yahh's Avus Blue E36 LS Swap

[yahh]

4-8-14

I'm not sure if you guys have followed the e30 thread but I have sold off the e30's powertrain and purchased and LS1 and w12 t56 from an 04 GTO with 82k miles on it. 04 GTO's came with the C5 Z06 motor/trans which is basically a LS6. The car will be built as a canyon carver/dailyable track car. Once I found an engine, I spent the next few weeks researching what was required to swap it into an E30 and I decided that an e36 or e46 would make much better use of the power along with having the extra room would make the entire swap easier. Now i'm still only 21 years old so insurance on an e46 would be bat shit crazy, so that leaves me with an e36. The next day I get on CL, bimmerforums, m3forums etc and start looking for a shell and bam, I find a pretty clean Avus blue shell located in Memphis with 86k on the original shell and a clean title with all matching VIN #s. On top of that it comes with AC Shnitzer wheels and TEIN SS Coilovers (almost new) for a decent price. Perfect! So that weekend I set off on a 1700 mile round trip to pick up my new car with a good friend of mine and the Jeep!


E30 vs e36


Pros for e36
-Can run 255 tires vs 225 for e30 without major body work
-36 tires options at that size vs 4 for e30
-Can use stock brake booster vs running manual brakes or hydroboost for e30
-More engine bay space = more space for manifolds/downpipes
-Stronger rear end
-Ls1 swap has been done quite a few times so there is a lot more info


Pros for e30
-Better Looking
-Already have a fully re-built car
-Lighter
-Handles Great


Here is the shell!
Buddy took some pictures of the new shell yesterday while I was working on it.







After her first bath!





And here is the LS after delivery.






Stuff that's come in already.


Full wiring harness - unfortunately this one will be shipped back and i'm hunting for another. After a quick inspection, I found some frayed wires and a few that were cut.





Vorshlag Engine/Tranny Mounts - Turned out to be replicas. Fitment was OK but needed some adjustment.





Oil Pan/ Baffle





Pickup Tube





Dipstick and Tube




4-9-14

Brake Rebuild stuff came in.


OEM ATE brake seals/o-rings for front and rear
ECS Stainless Brake Lines
ATE Type 200 Brake Fluid
Dupli-Color Caliper paint to make them pretty





Also ordered rotors+pads last week, waiting on it to ship. Centric slotted rotors like always and Hawk Ceramic Brake pads.

4-14-14



One caliper cleaned
Caliper Rebuild by yahh-, on Flickr


Caliper Rebuild by yahh-, on Flickr


2 Finished


Caliper Rebuild by yahh-, on Flickr


All the pistons look great!
Caliper Rebuild by yahh-, on Flickr


Guide pins all look good and don't need to be replaced
Caliper Rebuild by yahh-, on Flickr


Set of 243 Heads came in. They well be shipped off to Advanced Induction for porting/polish, with a full rebuild, slight milling, and for them to spec me a cam. Swapping to these heads and porting with the cam should put me in the 440-480 rwhp range.


243 Heads by yahh-, on Flickr
243 Heads by yahh-, on Flickr


Fast 102 ported by MadMan


Fast 102 by yahh-, on Flickr


102MM Throttle Body Opening


Fast 102 by yahh-, on Flickr

4-27-14


Worked on the brakes this weekend after pulling a bunch of e30 parts that I sold.
Paint booth for the day haha
Rebuilding Calipers by yahh-, on Flickr


Curing with a Kerosene heater
Rebuilding Calipers by yahh-, on Flickr
Rebuilding Calipers by yahh-, on Flickr




Rebuilding Calipers by yahh-, on Flickr


\Still need to pop the seals and pistons in and they will be ready! Also putting new bleeder screws on.


Rebuilding Calipers by yahh-, on Flickr
Rebuilding Calipers by yahh-, on Flickr

5-13-14


Eclipse Gone by yahh-, on Flickr


As you can see the Eclipse is gone and won't be stalking my builds anymore and the e36 has been moved into the garage as i'm nearly finished with hoarding parts for the swap.




A LOT of updates coming this week. Here is some of the stuff that has already come in.


