BuildaBeemer: Building a BMW E46 Track Car

[Zound]

Hi Guys,

Here's a quick update on some of the stuff that we have been working on since our last race at Zwartkops. Hoping the overheating issues are behind us and that we can focus on driver development and fine tuning the vehicle.

We've added a small, lightweight lithium (LiFePO4) Battery and relocated it to the passenger side of the vehicle. Result - significant weight loss and better weight distribution in the vehicle.

We've uploaded a new tune to the DME that breathes some character and excitement into the exhaust note. We've got pops and bangs!

We'll have to see if we get any flames shooting out of our custom free-flow race exhaust...


[video=youtube]

What do you think?

 

[danieltau]

raise: that exhaust note

 

[Zound]

So we went to the dyno on Friday...

Still struggling with some small amounts of reported knock and the ignition advance being pulled back a few degrees. Will try to get this ironed out when I write the next tune for the car.

Here's what we ended up with:

View attachment 6

Peak Power: 201.1 HP at 5700 RPM
Peak Torque: 284.5 Nm at 4090 RPM

 

[Zound]

So we had a small incident at Kyalami... Fortunately the damage appears to be only cosmetic.

[video=youtube]

View attachment 8

 

[UpNcOmiNg!]

Oh man!!
Dammit! Any idea why she slid out like that? Overheated tyres?

Sorry man. Thankfully it does look cosmetic only.

 

[Rayzor]

That really sucks man, hopefully its just cosmetic damage.

 

[Crash_Nemesis]

Oh man!!
Dammit! Any idea why she slid out like that? Overheated tyres?

Sorry man. Thankfully it does look cosmetic only.

The esses are known for unsettling cars and being off camber. More rear toe in and a stiffer front swaybar usually help negate corner entry oversteer. I wouldn't imagine overheated tyres being the cause, but tyre pressure rather could also be a factor. Whatever the cause, thankfully everyone is okay and the car lives to fight another day. We only learn from our failures. I have no doubt you guys will come back stronger from this.

 

[Zound]

[video=youtube]

 

[Zound]

Sent from my iPhone using Tapatalk

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So we’ve got the motor stripped.

The Head and Block will be going to the machine shop on Monday for testing and probably some optimisations.

Here’s the block:

Here’s the head:

Sent from my iPhone using Tapatalk

 

[Carbonic135]

Oh man!!
Dammit! Any idea why she slid out like that? Overheated tyres?

Sorry man. Thankfully it does look cosmetic only.

The esses are known for unsettling cars and being off camber. More rear toe in and a stiffer front swaybar usually help negate corner entry oversteer. I wouldn't imagine overheated tyres being the cause, but tyre pressure rather could also be a factor. Whatever the cause, thankfully everyone is okay and the car lives to fight another day. We only learn from our failures. I have no doubt you guys will come back stronger from this.

I think you’re spot on, Crash. We’re only running 0.3 total rear toe, camber also too conservative at 2 deg, and our tyre pressures were WAY off - 1.5 bar cold ?. Car felt a lot better when we went to around 2.5 hot, which equates to around 1.9 cold.

 

[Zound]

So our head, block and valves are receiving some attention at the machine shop.

We'll be getting it back soon and will need to hit the ground running and begin the re-assembly process.

We are of the opinion that we need to consider a thicker head gasket, because of the material that has been removed from the head and block as well as future proofing the motor for a potential turbo build (lowering the compression slightly).

The question is, how much thicker and where do we source a thicker head gasket from?

 

[Camnefdt]

So our head, block and valves are receiving some attention at the machine shop.

We'll be getting it back soon and will need to hit the ground running and begin the re-assembly process.

We are of the opinion that we need to consider a thicker head gasket, because of the material that has been removed from the head and block as well as future proofing the motor for a potential turbo build (lowering the compression slightly).

The question is, how much thicker and where do we source a thicker head gasket from?

how thick will depends on compression ratio you want to achieve, can easily be calculated using some measurement.

I have also seen some guys before using a copper 'shim' type gasket(machined to the same shape etc of the normal gasket) along with the head gasket to get a thicker one. But if i remember you have to make sure you have a proper crush fire ring to seal adequately.

