S38B38 into my 1977 e12 chassis'd 633CSi

[Shipper]

We are nearly done. The gauge cluster is the last item that is causing a few difficulties. All other wiring now complete. Needs to all come back together and when she is back with my mechanic, we will need to bolt the rear battery tray/strut tower brace in correctly but it will be much quicker in the shop than on the electricians garage floor.

So a few posts given the number of photos.

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All wiring in the engine bay is done. Tis a thing of beauty. Everything has been completely re-wired.

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The Megasquirt Pro III harness was lengthened. The PLX gauge harnesses were lengthened. All non used wiring was removed.

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Lovely and neat.

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With the M-Power rocker cover on, she will be a thing of beauty.

[Shipper]

We are repairing the rechargeable torch. We are repairing the horn, the lights in the hood (to LED) and the window washer pump as no water pumps.

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The Megasquirt ECU and all PLX gauge control boxes are tucked neatly up under the glove box.

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It is all in and working. We will tidy it all up prior to putting the glove box back in.

[Shipper]

There's still the gauge cluster to go back in. The new 300km/h M Power Cluster. The electrician has got about half of the correct pins worked out with more to go.

The dash loos messy but all is under control awaiting the new cluster. The speed cable from the old cluster will come out as it ran to the gearbox. The new cluster will take a wire from the speed sensor on the new diff.

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Mechanic checking out the electricians work.


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Battery in the boot (trunk). We will bolt to shock tower tubs back at the mechanics shop. Note the isolation switch. Snazzy!

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Battery will be closed cell so a little expensive but no one wants acid spilling. Will be a small race quality battery as it needs to fit into the strut brace tray.

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If you look closely, and know what you are looking for, you can see the speed sensor cable. It's about 8mm in diameter.

[Shipper]

Everything wired up properly, with race quality wiring, to proper industry standards and on properly made sound brackets.

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Look, not battery. Wiring includes a circuit for an extra fan, wired into the Megasquirt. So if we need to run two high performance fans the Megasquirt is already wired for it.

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So neat.

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With no battery in the front, room to move.

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MAF sensor now has its own loom and brackets. Neat!

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More wiring porn!

[Shipper]

That MAF sensor again with its ow custom bracket and wiring loom.

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New LED headlights to go in. All indicator, driving, tail and brake lights replaced and wiring fixed.

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This is a throw away dash and I have a brand new one in the garage ready to swap in, so we will just mount the PLX gauges here for now. They are multi-gauges and you touch to cycle through so they need to be within arms reach.

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She even looks sexier now she is close to being finished!

[Pfitz911]

Looks fantastic josh
Can’t wait to hear it roar on the road. What a beautiful shape our 6’s have!!
Well done mate, onwards and upwards from here!!

[Nullified]

Great to see your progress, did you change the tail lights to led? It will give you an advantage of a half a second in notifying the car behind you.

I will make my car full led for this reason, and are those plx gauges multifunctional to be able to not use that dash pod?

Keep on going and get it roadworthy to enjoy it.

[Shipper]

We should be ready soon. I think the tail lights will be stock, but the flickering issue will be fixed.


Should be ready in the next week or so. Then we will change that steering wheel to the M-Tech wheel I've got put aside. I'll sell the timber steering wheel to some e9 guy here in Aus.

So getting closer. I'm currently organising the auto-tune runs.

[e24mpwr]

If Project Binky can be a YouTube phenomenon, this could have been too.

Looking forward to a successful end of your journey!

[GazM3]

Looking forward to it been driven

[Shipper]

We are all but done. All electrical work is finished and the car back together bar one little gremlin.

The tacho on the new gauge cluster is not working. It could be as simple as the needle falling off of the pin. We are working on this now. Otherwise, new headlights are in. Glove box back together. LED lights under the bonnet (Hood) and even the rechargeable torch in the glove box has been reconditioned as new.... and works!

So so close, nearly ready to book the dyno run in.

[Nullified]

Perseverance goes a long way!

[Shipper]

Electrical work is now finished. Organising the static tune and then road auto-tune as I type.

I'll get photos over the coming weeks but left to do, for now (a lot more to do later) is;

1. static tune as running rich.
2. Auto-tune in all gears on the road. will take an hour or so.
3. Dyno power tune. May take a while to book in.
4. M-tech steering wheel in.
5. Two recaro sport seats in.
6. rear strut brace and batter cradle bolted to the car.


