ITR Z3 rebuild thread

[Z3_GoCar]

I thought I'd document the rebuild of the Z3, mod-Zwei.

Well, here's the rear suspension sub-frame in the back of the truck

http://49thaero.tripod.com/sitebuildercontent/sitebuilderpictures/twisted_racer1.jpg

This was the barely perceptable tweeked side. On the other side:

http://49thaero.tripod.com/sitebuildercontent/sitebuilderpictures/twisted_racer2.jpg

The twisting is more severe and toed in for extra stability :o Also notice the single "Mickey" mouse ear on the differential. This is how it sat for the last couple of months. Then two weeks ago I went to the auto-hobby shop. Next update; the new arms have new bearings, are on, and it's back in the car along with a bondo-update and a new steel hood in Imola Red.

James

[Z3_GoCar]

Thank you Mr. webmaster. With the photo hosting I can update the state of my Z3 : )

Here's a close up before of the rear wheel, finder, and door:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=13

and here it is after some hammering, body filler and a new trailing arm:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=125

This is the front horn before I started pulling and hammering on it:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=15

and this is the left side now:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=123

I've got several more, so I'll post them later.

James

[JeffYoung]

Wow, that is a lot of work my friend. Good job on it, looks like she is shaping back up right nice.

[Z3_GoCar]

One of the areas that really looked bad was the rear. The gap between the finder and trunk lid was much wider on the left. Now it's much closer to the right side:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=124

Actually both the rails running from the strut towers were pushed down. Now after lots of hammer work they're closer to where they were. Also, the main horns look straight.
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=122

With the core support out I plan to pull the motor and take whats left of the pan off. The least expensive route may be to find a doner M-52-28 to put back in that I won't have to touch for a couple of races, and I know a salvage yard motor will probably be legal, and now I'll have a spare motor to rebuild evantually. I like to imola red, I'm thinking of painting the windshield frame and maybe a strip around the top of the door red, then leaving the main body color silver. This next photo is how the hood fits over the finder and door, also note I've taken the apron cap off of the windshield frame, this piece of sheet metal has been on order for the past month along with a new set of brake lines for the rear.

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=128

I've been busy with the primer and spot filler. I've been using plasticote's grey from the local N-A-PA. It's lacquer based along with the spot filler, I've found several links for factory silver and red in spray cans. See the $50 paint job thread. Slowly but surely I'll have it together eventually.

James

[Z3_GoCar]

Wow, that is a lot of work my friend. Good job on it, looks like she is shaping back up right nice.

Thanks Jeff,

It's suprising how cathardic, and cheap hammering on metal can be. I was fortunate that the damage wasn't much more than skin deep.

James

[NORRIS]

Hey James.

I'm impressed, you're going to fix the whole thing WITHOUT even taking it off your trailer!!

[JoshS]

Looks good! Glad it's coming back together. Do you have any idea of when it might be track-worthy again?

[Z3_GoCar]

Hey James.

I'm impressed, you're going to fix the whole thing WITHOUT even taking it off your trailer!!

Hasn't been off since you helped me pack up last Labor day. I'll probably push it off to pull the motor, but I'm waiting untill I get the windshield apron, so I can weld it on at the same time as I pull the motor. I took it off the jack-stands and it's back on the wheels.

I didn't get a chance to talk to you after Long Beach. Did you have fun?

James

[Z3_GoCar]

Looks good! Glad it's coming back together. Do you have any idea of when it might be track-worthy again?

Hey Josh,

I hope to be out before the end of the season, now that I'll have a regional license to keep up. I'm always running at the end of the season and not the beginning.

BTW, the ITC #63 510, we did the same super-school.

James

[Z3_GoCar]

Newsflash,

I just recieved a package from Pelican Autoparts, it's my new rear brake lines and the header panel for the drivers side windshield frame. I ripped the old one off and tried to beat it back into shape before deciding it just wouldn't give anything close to the original shape. I also just purchased a used oil pan and intake manifold. I'll go through the motor and re-bearing/ring it, maybe even check out the valves, and contact my tuner to see if he has a source on matched stock bosch injectors. Unfortunetly, the race car now has competition for my wrench time as the ac pump on the truck froze up, with only one belt it's out of action. I think soon I'll be looking for a basic 1/2 ton to tow with.

