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Thread: S38B38 into my 1977 e12 chassis'd 633CSi

  1. #26
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    I think the best way to deal with this issue is to place the new bomb proof diff mount and look at where we need to strengthen the chassis. We need to spread the load and stop the chassis floor from warping. I've got the new bomb proof diff mount on my desk here in Sydney Australia and it looks strong enough. But my old e12 rear floor uses very thin steel.

    So I'll post the new mount to my fabricator, we'll run a few dummy mountings and from this work out how best to strengthen everything.

    Below is where we are now at. So close..... I can almost feel it.......... and the wind in my hair with windows down and 390hp of straight 6 howling through the mountains at 100mph.

    photo 1.JPG

    photo 2.JPG

    photo 3.JPG

    photo 4.JPG

    photo 5.JPG
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  2. #27
    Join Date
    Feb 2009
    Location
    Pittsburgh, PA
    Posts
    1,605
    My Cars
    '86 635CSi
    Heck of a build here. I'm liking this a lot. Thanks for the updates!

  3. #28
    Join Date
    Aug 2008
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    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    New military gauge bushes in. Getting closer. Cut rear cross member ready to strengthen.

    20150908_175610_zpsxooyz36e.jpg

    20150908_175605_zpsdn5iqpkf.jpg

    20150908_175455_zpszhnjik5k.jpg

    20150908_175451_zpsedrnadsv.jpg

    The subframe above needs some modification.

    20150908_175443_zps9jglvjgo.jpg
    Rear floor prepped ready for strengthening. Bomb Proof Mount being positioned and checked. We'll weld steel fin plates (3 of) in the cut out above the diff mount and run steel gussets each side (lined up to match the fin plates so 3 each side of that square cut out). We'll then place new 6mm plate to fix cut out and allow for fitting Bomb Proof Mount.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  4. #29
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    My Cars
    1x633, 1x E3 2 DR Racer
    And a shot or two more.

    20150908_175424_zps9yuythnk.jpg

    Not the diff going in. Just a dummy to look at fitting.

    20150908_175410_zpsbdwiz3le.jpg
    & an underneath of those extractors.

    And here's a link to the new pistons in the engine. 100g lighter than OEM. Balanced and 95mm.

    https://store.vacmotorsports.com/cp-...8-l-p1290.aspx
    Last edited by Shipper; 09-09-2015 at 04:40 AM.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  5. #30
    Join Date
    May 2004
    Location
    Stafford, VA
    Posts
    94
    My Cars
    81 RHD 635, 85 M635csi
    This build is impressive...gives me ideas with my RHD...

  6. #31
    Join Date
    Dec 2005
    Location
    Melbourne, Australia
    Posts
    1,863
    My Cars
    E24, E34 x2, E36
    Nice to see some progress Josh. You always get an extra set of steak knives with this project. "Wait there's more".
    BMWs
    90 E34 M5
    84 E24 M635csi
    94 E34 540i/6 SC 16psi E85
    97 E36 M3 euro SC still u/c

    OTHERS
    11 Audi S5 APR stg2
    19 Volkswagen Amarok V6


  7. #32
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    1x633, 1x E3 2 DR Racer
    I've got a new dash to go in. I've got an M6 front spoiler to go on. I've got ALPINA and M-Tech cloth coming to do interior refurbish.

    But all that can wait. I want to drive, drive and drive some more. A lot.

    I'm put a hole in the parcel shelf, left side, so I can secure the baby seat to the boot (trunk) floor. I'll put a fastening point on the floor as well.

    I want, when the weather suits as there is no longer any aircon, to take my gorgeous wife and beautiful son for a long weekend away in the mountains. What a hoot!

    More fabrication photos below as we work out the best way to strengthen this area.


    Modified the Bomb Proof Mount to fit e12 chassis. Really just welding up and re-positioning bolt holes.
    DSC00410_zpsutjpqhxu.jpg


    Running solid square bar through diff mount transverse member to stiffen up.
    DSC00412_zpslr4khwif.jpg


    Bar wont' be this long but it does help spread the load.
    DSC00413_zps93q1tiii.jpg


    New 5mm floor section to in-fill the cutout area. Bomb Proof Diff Mount base positioned to suit.
    DSC00415_zpsgbghpa6p.jpg


    Will fillet weld the puddle welds post dummy fit.
    DSC00416_zps9hautyz1.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  8. #33
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    What a shoot fight to get this done.

    After 16 months with the last mechanic and such a shoot fight to get anything done (good quality work, very intelligent guy who knows is stuff but, horrid communication and client attention and horrid time frames) the latest team have made great headway. This week we will be ready for exhaust back on and then a week of testing. So, where are we?

