x_atlas0
Well-Known Member
The original intake manifold can fit if you switch to a 2002tii brake booster, as it has a smaller diameter. At least, that's what aaerach did and it seemed to fit. You could also adjust the engine angle a bit.
My 1974 Inka S38B35 project
- Thread starter xjan99
- Start date
xjan99
Well-Known Member
Yeah, I have read about that option, but many also say they do not like the brake feel with the 2002tii booster. So we are going a bit different route there.
x_atlas0
Well-Known Member
Really? I haven't heard about that before. I've been driving it with the tii booster for ~15 years, but I never drove it with the original booster in place. Brake engagement is good, bite point is high, and pressure can be modulated well, but it does require a bit more stroke.
xjan99
Well-Known Member
Progress update for January..
A lot of time was spent fabricating the tilt-slide mechanisms for the front seats. I must check the head-room now and see if it is satisfactory or should we redesign the original seat attacments to lower the seating position.
And adding-testing more parts under the hood. The S38 coolant radiator works well ofcourse with the right hoses.
Next up was testing the drive shaft. It does not fit as needed, so it was cleaned and sent off to a speciality shop to be lengthened ca. 30mm and also balanced.
Looking at the steering rack pump brackets on M30 and S38, we decided to go with the S38 bracket and ordered a M5 steering pump
Next up, the new sill covers were tested and made to fit perfect.
And new mirrors attached:
We also set the car on wheels. Although on some lowering springs it sits way higher than I like so most probably we will order coilovers from Germany. But... ain't it a beauty already
?
Most of the work on the body is done, so we are going to move along to refurbishing the axle parts etc soon. New bushings, brake calipers, etc all ordered.
We also have an idea to develop a more contemporary AC solution which would work with the regular heater box
A lot of time was spent fabricating the tilt-slide mechanisms for the front seats. I must check the head-room now and see if it is satisfactory or should we redesign the original seat attacments to lower the seating position.
And adding-testing more parts under the hood. The S38 coolant radiator works well ofcourse with the right hoses.
Next up was testing the drive shaft. It does not fit as needed, so it was cleaned and sent off to a speciality shop to be lengthened ca. 30mm and also balanced.
Looking at the steering rack pump brackets on M30 and S38, we decided to go with the S38 bracket and ordered a M5 steering pump
Next up, the new sill covers were tested and made to fit perfect.
And new mirrors attached:
We also set the car on wheels. Although on some lowering springs it sits way higher than I like so most probably we will order coilovers from Germany. But... ain't it a beauty already
?Most of the work on the body is done, so we are going to move along to refurbishing the axle parts etc soon. New bushings, brake calipers, etc all ordered.
We also have an idea to develop a more contemporary AC solution which would work with the regular heater box
day66
Well-Known Member
Great progress and interesting to see the bumper/spoiler set up - I was thinking of something very similar for mine, so it's great to see how it looks in the metal.
Hello, If you want to use a bumper I think you should buy a fiberglass bumper from "Alberto" it is very light and you can paint any color you want, I did the same check the picture
Attachments
xjan99
Well-Known Member
My first thought was also to use a fiberglass one, easier to modify. But the strength of the sturdy metal bumper is something else in case of...
xjan99
Well-Known Member
Update for work done in February, total hours spent so far: 1344h
A lot of parts arrived from W&N again, mostly related to axels.
And also camber/toe kits from Ireland Engineering:
which we installed together with reinforcing the subframe too:
Ready for paint:
These got dismantled and
cleaned
Next, we opened up and drained the diff
Cleaned from the outside:
And although we were happy to confirm, it is a 40% LSD, it is not usable and needs repairs...
A lot of parts arrived from W&N again, mostly related to axels.
And also camber/toe kits from Ireland Engineering:
which we installed together with reinforcing the subframe too:
Ready for paint:
These got dismantled and
cleaned
Next, we opened up and drained the diff
Cleaned from the outside:
And although we were happy to confirm, it is a 40% LSD, it is not usable and needs repairs...
Belgiumbarry
Well-Known Member
W&N is having a party now
we need @BMW Pete to post a picture of his boat
xjan99
Well-Known Member
Update for March. 90h spent, mostly on drivetrain parts - refurb, coat, paint... not much to say, so just enjoy the process in the pics
And we decided to reinforce these bits too, yes:
Driveshaft, with the new corrected length and fully refurbished parts ready for paint
But more interesting part is.... after testfitting the seats as-they-were, I was not happy about the sitting height. The CSL seats are very narrow too, so even with my skinny ass and 184cm (6'2"?), only a mere 1 cm (1/2 inch) between my head and the to-be headliner (yes, I also have a sunroof). We discussed different option and this is what we ended up with - a complete revision of the seat attachment that also provides more rigidity for the whole body. Passenger side to follow suite.
And we decided to reinforce these bits too, yes:
Driveshaft, with the new corrected length and fully refurbished parts ready for paint
But more interesting part is.... after testfitting the seats as-they-were, I was not happy about the sitting height. The CSL seats are very narrow too, so even with my skinny ass and 184cm (6'2"?), only a mere 1 cm (1/2 inch) between my head and the to-be headliner (yes, I also have a sunroof). We discussed different option and this is what we ended up with - a complete revision of the seat attachment that also provides more rigidity for the whole body. Passenger side to follow suite.
xjan99
Well-Known Member
Moving on, here is what happened in April. Not much, with only 39h spent, but still...