James

[Z3_GoCar]

I just added this picture, one of the few I have of the car in action:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=141

This was at Buttonwillow, the 200Sx belonged to Naji, who had an encounter with the tire wall the same weekend that I rolled.

James

[Z3_GoCar]

Just to keep this thread going, I just uploaded this vid to google:



Ah, the good times I had in this little car :eclipsee_steering:

James

[lateapex911]

One thing you can say about using the trailer to work on, it's easier to find places to tie the car to while you pull/jack things back in place!

Good work James, be sure to get the factory dimensions on the front horns, etc to make sure everything is square and proper.

[Crashtest]

you gonna come run that thing in SFR ITR?
we are needing more people....

[Z3_GoCar]

you gonna come run that thing in SFR ITR?
we are needing more people....

Hey James,

You might see me at a couple of races next season, but I doubt I'll make the long drive for me to Thunderhill. So, most likely a Laguna-Seca race then maybe at Infineon.

A brief update, the car is off the trailer and I've pulled the motor a transmission yesterday. It only took a couple of hours including removing the hood and disconnecting the power steering lines and clean up. I'm really sad about the pan. Because, it was from a euro e-36 M3 and is a couple of quarts larger than the stock pan I've got to replace it with. I wish I knew someone who could weld it back togeather. I still have to split the transmission, and put the motor on the stand. Maybe I'll be doing that tomorrow. I'd be taking more photo's if I weren't doing all the work myself.

James

[Sandro]

james,

if the pan is steel I can weld it for you (but Im guessing its aluminum)

[Z3_GoCar]

james,

if the pan is steel I can weld it for you (but Im guessing its aluminum)

I appreciate the offer, but alas it is aluminum. I yanked off the transmission and pulled the clutch. Now I'll need a torch to break the locktite on the flywheel bolts and mount the motor on my engine stand. In the meantime here are some photos I snapped this afternoon:

Same as the Subframe, the truck bed makes a good place to take it off the hoist:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=165

Here's the hole in the oil pan, I have the missing triangle piece:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=166

The motor mount was litterally ripped in half:
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=167

James

[Crashtest]

your pan can be fixed...
that is not that bad
I had a cracked ducati engine case welded before and it worked fine...
if you cant find a guy down there I am sure someone up here in santa cruz can weld it....
the hardest part is getting the oil out of the metal to weld it.
send me your info if you need help..
crashtest22 at gmail

[NORRIS]

James.

If you can get the pan to me. I know a very good certified welder who can work miracles with aluminum.

[Z3_GoCar]

your pan can be fixed...
that is not that bad
I had a cracked ducati engine case welded before and it worked fine...
if you cant find a guy down there I am sure someone up here in santa cruz can weld it....
the hardest part is getting the oil out of the metal to weld it.
send me your info if you need help..
crashtest22 at gmail

Is it alright if I call you JC?? The one chunk is only one piece of many and several rips in the aluminum. Also, it's a double wall casting, with a cast in windage tray, that would need to be removed to get to the inside. Actually, it's a really neat piece and it's also got a double pick-up on the pump, the main rear one and a smaller one in front.


James

If you can get the pan to me. I know a very good certified welder who can work miracles with aluminum.

Hey John,

Thanks for the offer, but I might know someone locally who can do it also.

James

[Z3_GoCar]

I've got the motor most of the way apart. Interesting fact about the oil pan is it's a double wall casting with dual sumps, same as on the S-54. If it were a lesser pump, all the internal parts would be avalible seperatly. But since it's a motorsports unit it's only avalible as a single $600 part.
http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=177

I suspect that the oil relief has been causing low oil pressure issues. Here are more pictures of the damage:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=178 The crack in the front sump area, note the built in windage tray and dual wall casting.

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=180Close up of the rear sump, notice the pieces.

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=181Note the rip in the back of the sump.