    1. Rear subframe in. The e28 rear subframe swapping out the e12.
    2. LSD in.
    3. E34 540 rear brakes in. Got the fronts but they can wait.
    4. Engine in. Needs auto electrician to finalise and mechanic to hook up missing hoses, lines. But apparently starts and runs. So 370hp plus hear we come.
    5. Car now sits level in stead of nose in air.
    6. rear floor strengthened.
    7. New drive shafts to go in with correct bolt pattern.
    8. New cables for hand brake going in.
    9. New rear brake lines for bigger brakes.
    10. Battery to the boot/trunk.

    So hopefully we are;

    a) finished this week and ready to go to the exhaust shop to get the high performance exhaust put back on.
    b) once exhaust is on, late this week or early next week, a week to clean up engine bay. Testing for say 200 miles to iron out the bugs, oil change from start up oil, tuning and then final hot day run. Final check and then interstate for 1100km.

    Wish me luck. Did I mention "what a shoot fight"? Note how I'm not swearing?

    Photos:

    Very dust covered but she'll wash up good. Sitting nice and flat.
    20151005_135141_zpsgqy5e4uk.jpg


    370hp plus and 450nm of torque hidden up front attached to a 5 speed manual and an LSD.
    20151005_135231_zpsduutga6i.jpg


    Race air filter sitting in the parts bin and the bottom right of the photo, that little bit of blue? Is the tubing to the intake. Battery will be moved to the trunk this week.
    20151005_135242_zpsjpqltmk8.jpg


    I'll put the M6 front spoiler on this year and the new uncracked dash. In this too deep to skimp on the last two pieces of the puzzle (assuming you exclude the interior, which is 82 pieces of the puzzle and yet untouched.
    20151005_135250_zpsypv5nbfk.jpg


    I think Gertie is really starting to look good now. Wait until we start her up under full hp. Still in limp mode until we get a speed sensor into the e28 diff, through gauge cluster and into ecu.
    20151005_135322_zps9tw7rapc.jpg


    she'll be a wee-ripper!
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  9. #34
    Join Date
    May 2006
    Location
    NYC
    Posts
    338
    My Cars
    91 325IC/87 M6/08 X5
    Nice to see where this has gone. Cant wait to see the finished product.

  10. #35
    Join Date
    Jan 2004
    Location
    WINSTON SALEM, NC
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    6,497
    My Cars
    07 RAMHEMi - H&B 630csi
    good info!! im def going to check my rear for cracks

    considered the e28 swap as well.

  11. #36
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    Purchased a 2 dial perfect condition gauge cluster so I can hook up the speed sensor from the E28 LSD to the S38B38 ECU. So the old 3 dial is out and new 2 dial is in.

    Then, car ready to run.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  12. #37
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    My Cars
    1x633, 1x E3 2 DR Racer
    3 inch straight through exhaust now going on. Car will soon be ready to go. Photos to come in 2 weeks then performance figures to follow December and January next year. I'll track her and may do a few acceleration runs using some wang-fang-dangled apps to see what she can really do. Should be fun.

    You may ask why the single 3 inch exhaust? Well the previous mechanic was going to put in twin 2.5 inch but after paying him, and he paying his exhaust guy, the exhaust guy said "get stuffed" and my ex mechanic said "not my problem" despite being the sole reason for the "get stuffed". Non delivery on the engine install by the last guy has also meant that the car is being finished by someone else. Someone new, highly professional and at least capable of doing the works. So, simply put, I was not interested in paying another $2.5k which was the best quote we could get for a 2.5 inch twin system, after already out laying $2.5k to said previous mechanic and his unethical exhaust guy who runs off with peoples money. So I need to economise. single 3 inch it is.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  13. #38
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    Car is now all together and speed sensor in diff wired to E24 gauge cluster (2 dial rather than the earlier 3 dial e12 gauge cluster which is now out) which in turn is wired to the ecu.

    First run of car found that the oil filter canister had a faulty bleeder screw. Oil sprayed all over the engine bay.

    Mechanic has cleaned engine bay (2hrs of work) and is now going to spend a few good hours checking every screw, bolt and nut and ensure all are tight.

    Fortunately, the car ran with great oil pressure and was only on a short run with an experienced mechanic so as soon as he smelt something he returned to the shop. Checking oil when it came back to the shop they found it was still just above the minimum line on the dip stick so very luck.

    Car should be finished this week and then need to pick up but unsure as to when as it is interstate and Xmas is close.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  14. #39
    Join Date
    Dec 2005
    Location
    Melbourne, Australia
    Posts
    1,863
    My Cars
    E24, E34 x2, E36
    Hey nice to see it nearly finished.
    BMWs
    90 E34 M5
    84 E24 M635csi
    94 E34 540i/6 SC 16psi E85
    97 E36 M3 euro SC still u/c

    OTHERS
    11 Audi S5 APR stg2
    19 Volkswagen Amarok V6


  15. #40
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    My Cars
    1x633, 1x E3 2 DR Racer
    Had real issues with the ECU picking up a speed signal from the e28 LSD.