 

[Crash_Nemesis]

Vac motorsports have some very good Multi Steel Layer head gaskets. Perhaps have a word with VAC in regards to what you want to achieve. They are very clued up and should be able to help point you in the right direction.

https://store.vacmotorsports.com/va...red-steel-head-gasket-bmw-m52tum54-p1072.aspx

 

[Zound]

Thanks for the suggestions guys.

I had come across the offerings from VAC motorsport, but I was hoping that there would be a local distributor in our midst?

Our time-line for this engine rebuild requires us to get it done before the next race on the 14th of November, so sourcing a component from an international supplier will be a challenge to fit into our timing requirement.

Craig has got busy with some panel beating and body repair. Excited to see the end result!

We've started cleaning many of the engine parts. It's so satisfying when the end result had the part looking like new.

The engine bay is also looking a whole lot cleaner now.
Before

After

By the way, has anybody had experience with the steering column rubber coupler?
It seems like there is a small amount of play in that unit, not something I think we would want in a purpose built track car.

 

[Crash_Nemesis]

Awesome work guys.

Regarding international shipping, I cannot give an opinion for how delivery timing would be in today's world thanks to the Covid-19 crisis, but my previous experience in ordering parts from Vac Motorsports has been a positive one. If they have stock, the parts are shipped pretty much immediately.

For example, I ordered a substantial amount of engine parts for my S54 back in 2015. I had pistons, valves, Rod bearings, piston rings and a MLS head gasket sent over. I just checked my emails and can confirm that the shipping took 3 days after the order was placed. I recall being very surprised when I got an email from TNT shipping on the Friday morning, asking for me to complete payment for the customs clearance of the shipment after having only placed the order that Tuesday, 3 days prior.

Again, I cannot say this will be your experience due to Covid-19, but perhaps have a word with the guys over there and see if they've experienced any problems with international shipping and whether they can guarantee a decent delivery time. Obviously if you can source something locally that is of the quality you need for your build, then that would be the route to take. Perhaps someone stocks Cometic MLS head gaskets locally?

 

[Carbonic135]

Awesome work guys.

Regarding international shipping, I cannot give an opinion for how delivery timing would be in today's world thanks to the Covid-19 crisis, but my previous experience in ordering parts from Vac Motorsports has been a positive one. If they have stock, the parts are shipped pretty much immediately.

For example, I ordered a substantial amount of engine parts for my S54 back in 2015. I had pistons, valves, Rod bearings, piston rings and a MLS head gasket sent over. I just checked my emails and can confirm that the shipping took 3 days after the order was placed. I recall being very surprised when I got an email from TNT shipping on the Friday morning, asking for me to complete payment for the customs clearance of the shipment after having only placed the order that Tuesday, 3 days prior.

Again, I cannot say this will be your experience due to Covid-19, but perhaps have a word with the guys over there and see if they've experienced and problems with international shipping and whether they can guarantee a decent delivery time. Obviously if you can source something locally that is of the quality you need for your build, then that would be the route to take. Perhaps someone stocks Cometic MLS head gaskets locally?

Thanks Crash. I used to enjoy similar shipping speed from Schmiedmann in Denmark (they use DHL) but it’s become a bunch slower in recent times. We’ll definitely look at VAC though - I get a rush of blood to the head every time I read your engine parts list in your signature  raise:

 

[Crash_Nemesis]

Thanks Crash. I used to enjoy similar shipping speed from Schmiedmann in Denmark (they use DHL) but it’s become a bunch slower in recent times. We’ll definitely look at VAC though - I get a rush of blood to the head every time I read your engine parts list in your signature  raise:

Ha ha... thanks Craig. I am very happy with the engine build.

I have a strong feeling that you guys will be doing similar engine updates to your track car come the next season or two. I look forward to seeing the progress, as I thoroughly love the thread and the videos you've been posting. Feels like I am living the race driver lifestyle vicariously through your build thread. :smilebounce:

PS. The engine build of my S54 is on my youtube channel if you ever have 40 min or so to spare and wish to have a gander. Link in my sig.

 

[Zound]

We've started to reassemble the motor!

And Craig is balancing the rotating assembly:

 

[Captain_Stealth]

why dont you look for getting m50 non vanos rods

They fit and if I recall you did wanna go turbo and since the motor is apart you might aswell do it

 

[Bernard///M3]

Well Done Guys!!
Hope the car will be ready for 14 Nov. looking forward to have a good dice with Nick in Class D!

Great stuff from Dino and Chris Fameliaris. That’s what the club is all about.