To fix it I'm thinking of bending up some 3/16" aluminum plate and building a new bottom end for the sump. Maybe even mill in some fins into the plate.

James

[Z3_GoCar]

Since video has been added. Here's the last couple of laps before all the carnage:
http://www.myscca.com/includes/flvplayer.swf?file=http://www.myscca.com/video/250/2007/12/02/4671ccf1a8115f387fcdc7e04997.wmv.flv&autostart=true

I'll never forget that fateful moment I looked down and decided to up shift to 5th :blink:

James

[Z3_GoCar]

Here's what I was thinking would be my inspiration for the rebuild paint scheme:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=191

Would the shark mouth be to over the top on the shark car? What do you think?

James

[JeffYoung]

Dude, it's a race car. DO IT.

[Z3_GoCar]

Dude, it's a race car. DO IT.

Yeah, if I can't do it on a race car, where can it be done?

[Z3_GoCar]

I just pulled the tape and bolted it up to see how it'd look. What do you think??

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=194

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=193

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=192

[JoshS]

Before, it was a cute hello-how-are-ya sort of car. That looks a lot more menacing, like you mean business!

[Z3_GoCar]

Hey Josh,

I was also thinking about putting something like, "Have a nice day CHUM!" on the back. You know for a little more shark reference. Maybe I can get an aviation museum to sponsor me.

[Z3_GoCar]

Here's a new update.... I finished spraying the door, finders, top and hood. Here's how it looks from about 10 feet:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=196

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=197

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=198

I've still got to weld the apron cover on the windshield frame and fill and paint the low spots. The motors out at the local machine shop for a valve job and a hone. I'm going to ring and bearing it. Looks like the rods, mains, and bore were all stock and will stay that way for now.

James

[rthiele]

Niiice! :happy204:

Just make sure the rest of the car matches the outstanding front and does not fall down.

[Z3_GoCar]

Niiice! :happy204:

Just make sure the rest of the car matches the outstanding front and does not fall down.

Thanks Rob,

I'm in the middle of removing the old decals and preparing for some new. It should look sharp.

I just got the welded pan back, and it was really badly damaged. But my welder fixed it and it's back:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=209

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=210

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=211

[ismaelae86]

nice i really like the bumper looks real mean can wait to see when everything matchs :)

[Z3_GoCar]

Thanks,

I've still got to get replacement stickers for BMW Club Racing, then I can remove the stickers on the passengers side. I still have to paint the repaired windshield frame and get a new front windshield, and touch a couple of spots. The motor's in the shop, when I get a stock flywheel it'll get a rebalance, and I'll have a stock intake manifold to install too.

[Steve @ TeamDI.com]

Sweet! But where is your Jaffster knob? :)

[Z3_GoCar]

Sweet! But where is your Jaffster knob? :)

Teh Jaffster has spoken, I must obey :p

I was sharing knobs with my street Z3, but settled on a knob from Bav-Auto. It glows red in anger:D

James

[Z3_GoCar]

I know it's been a while since I posted any progress. The motor should be ready for me to pick up from the machine shop soon. I'm still chasing a couple of leaks in the pan, but I know where they're at and will have that fixed soon. While I'm waiting on the motor I decided to try bolting up the radiator core support and headlights to see how they fit togeather:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=317

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=318

Since I just bent the old core back out, and bolted it on it appears to fit. I also have the windshield frame painted to match. Since I removed the rear bumper I could re-install the 30lbs of weight the factory bolts under the bumpers.

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=319

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=320

My next step will be to buy a spare tire and carrier and reinstall back in the stock location. That should be good for at least 10lbs right under the trunk on the passengers side. I'll need all the pork I can get on it to go from 2575lbs to 2850lbs.

[lateapex911]

Since I removed the rear bumper I could re-install the 30lbs of weight the factory bolts under the bumpers.