Borgeson Steering Shaft and Flaming River U-Joint (waiting for one more to arrive for other side)


Borgeson 1 by yahh-, on Flickr
Flaming River U-Joint 1 by yahh-, on Flickr
Borgeson 2 by yahh-, on Flickr


Rotors ( Centric Double Slotted as always )


E36 Rotors by yahh-, on Flickr
E36 Rotors 2 by yahh-, on Flickr


VS E30 Rotor Size


E36 vs E30 Rotors by yahh-, on Flickr


Hawk Ceramic Pads


Hawk HPS Ceramic by yahh-, on Flickr


All New Lemforder (OEM) Ball Joints for the control arms


Balljoints 2 by yahh-, on Flickr

Balljoints by yahh-, on Flickr


Corvette Fuel Filter/FPR


Fpr & Filter2 by yahh-, on Flickr

Fpr & Filter by yahh-, on Flickr


Fuel Line


Fuel Line by yahh-, on Flickr


Fittings


Fittings 2 by yahh-, on Flickr

Fittings by yahh-, on Flickr



Fuel Pump adapter with HFP 300 Pump


Rally Road HFP 300 by yahh-, on Flickr


Driveshaft adapter so I can get a custom driveshaft made


Dana 1044 Adapter by yahh-, on Flickr


Heads will be sent of this week or next week for CNC porting and a custom cam.


Exact things that will be done are


-Ai 226cc Full CNC Porting
-PSI 1511 MaxLife Endurance Springs
-New GM OEM Valve Seals
-Any Compression Ratio from 9.9-11.5:1, or Ai optimized for cam selection
-Any HR Camshaft - Ai Custom Grind, or you may specify a grind yourself
-Ai One Piece 4130 ChromeMoly Hardened Pushrods 5/16" & .080" Wall Thickness
-GM OEM .051" Head Gaskets
-In-house QC inspection of your individual camshaft


Typically manages 440-460rwhp SAE corrected

- - - Updated - - -

5-16-14


Second U-Joint Came in


0514_0705 by yahh-, on Flickr


Fast Anodized Billet Rails


0514_0703 by yahh-, on Flickr

0514_0704 by yahh-, on Flickr



Installed on the intake


0514_0706 by yahh-, on Flickr

0514_0707 by yahh-, on Flickr


Ford 30lb injectors (But they don't work with the fast102 so I ordered a different set )


0515_0702 by yahh-, on Flickr


And something else came in today.


0516_0697 by yahh-, on Flickr

0516_0698 by yahh-, on Flickr

0516_0699 by yahh-, on Flickr


Installed


0516_0710 by yahh-, on Flickr

0516_0709 by yahh-, on Flickr

0516_0711 by yahh-, on Flickr

0516_0713 by yahh-, on Flickr

0516_0714 by yahh-, on Flickr

0516_0717 by yahh-, on Flickr

0516_0719 by yahh-, on Flickr

0516_0720 by yahh-, on Flickr



Wheels should be here monday. Bunch of other stuff on the way.

5-19-14

Wheels and tires also came in today.


0519_0721 by yahh-, on Flickr

0519_0722 by yahh-, on Flickr



Test Fit
0519_0726 by yahh-, on Flickr

0519_0727 by yahh-, on Flickr




255 vs 235
0519_0723 by yahh-, on Flickr


5-21-14


Coilovers came in today! So I ended up going with fortune auto 500's and when they got here, well they weren't 500's instead they're the dreadnaughts! Inverted mono tube, nitrogen filled shocks with swift springs (8k front, 9k rear). They are upgradable to the dual rebound external canisters as well! I ended up going for fortunes because they are about 20 minutes from me and can rebuild them within 24 hours if need be!


0521_0745 by yahh-, on Flickr

0521_0746 by yahh-, on Flickr

0521_0747 by yahh-, on Flickr

0521_0748 by yahh-, on Flickr

0521_0750 by yahh-, on Flickr


For the price I paid, i'm ECSTATIC!

5-23-14


Long weekend ahead so I'm going to attempt to turn some wrenches.


After work today I pulled the front end off for easier access.
0523_0752 by yahh-, on Flickr

0523_0751 by yahh-, on Flickr


Then dropped the steering rack (converting to a z3 rack which is 2.7 ltl vs 3.0)
0523_0753 by yahh-, on Flickr


Wheels Off
0523_0754 by yahh-, on Flickr


Rack off
0523_0755 by yahh-, on Flickr


Drives side Tein Coilover pulled and Fortune Auto installed
0523_0756 by yahh-, on Flickr

0523_0757 by yahh-, on Flickr


I have a wedding to attend to tomorrow, but sunday and monday should show some progress. Hoping to have the motor in for at least a test fit this weekend.

5-25-14


After watching the race at Monaco this morning I stepped out and got some work done.