    Apparently, you are meant to run the speed sensor from the diff to the gauge cluster, then from the gauge cluster to the ECU. We tried both an e12 3 dial gauge cluster and the 2 dial e28 gauge cluster. Just could not get it to work.

    I now know that the best solution is a signal simulator. Fix it in the engine bay or under the dash, connect 3 wires and away you go.

    The signal simulator is on its way from the Netherlands as we speak.

    Hopefully in and working this March.

    Here are two links to suitable speed signal simulators. Far cheaper than an auto-electrician charging you $$$ to work out it cannot be done.

    http://people.zeelandnet.nl/jeejansen/

    http://www.kempower-motorsport.com/i...product_id=144
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  16. #41
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    New Update:

    1. Speed Signal Simulator in and working.
    2. Car test driven for about 1 hour to0 around 3500rpm (zero miles post rebuild of engine so taking it easy).
    3. Scared the hell out of the guys at the car restoration business with its acceleration and speed and they loved the banshee wail that was building at 3500rpm.
    4. Ran beautifully, no heat issues (although a cool day around 20 degrees Celsius and not an Aussie Roaster!) but a banging from the back.
    5. The rear shock shaft had driven its way through the upper panel work (parcel shelf).
    6. Being fixed now. Appears retention washer to top of shock missing.
    7. Race extractors touching the steering box. Being fixed as we speak.
    8. Brakes pulling to one side. 540 disks and callipers in the rear. Rebuild or rust may be an issue.
    9. Maybe a bent wheel or very badly out of balance.
    10. will get wheels aligned and re-balanced.

    See photos below of the shock issue. It's only one side and an easy fix. The last mechanic did such a crap job with the wiring that although spending $1,250 just now with a qualified auto-electrician to stop our feet and pedals being tangled in the wiring and relays (it was that ruddy bad!!!), he now wants to completely remove the entire wiring loom and re-do it as his repair works are, in his own words, only masking the major issue at hand and in typical Aussie fashion notes that 'wires are running all over the bloody place'. Currently getting this priced.

    So a few weeks? Well it runs.... and ruddy fast!!!!!!

    DSCN1650_zps1cfds4c6.jpg

    DSCN1652_zpsub39a6kf.jpg

    DSCN1651_zpsp4z4h8z0.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  17. #42
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    Here you can see the proximity of the older e12 steering box and the S38B38 race extractors. Hence the knocking/rubbing issue and I'm not keen to boil my steering fluid every time I put my foot down.

    20150303_160035_zpsz1ay7btm.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  18. #43
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    Car finished. Finally. And now driving well.

    This week she'll be heading to a BMW specialist who builds BMW racers for a final going over, oil change, fixing a few minor conflicts and certification so I can get the car registered. Then the 1,100km trip home. Hopefully more photos and vids to follow this month.
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  19. #44
    Join Date
    Aug 2008
    Location
    Sydney Australa
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    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    Finally home. And scary fast. I'm yet to dyno and will get this done in the coming weeks. Need to confirm the tune is correct. She is fast. Scary throw you back into your seat fast. LS3 V8 fast.

    20160423_133709_zpsaarr4enl.jpg

    20160424_155955_zpslr7m4bu9.jpg

    20160424_160008_zpsnb3lyfq7.jpg

    20160424_160010_zpscxiyg4ql.jpg

    20160424_160620_zpst0nu86ph.jpg
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  20. #45
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  21. #46
    Join Date
    Aug 2008
    Location
    Sydney Australa
    Posts
    2,413
    My Cars
    1x633, 1x E3 2 DR Racer
    1977 633 CSi RHD Euro. S38B38 3.8L M5 Transplant. 5 Speed Getrag Dogleg. 3.73 LSD. 390hp, 331lb/ft
    1971 3.0CS E3 2dr Alpina Special Coupe Racer, 347hp, 295lb/ft

  22. #47
    Join Date
    Apr 2008
    Location
    Greenwich, CT
    Posts
    2,038
    My Cars
    1985 BMW 635csi
    Wow!!

  23. #48
    Join Date
    Sep 2009
    Location
    Lititz, PA
    Posts
    1,825
    My Cars
    99 740iL, 12 VW TDI
    Wow alright, you Aussies know your 635's. Waite wasn't Jim Richards a kiwi?
    Love this car. Awesome well thought out thorough build. Looking forward to hearing the beast.
    Last edited by daniels635turbo; 04-24-2016 at 11:37 AM.

  24. #49
    Join Date
    Sep 2009
    Location
    Denver, Colorado
    Posts
    2,876
    My Cars
    1985 535i, 1980 635CSi
    Need more photos and video!

  25. #50
    Join Date
    Jul 2008
    Location
    Socal
    Posts
    3,439
    My Cars
    Euro 81 628csi. 02 325i
    Beautiful... How does the car drive with these large wheels? I too have a e12 and am worried anything over 16s would cause issues.

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