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=319

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=320


Wow....and people made (lots of) fun of GM when they did the same thing to the Camaro convertible in '67. Except those were liquid filled with an internal mass on a spring.. The earned the term "Cocktail shakers". Higher tech than BMW! And 40 years earlier, LOL

http://cgi.ebay.com/ebaymotors/-1969-CAMARO-COCKTAIL-SHAKER,-DAMPENER,-LEFT-FRONT_W0QQitemZ350193815099QQcmdZViewItemQQimsxZ20 090423?IMSfp=TL0904231410009r28098

[JoshS]

One of the many things that make the coupe better! I threw out my spare tire carrier, James, too bad.

[Z3_GoCar]

Josh, I'd rather have the 30lbs in the back bumper than in the roof and rear window glass. :p

That said, as a race car the biggest advantage of the coupe is your aero. The chassis ridgidity advantage is made negelable by the cage. The vorticies and turbulance on the bubble like hard top really make the roady trickier to drive in the faster corners. Even in a class like STU, your wing gets to be above roof level and mine has to stay 3" under it.

[Z3_GoCar]

It's been a while since I updated this tread.

After a year at a local machine shop I have the block back, but finding rings to fit the CP pistons was a real chore. I finally had the pleasure of dealing with Chris at VAC motorsports, who was very helpful with the torque plate, but ultimately I had to order from Total Seal. The head is still at the machine shop, but due back soon. We ran into having some lifters that aren't fully extending.

I'm also thinking about pumbing a cool shirt and also running chilled water through my heater core for a cool air source. I've also replaced the front control arms and tie rod ends, but still need to find a high pressure power steering hose. Expiration dates are comming up on the fire bottle, have to have the belts re-webbed, and new window net, along with the seat's date passing. So there's a lot to do before I get to drive again.

[Z3_GoCar]

Tonight I placed the main-bearings in the block and inserted the crank, but have hit a road block. It seems my Bently manual doesn't have torque specs for the bottom end. So I need torque specs for the main bolts, rod bolts, main cap truss bolts, maybe even the piston oil jet bolts. Would these be on the ETK disk? I'll probably need to get one sooner or later, rather get it later than sooner though. So can anyone help me with these specs for a M-52 aluminum block single vanos?

Update.....
Nevermind, I've found a pdf of the specs from google. Good thing I ordered new main cap bolts as they're torque to yield just like the head, rod, flywheel, and cluch cover bolts. They're not here yet of course, but I'll assemble the bottom end without torquing the caps and when I get the new main cap bolts I'll torque the caps down then. Next the pistons will go in and torque the rods cap bolts.

[Z3_GoCar]

Here's what I was up to tonight:

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=353

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=355

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=356

http://www.improvedtouring.com/forums/picture.php?albumid=2&pictureid=358

I've also been cleaning the front cover, rear seal cover, and the S-52 intake manifold :P I plan to have the motor togeather except for the cams by next week. In a couple of weeks I should have it back in the chassis and ready to fire up.

[Z3_GoCar]

Last weekend I had a friend come over with a special tool to install the camshaft without breaking it. Here's a picture of the tool while we were installing the exhaust cam:


http://i259.photobucket.com/albums/hh284/lpcapital/James%20Motor/DSC03212.jpg


Also, he helped me set the timing on the cams and took a video of the cam adjustment in action:

http://vid259.photobucket.com/albums/hh284/lpcapital/James Motor/th_MOV03213.jpg (http://s259.photobucket.com/albums/hh284/lpcapital/James Motor/?action=view&current=MOV03213.flv)

[Z3_GoCar]

I placed the motor last Friday, and have been working to hook it up since.

Saturday evening:

http://www.calclub.com/gallery/data/500/IMGA0304a.jpg



Tonight's photos:
http://www.calclub.com/gallery/data/500/IMGA0317a.jpg

And:

http://www.calclub.com/gallery/data/500/IMGA0318a.jpg


I know that the 30lb injectors aren't going to fly, but since they're the ones I have a current tune for, they're going to be used to start the motor for the first time in over three years. I still need to fix the power steering hose, but at $220 for a new one and no sources for a second hand one, I'm waiting untill next month.