Started by stripping off the stock GTO manifolds, mounts, etc .


0525_0758 by yahh-, on Flickr

0525_0759 by yahh-, on Flickr


Put the engine mounts on and then dropped the oil pan and the windage tray


0525_0761 by yahh-, on Flickr

0525_0760 by yahh-, on Flickr



Familiar huh?


0525_0763 by yahh-, on Flickr


Wouldnt fit with the AC compressor so I had to take it off and try again!


0525_0764 by yahh-, on Flickr


Dropped the subframe a few inches and BAM! Houston we have landed.


0525_0765 by yahh-, on Flickr

0525_0766 by yahh-, on Flickr

0525_0767 by yahh-, on Flickr

0525_0768 by yahh-, on Flickr

0525_0769 by yahh-, on Flickr

0525_0770 by yahh-, on Flickr


IT FITS!


0525_0771 by yahh-, on Flickr

- - - Updated - - -

5-29-14


Few more parts are in
Improved Racing F-Body Oil Baffle


0529_0776 by yahh-, on Flickr

0529_0777 by yahh-, on Flickr

0529_0778 by yahh-, on Flickr


Magnaflow X Pipe
0529_0779 by yahh-, on Flickr

0529_0780 by yahh-, on Flickr


Set of mufflers
0529_0782 by yahh-, on Flickr

0529_0783 by yahh-, on Flickr

0529_0784 by yahh-, on Flickr



A bunch of Oem parts. Nuts,bolts,e brake hardware,e brake shoes, wheel bearing clips


0529_0785 by yahh-, on Flickr

0529_0786 by yahh-, on Flickr


F body shifter adapter
0529_0787 by yahh-, on Flickr

6-3-14


More updates


Picked up a 5 speed swap side job alongside some suspension work so I haven't really had time to work on the LS swap but..


3.91 LSD Diff came in and first set of mild steel piping came in to use to mock up the manifolds.


Paid for the head porting/rebuild and cam/springs/retainers , just need to ship them off now.
Advanceinductions by yahh-, on Flickr


Powerflex bushings. Still haven't figured out what to use for the differential.


0603_0789 by yahh-, on Flickr


All the stainless piping should get here tomorrow for manifolds/exhaust. Final setup is 1 7/8 runners for the manifolds to 3" collectors, magnaflow x pipe, and morosso spiral flow mufflers. Might add 2 more vibrants in the rear depending on how loud it ends up.




7-4-14


Finally got some time to work on the car


Rally Road HFP 300lph Fuel Pump Kit Installed
Fuel Pump by yahh-, on Flickr

Fuel Pump 2 by yahh-, on Flickr


Pulled out the motor again and split the trans to install the speed bleeder and to convert the quick disconnect to -4an for the clutch line and a TCK Speedbleeder.


Splitting Trans by yahh-, on Flickr
TCK Slave Speed Bleeder + Quick D/C to -4an by yahh-, on Flickr
TCK Slave Speed Bleeder by yahh-, on Flickr


Converting m10x1.0 to -4an for the clutch line on the Slave side
Clutch Line Adapter -4an by yahh-, on Flickr


Quick Disconnect fuel fitting converted to -6an to mate to the Corvette FPR/Filter.
Quick Disconnect to -6an by yahh-, on Flickr


Cutting Steering shaft to length and z3 steering rack + cooler installed
Cutting Steering Shaft by yahh-, on Flickr

Steering Rack + Cooler by yahh-, on Flickr

Steering Rack + Shaft Installed by yahh-, on Flickr


ABS Lines Extended
ABS Lines Extended by yahh-, on Flickr

ABS Lines Extended 2 by yahh-, on Flickr


Spark Plugs
NGK Spark Plugs by yahh-, on Flickr

- - - Updated - - -

7-5-14

Laid primer on the mounts
Priming Mounts by yahh-, on Flickr

Painted Black
Painted by yahh-, on Flickr

Installed
Mount installed by yahh-, on Flickr

Exhaust Manifold Flange Installed
Exhaust Flange Installed by yahh-, on Flickr

AN Fittings for Power Steering
AN Lines for Power Steering by yahh-, on Flickr

On Rack
AN fitting for Rack by yahh-, on Flickr

Old Plugs / New Plugs
Old Spark Plugs by yahh-, on Flickr

New Iridiums by yahh-, on Flickr

Wires
MSD Wires 2 by yahh-, on Flickr

MSD Wires by yahh-, on Flickr

F-Body(L) vs GTO(R) Shifter cups - this moves the shifter so I don't have to cut a bigger opening
GTO VS F-Body Shifter cup by yahh-, on Flickr

Cup Installed
F-Body cup installed by yahh-, on Flickr

B&M F-Body Short Shifter installed
F-Body B&M Short Shifter by yahh-, on Flickr


After I finished the transmission swap on the e30 for a local, I went and bought myself these. I'm in love.
Snap-on Ratchets by yahh-, on Flickr


Time for lunch and soccer and then putting the trans back on the bell-housing and putting the motor back in the car to start on the headers.

