hook up fuel lines.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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Nickp
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| posted on 25/8/17 at 09:59 AM |
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Your gearstick- You can slit the alloy outer using a cutting disc. It can then be prised off along with the rubber inner. This leaves the steel shaft
at just the right length. I used a die to cut a thread to fit a nice gear knob.
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craigdiver
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| posted on 25/8/17 at 10:28 AM |
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quote:
Originally posted by Nickp
Your gearstick- You can slit the alloy outer using a cutting disc. It can then be prised off along with the rubber inner. This leaves the steel shaft
at just the right length. I used a die to cut a thread to fit a nice gear knob.
Thanks Nick, ill wait till after the IVA before I fit the skull gear nob though! ;-)
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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rodgling
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| posted on 25/8/17 at 12:15 PM |
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quote:
Originally posted by Nickp
Your gearstick- You can slit the alloy outer using a cutting disc. It can then be prised off along with the rubber inner. This leaves the steel shaft
at just the right length. I used a die to cut a thread to fit a nice gear knob.
Alternatively, the Z3m stick is what I use in my car as it has the shortest throw of any of the standard E36 gearsticks and it's pretty much
perfect for me, the knob ends up at a good height so it's a small movement of the hand to change gear.
[Edited on 25/8/17 by rodgling]
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craigdiver
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| posted on 26/8/17 at 04:08 PM |
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Strange day
Had a strange day, had a list of things I wanted to do today but never got much done, took 4 hours to fabricate fuel tank cradle and securing
brackets. Changed engine oil and fitted kopex for front to back cable run so that I got a few things done off the to-do list.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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David Jenkins
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| posted on 26/8/17 at 04:27 PM |
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My build was like that, towards the end - loads of little jobs with no obvious end in sight. Eventually I wrote all the jobs down on an old
whiteboard and crossed them off as I got them done. I felt a lot better when I looked at the board and saw all the crossed-out tasks. Even when I
realised that I'd forgotten tasks and had to add them to the board, it still felt good to see the crossed-off list.
The list also helped when my time was limited - I could look at the board and think "I've got 30 minutes to spare, I can do that little
task". Doing that slowly eroded the taks until I could see that I was getting close to finishing.
Mind you, it didn't help when I'd do a task one day, then come back the next and decide that I didn't like it and had to start
again! But that's my character flaw...
[Edited on 26/8/17 by David Jenkins]
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craigdiver
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| posted on 30/8/17 at 06:14 PM |
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Great afternoons work, got front hubs fitted and wheels mounted - shocks arriving tomorrow from rally design.
Rear bulkhead fitted, awkward to get to the lower rivets but done now and silkaflex used to bond it to chassis.
Anyone found black cloth like used in the interior of lamborginis?
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 30/8/17 at 06:17 PM |
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And seatbelt eyebolts fitted with assistance from forum member adithorp.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 31/8/17 at 05:20 PM |
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Drivers side tunnel panel fabricated with a little TLC fettling with the precision sheet metal adjustment tool ;-)
[Edited on 31/8/17 by craigdiver]
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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craigdiver
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| posted on 9/9/17 at 08:23 PM |
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Carpet fitting & engine starting
Been busy over the last couple of days. I had ordered material that was supposed to be similar to the stuff on the interior of lamborginis but
didn't like it so bought black (anthracite) cord carpet from carpetright for £2.99/sqm. Glued onto my rear bulkhead and drivers tunnel panel -
really happy with the finish. Fitted tunnel panel with M5 rivnuts and stainless countersunk hex screws with solid cup washers - again delighted with
finished look. Fitted drivers seat and sat in the car making vroom vroom noises ;-)
Next job was to assemble fuel pump, level sender, fuel return & rollover vent valve. Went ok but needing to work out how to secure BMW fuel pump
in tank, might need to buy aftermarket submersible pump that can be cable tied in internally.
I am about to buy a modified ECU which does away with; the BMW EWS security, after cats lambdas, limp mode. Also increases power to almost 200bhp. And
I wanted to prove engine was running ok with standard ECU before getting new ECU and heavily butchering the wiring loom.
Next job was to pull out the original BMW wiring loom to hook up and attempt to start the engine. Took ages to untangle it and find the connectors.
Connected all the negative points. Fuel pump not firing on ignition power up so hooked up a seperate power supply and tested. Good fuel rail pressure.
Turned engine over for a while but wouldn't even attempt to fire. Running out of time I pulled the plugs in case got fuel in the cylinders.
Next I'll pull engine fault codes and post on BMW forum to get some help to find the issue(s). Strange that the fuel pump isn't being run
for a few seconds on ignition.
Finally I sanded down the mk2 escort rack, painted & fitted. Need to measure up what extensions I need.
If it ain't broken, fix it anyway (just because).
Building - BMW powered Haynes Roadster/442E hybrid.
Volvo C30 T5 Polestar
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