[Z3_GoCar]

I had to pull the motor one more time as I couldn't get the clutch slave cylinder back into the transmission. While it was out, I also welded up a slight tear in one of the transmission nuts and pounded it back into shape. I also welded washers to the radiator core where the A/C condenser mounts. I was using this for the hood pins which pulled through, now it's nice, solid, and painted silver. I've only got to install the radiator and oil cooler and I'll be ready to light this puppy off. I should be ready to run this weekends double/double at AAA Speedway.

[Z3_GoCar]

It's alive!!!

Looks like this weekend I'll finally be :eclipsee_steering:

Well maybe not. I guess it was too much to hope that the radiator had survived intact. It's got a little weaper in one of the tubes. I'll probably just go with an OE replacement ~$200.

[Z3_GoCar]

I was going to go to a test and tune day last week, but then the weather intervened. I didn't feel like getting stuck on the wrong side of the mountain for a couple of days for the pass to clear, also driving in the rain has a lack of appeal. So, I've gone over the car once more, stringed the toe, and made a gauge to measure and adjust camber. I also gave the trailer a once over. This Saturday there's another test and tune day forcast high is 67* and 0% chance of rain, low in the pass is 34* so I'll have to keep an eye out for black ice on the drive. Can't wait to get back out there and put some break-in miles on the motor.

[Z3_GoCar]

Has a successfu, but long, day yesterday. I left the house at 4 dark 30, and made it to Buttonwillow 3 hours later. The run groups were alternated between open wheel and closed wheel, and closed wheel was up for the first run, but before the track was opened we were allowed to take "Sedan Laps" because of fog. I took the last sedan lap.

With everything seeming to be going well, I got in line for the first run group. My main objective for the day was to just run some break in laps and get the oil warm. So during the first couple of sessions I kept the motor below 5000 rpm. After the first session, as I was driving in I was hearing a cricket like sound, which I found to be comming from the body. Once I opneed the hood I found a little oil leak, with a little drip hanging off a banjo bolt, I found the source, tightened it up, and cleaned the leaked oil up with a little simple green.

[Marcus Miller]

Congrats James!

[Z3_GoCar]

Congrats James!

Thanks Marcus:026:

Here's a little vid :eclipsee_steering:

http://www.youtube.com/watch?v=6lvVAbEg9rY

[Z3_GoCar]

Since my first race is this weekend at Willow Springs, I spent last Sunday with Speed Ventures doing one of their track days. Here's some video from my third session:

http://www.youtube.com/watch?v=2KNkXo2pFF8

I know that my laps times were good, for a fast ITB car :blink:

I'll need to shave off about 15seconds if I plan to stay ahead of Naji in ITA.

[Z3_GoCar]

This is some video for my qualifying session. I move the bullet camera, zip-tied it to the wink mirror actually, and get a better exposure. Note the ITE Vette that catches fire at the apex of turn #7.

http://www.youtube.com/watch?v=IUqPvOFFYVs

I'll post video from the race later....

Well it's later and here it is:

http://www.youtube.com/watch?v=bDLkalACITQ

[Z3_GoCar]

Since I raced my car two weeks ago, this will be my last post in this thread. As my rebuild is all but over. But I wanted to post a few final thoughts about my the rebuild and race at Willow Springs.

First of all, I couldn't have finished my rebuild without the help of many. The assistance of my friend Richard Kirshner, who's councile and help has been invaluable. Also, Luca Paindelli helped me with installing and timing my cams and Gilbert Magana helped me with installing my new windshield.

This was the first weekend where we had a full podium in ITR. John Norris and Brian Lampe also ran in ITR, both driving 325's. I was looking forward to racing with both of them in May, after my budget recovered. Unfortunetly during the race on Sunday Brian's car rolled, he walked away, but the damage to his car is much more extensive than mine. So he'll be building a new car, I hope he's back soon, but probably not before next season. Finally, I'd like to thank everyone who either posted or checked in here to see my progress. Race safe, and have fun, and keep the rubber side down :eclipsee_steering:

[JoshS]

Congrats on "done" and welcome to ITR!

[joeg]

Good Job.

That track is pretty big and wide; I'd like to try it someday.