7-8-14


Pulled the oil pan off again to actually put the pickup/windage tray/Baffle on and torque everything to spec.


Oil Baffle Installed by yahh-, on Flickr

Windage tray + Pickup by yahh-, on Flickr



Pressing out the old ball joints and lollipops and pressing in the new ones
Ball joints pressed out by yahh-, on Flickr

Powerflex FCAB + Ball Joints by yahh-, on Flickr

Powerflex FCAB by yahh-, on Flickr

Lemforder Ball Joints Pressed in by yahh-, on Flickr


Made the fusebox/relays to make the motor standalone
Fuse Box by yahh-, on Flickr

Fuse Box by yahh-, on Flickr

Fuse Box by yahh-, on Flickr


Magnaflow 3" high flow cats and Throttle Cable Came in


Throttle Cable + High Flow Cats by yahh-, on Flickr

[GoBLue]

Nice build and great pix!

[bimerok]

Nice

[Bluebimma]

Looks good

[yahh]

Nice build and great pix!

Nice

Looks good

Bunch of parts I was waiting for came in this past week.


Oversized diff bolt that hopefully wont brake with the power.



Differential Bushings/ RTAB Pocket Reinforcement plates/ Front Sub Reinforcement plates





Axle Rebuild Kits and rear swaybar endlinks





OE Front Swaybar Bushings / Brake Sensors / Backing Plate Bolts





Used Brake Ducting from a local buddy

[modernbeat]

Yeah...please don't say those knockoff parts are Vorshlag parts. It's bad enough when someone starts duplicating our parts, but when they make a lower quality version, and people attribute them to Vorshlag, that's just a low blow.

Vorshlag Engine/Tranny Mounts


Put the engine mounts on and then dropped the oil pan and the windage tray


Painted Black


Installed


Exhaust Manifold Flange Installed

[yahh]

Yeah...please don't say those knockoff parts are Vorshlag parts. It's bad enough when someone starts duplicating our parts, but when they make a lower quality version, and people attribute them to Vorshlag, that's just a low blow.

Bought them as the seller said they were used vorshlag mounts, turned out they're not but didn't complain as I paid about a third of the price of new ones . I'll update it up ther, no intent on misleading. I did buy the ABS Relocate and Lines from ya though.

[Spec3HOR]

Don't worry, the real Vorshlag parts took small alterations and even had their aluminum driveshaft blowout on first full throttle. Tried multiple times to work with them, they kept being "out of the office" and eventually no more response. I am sure I will get an email now that I mention it again on the forums, but then disappearance.


Yay!

[unnatrl]

Don't worry, the real Vorshlag parts took small alterations and even had their aluminum driveshaft blowout on first full throttle. Tried multiple times to work with them, they kept being "out of the office" and eventually no more response. I am sure I will get an email now that I mention it again on the forums, but then disappearance. Yay!

You paid for the good stuff and still had that happen? Sounds like a quality control issue. The price would lead you to think it wouldn't be an issue.

[yahh]

Did anyone else have problems with the vorshlag power steering lines? The one going from the power steering reservoir is about 2" too short.

[bimerok]

LS1 PS pump is different than yours. The reservoir on LS1 pump is in different location and the return nipple is also in different location on the LS1 pump.

[yahh]

LS1 PS pump is different than yours. The reservoir on LS1 pump is in different location and the return nipple is also in different location on the LS1 pump.

Great. I'll call them today. Mine is still an ls1 just gto pump vs fbody.

[bimerok]

Great. I'll call them today. Mine is still an ls1 just gto pump vs fbody.