So passenger side seat attachment was redone too, just like on the driver's side.
Then it was time to sort, clean and wire polish some bolts/nuts/washers, mainly related to axles.
And by now, these are also freshly coated. This is a nut-and-bolt resto(mod) after all, you know
Mailman delivered a package too. We 3D scanned, 3D printed a test part and sent the drawings off to China for CNC work. A new part was made there for the diff LSD unit. The old, the test piece and the new:
It fits!
On to assemble the rear axle and LSD now. Front struts were sent off to Mr. Raab in Germany who will return a fresh set of KW coilovers in a few weeks.
So passenger side seat attachment was redone too, just like on the driver's side.
Then it was time to sort, clean and wire polish some bolts/nuts/washers, mainly related to axles.
And by now, these are also freshly coated. This is a nut-and-bolt resto(mod) after all, you know
Mailman delivered a package too. We 3D scanned, 3D printed a test part and sent the drawings off to China for CNC work. A new part was made there for the diff LSD unit. The old, the test piece and the new:
It fits!
On to assemble the rear axle and LSD now. Front struts were sent off to Mr. Raab in Germany who will return a fresh set of KW coilovers in a few weeks.
xjan99
Well-Known Member
Summer came and this meant I was too busy with other stuff to even write an update. Here is a quick overview of what was done in May and June. Total hours spent so far: 1600h. And if you are wondering on costs accumulated (car, engine, work and parts), it is way past 6 figures already some time ago...
On to assemble the differential:
And reassemble the rear axle:
Next, the last bits of the body had to be tackled, the roof and sunroof frame had a lot of bondo, dents and rust...
The foam they used between roof and sunroof frame is the main culprit, why these cars' roofs rust from inside out. Water gets trapped in the foam and result is a new roof skin is needed.
And it was not perfectly straight (hence the bondo)
Nor did the gaps satisfy us here also, so we remedied these
And now the sunroof frame is fixed so it is glued back, no more nasty rust coming from the foam
There was also a bit of work needed around the rear glass area
And we also had to fill the parcel shelf speaker holes:
All in all, we can now say the metal work has ended, pretty much... 99% I think, as there are still some fabrication work needed for air filter box, steering pump brackets etcetc
On to assemble the differential:
And reassemble the rear axle:
Next, the last bits of the body had to be tackled, the roof and sunroof frame had a lot of bondo, dents and rust...
The foam they used between roof and sunroof frame is the main culprit, why these cars' roofs rust from inside out. Water gets trapped in the foam and result is a new roof skin is needed.
And it was not perfectly straight (hence the bondo)
Nor did the gaps satisfy us here also, so we remedied these
And now the sunroof frame is fixed so it is glued back, no more nasty rust coming from the foam
There was also a bit of work needed around the rear glass area
And we also had to fill the parcel shelf speaker holes:
All in all, we can now say the metal work has ended, pretty much... 99% I think
, as there are still some fabrication work needed for air filter box, steering pump brackets etcetc
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xjan99
Well-Known Member
A few slow months, but hopefully picking up speed again. Stuff done in the meantime is here:
First, we needed to customize the steering rack pump mounts
And as we are nearing completion on the body, we needed a new rig to be able to tip the car on the side too
Some more parts from W&N got sandblasted, primered and test-fitted too
New mounts underneath the car were made. Each and every corner we touch, we find rust so need to fabricate and repair to be "better than new":
And some reinforcements added too:
Next up, engine removed and on to the new dolly
Next we still need some fabrication work done related to the body harness and AC (will be custom and all new) and also we will start with refinishing the underside and inside of the car until the paint shop is able to accommodate us.
First, we needed to customize the steering rack pump mounts
And as we are nearing completion on the body, we needed a new rig to be able to tip the car on the side too
Some more parts from W&N got sandblasted, primered and test-fitted too
New mounts underneath the car were made. Each and every corner we touch, we find rust so need to fabricate and repair to be "better than new":
And some reinforcements added too:
Next up, engine removed and on to the new dolly
Next we still need some fabrication work done related to the body harness and AC (will be custom and all new) and also we will start with refinishing the underside and inside of the car until the paint shop is able to accommodate us.
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xjan99
Well-Known Member
Work is now starting on the interior surfaces and we are moving along with the AC/heat combo-box prototype too.
Cool! Curious to see some pics of the internals of the box.
x_atlas0
Well-Known Member
Yeah, I'd like to see more about that too. Is the evap core very small, or did you relocate some of the internals? I'm in the middle of doing something similar so it would be interesting to compare notes.
xjan99
Well-Known Member
@AC questions - all in due time
In january, ~60h was spent cleaning and degreasing, then filling cavities with epoxy primer, a bit of filler/sanding too + covering the body shell with epoxy primer then. Doors, hood, trunk etc to follow and by that time these will be done, the main body shell has cured enough to tackle the next steps - seam sealing.
In january, ~60h was spent cleaning and degreasing, then filling cavities with epoxy primer, a bit of filler/sanding too + covering the body shell with epoxy primer then. Doors, hood, trunk etc to follow and by that time these will be done, the main body shell has cured enough to tackle the next steps - seam sealing.
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Haha, your workshop looks like mine....
Well done so far.
Breiti
Well done so far.
Breiti
x_atlas0
Well-Known Member
Given all that work, I'm a little surprised you didn't weld up the seams to improve torsional rigidity.