Lot's of cosmetic work to do post this and a few additional mechanical items. But the above will give me a good looking fast 633 and I'll drive for a year or two before doing;

7. 6 speed swap. It is there, ready to go in, but I'm exhausted.
8. interior carpet. Got a new OEM carpet ready to go in, wrong colour so may change colour first.
9. original rear speaker pods back in.
9. new front spoiler.
10. new uncracked dash.
11. will take car to upholsterers and redo interior, door cards, parcel shelf, the lot.
12. Will re-paint in the next 5 or so years. Have a Group C kit for it from Adam but too exhausted to let the car go for that at the moment. So will pick the kit up and tuck it away when free.

[Nullified]

You have many plans left to do and they're exiting plans too! It will make it look like new again and will scare the hell out of many new vehicles. I like it!

[Shipper]

At this stage we have booked in Sunday October 27 to do the final check run and, if all is good, do the street ECU Auto tune, as best we can and to the speed limits set in Sydney. Hard to do an 8000rpm in 5th when the gearing calculator (https://e28goodies.com/gearing-calculator/) says that equates to 335km/h. We may get a 2500rpm run in at 105km/h.

Once done and at least running well over the rev ranges we can handle due to speed limits, we'll book the rolling road in.

[Bert Poliakoff]

Josh, That motor and "speed limits"??? Something doesn't sound right!! Well I am still waiting to hear the damage on my 2nd rebuild since the first only lasted 20 minutes. I think I must be following in your footsteps!!

[Shipper]

Road ECU Auto-tune finished. More so as we cannot find enough road to tune the engine. But, we are now tuned well enough to 3000rpm and up to third to drive to and from the Dyno. The dyno for all of the power runs will be booked this week. Here's hoping we can fit in this year.

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Boot (trunk) light now working.


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Spare parts in the boot. High performance battery in.


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LED's in the bonnet now working well. Run off of parking lights so are switched on or off inside the cabin.


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M635CSi Cluster in and working. slight issue with the tacho but auto-electrician will fix this, this week.


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One issue was the ECU was picking up a volt pulse. We ran the power to the Megasquirt directly from the ignition and this stopped the issue. Hence the mess here. The PLX gauges need finalising. We will place as per the photo.

[Shipper]

Wiring looks great in the engine bay. Injector cover to go on but otherwise the engine bay is complete.

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How neat is that wiring? Neat! It's ruddy neat!!

- - - Updated - - -

New headlights in. How cool are these??? Cool. Ya better ruddy say "Cool!!!"


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[Shipper]

Here we are getting some fuel. Nothing worse than getting the road tune function underway only to run out of fuel.

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[Nullified]

Good update, how much power are you expecting on the dyno run?

[Shipper]

I'm pretty sure, no matter what, we'll have enough power. Stock these engines had 350hp. Should the big cams, higher compression, going to 3.9 litres, light weight fly wheel, extra 800rpm to redline, performance valves and springs and balancing and blue printing give us around 50hp to 80hp more? One would think so.

Most importantly I'd want a great free revving engine that does not explode.

So 400hp plus, we will not chase the last 20hp if it does not come by sensible tuning and easily. That's a lot of hp for a car weighing 1485kg.

As for performance, the E92 M3 with the 4 litre V8 put out 414hp and 400nm of torque. My engine should put out around 420hp and stock had 400nm of torque. With the larger capacity and compression, it probably has 420nm of torque or something similar.

Given all of the above, the 6'er is 100kg lighter than the E92 M3 with possibly slightly higher power and torque numbers (or very similar to say the least). It should present like a fast E92 M3.

[Bert Poliakoff]

What happened to that stunning Alpina gauge cluster I forwarded to you 100 years ago??

[Shipper]

Was sold to Addam in QLD for his son's alpina.

[Bert Poliakoff]

I have been dreaming about seeing it in your car. I am surprised you didn't make a complete new panel to fit in the binnacle with all custom gauges. Maybe in the future for a finishing touch to go` along with the motor?

[Shipper]

I decided that a 300km/h 8000rpm MPower gauge cluster better suited a car with a 3.9 litre MPower straight six in it. Addam's 6'er is an Alpina tribute so the gauge cluster went to a good home. Current car, when the wheel is replaced with the MTech wheel, will blend well with the new gauge cluster.