Looking at your picture, it also looks like the 04 LS1 GTO has different pump than 05+ LS2 GTO pump. On yours it seems that the pressure line comes out at the bottom and back of the pump versus the top of the pump on LS2.




vs LS2 (The blue line)

[unnatrl]

Looking at your picture, it also looks like the 04 LS1 GTO has different pump than 05+ LS2 GTO pump. On yours it seems that the pressure line comes out at the bottom and back of the pump versus the top of the pump on LS2. vs LS2 (The blue line)

They are different from 04 to 05/06. The replacement parts are also a lot more expensive. Luckily an Fbody pump and alternator are an easy swap. Ask me how I know :-)

[yahh]

I was trying to stay with all GTO accessories because of the belt routing and warranty I have on my motor. Only thing changed has been the f body oil pan obviously. I'll just get one made locally. Any an fitting brands to stay away from?

[yahh]

Uh oh whats this?


Advanced Induction Heads by yahh-, on Flickr


Advanced Induction Heads by yahh-, on Flickr
Advanced Induction Heads by yahh-, on Flickr
Advanced Induction Heads by yahh-, on Flickr
Advanced Induction Heads by yahh-, on Flickr
Advanced Induction Heads by yahh-, on Flickr
Advanced Induction Heads by yahh-, on Flickr

[jai5]

I'm loving your pics!

Keep it up, looks great.

[alwaysinboost]

awesome build!

[Inflame]

I'm on the brink of going LS1... Just scared of the wiring!

[yahh]

Don't be scared. Worst case scenario you can send it off and have it made into a stand alone harness.

Rear "balljoints" , E-Brake Lines, Axle Nuts , and 2 subframe bolts. Bent one a bit when taking the subframe off.
E-Brake Line + Bushings by yahh-, on Flickr


FAST Fuel Pressure Gauge by yahh-, on Flickr


Valve Cover Gaskets by yahh-, on Flickr


Pushrod measuring tool by yahh-, on Flickr


OE MLS Headgaskets by yahh-, on Flickr


SPC Rear Camber Arms by yahh-, on Flickr


LS7 Flywheel by yahh-, on Flickr


LS7 Clutch by yahh-, on Flickr


GTO T56 Slip Yoke by yahh-, on Flickr


E36 FXR 3.0 Projector Kit + Ballats and Phillips Bulbs by yahh-, on Flickr

[Inflame]

What oil pan do you do have to run to clean the subframe? I decided to bite the bullet and do the swap.

[unnatrl]

What oil pan do you do have to run to clean the subframe? I decided to bite the bullet and do the swap.

Fbody oil pan

[lovnbmws]

FYI you may not want to run your brake lines along the frame rail. I originally routed my lines the same way but then it was suggested they would be too close to the headers possibly creating a pinch point and/or cooking the brake fluid.

ABS Lines Extended
ABS Lines Extended by yahh-, on Flickr

ABS Lines Extended 2 by yahh-, on Flickr

Heres a progression of my brake line set up:

I had some clearance issues with my brake lines.



At the back of the frame rail the headers get very close to where I routed my rear brake lines so I moved the two rear lines to run below the frame rail.



I also found the blue vapor return line is easily reshaped after warming it with a heat gun.

[yahh]

Thanks for the heads up, i'll see once I get the manifolds on

[yahh]

8-27-14

Big update #1 WORK Emotion 18x9.5 +25 and 18x10.5 +22 in Gunmetal
WORK Emotion 18x9.5 +25 and 18x10.5 +22 by yahh-, on Flickr
WORK Emotion 18x9.5 +25 and 18x10.5 +22 by yahh-, on Flickr
WORK Emotion 18x9.5 +25 and 18x10.5 +22 by yahh-, on Flickr
WORK Emotion 18x9.5 +25 and 18x10.5 +22 by yahh-, on Flickr
WORK Emotion 18x9.5 +25 and 18x10.5 +22 by yahh-, on Flickr
WORK Emotion 18x9.5 +25 and 18x10.5 +22 by yahh-, on Flickr


Added a 12mm spacer in the front for additinal strut clearance and it sticks 1 1/2" past fender. Rear will stick out similarly so I will be getting 2" flares all around and attempting to run a 315/30 rear and 275/35 front.

8-30-14 Picked up some more stuff today.


Samberg LS Swap Manifolds by yahh-, on Flickr
Samberg LS Swap Manifolds by yahh-, on Flickr
Samberg LS Swap Manifolds by yahh-, on Flickr
Samberg LS Swap Manifolds by yahh-, on Flickr
Samberg LS Swap Subframe/Mount by yahh-, on Flickr
Samberg LS Swap Subframe/Mount by yahh-, on Flickr
Samberg LS Swap Subframe/Mount by yahh-, on Flickr
Samberg LS Swap Subframe/Mount by yahh-, on Flickr