Brake Update:
It’s time for an update on the brakes. Bottom line the e36 brake booster was too wide and hit the driver’s side header. So went the GM Hydroboost route. This one is off a 2004 mustang GT. Bought off eBay as I could not find one at PickNPull.
The GM stock master cylinder that came with the hydroboost was too long and hit the shock tower. So I ordered a Willwood master cylinder which is shorter. The GM pushrod seems to be the right length with this Willwood. I’ll have to wait and see when I actually get fluid in the system.
I needed to remove the stock firewall mount from the GM hydroboost. Instead I made my own out of some flat stock steel.
The brake rod needed to be customized as well. I cut off the e36 mounting rod and used the end that connects to the brake pedal. Soldered that onto the GM rod at just the right distance so that is pushes in the e36 brake sensor button. This took me about 4 times putting the hydroboost in and out to get just right.
Below are some pics of the final measurements. It took several test fits to get all the required spacing and fitting correct. Cross your fingers.
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Last edited by Contracheatcode; 04-10-2021 at 03:19 AM.
Wow, that is lots of good, fiddly work!
Diving in at the shallow end!
I cant wait too see more progress on this build. I too have dreams of an ls swapped e36 that can pass CA bar.
I've done my fair share of getting my old turbo'd Infiniti "smogged" it got old fast, and now its even harder and more expensive to get
a "smog" done.. I would rather just pay the $60 every 2 years and not have to worry about CHP or any agency popping my hood and sending me to the Ref.
I'm curious to what your plans are for the driver-side manifold, especially with with the sikky steering shaft.
Also I'm glad to hear that the sikky mounts have a good fitment. my plans include buying their stage 3 kit and use all that I can minus the headers.
I have the drivers side exhaust manifold inverted. I am 99% confident there is plenty of clearance to make a soft 45 degree to turn towards front of car. Then the magnaflow cat that is like a 4 inch diameter and 11 inch long will fit kinda where the stock e36 air filter was. Then route down and back by the steering shaft. It might have to route up and under the large hole near the headlights.
It should look pretty cool and will keep you posted. Calling my exhaust guy this week.
Good luck on your build.
BTW. Its not jus the exhaust that’s a pain. The whole EVAP system is annoying. Like the secondary air pump. Arg.
Mike
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Well. It’s been a while, so I thought I would get back on the build.
Update on the radiator support: Goal is to have AC condensor and Power Steering cooler also attached. I decided to make a custom bracket as everything is such a tight fit. I would have more room if I cut up the crossmember that holds the headlights, but I really did not want to go there and have this snowball.
Here’s the support mocked up and nearly ready for PowerCoating. About a finger clearance to belt and 1/2 finger to intake just above.
Question: I have about a finger of clearance to the belts. That should be fine right? Motor movement is mostly left and right? Thoughts? Pics below.
Last edited by Contracheatcode; 11-08-2021 at 01:25 PM.
Update: It’s time to restart the build. I need your input and advice so keep it coming.
Goal Setting: I believe in setting goals. So my goal is to make progress every day towards an CARB legal e36 M3 LS1 swap. No daily progress is too small.
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Exhaust Update: To recap, 90% of the issue with and e36 LS1 swap is the drivers side exhaust manifold. There just no room as the manifold on the drivers side points right into the steering shaft.
Drivers Side Manifold Solution: Invert the driver side header to have it exit towards the hood. Then wrap custom exhaust pipe up and then back down. This keeps the stock headers and also everything is still in same linear position as stock. GENIUS, I know.
So, custom exhaust money was spent and now the exhaust is done. I’ll take more pictures when wiring is all out of way.
Today’s progress: Start to plug everything into the wiring harness from Wiring Specialists. I also flipped my fans so the fan wiring exits toward top of the Sikky radiator. This is because the custom exhaust routes near bottom of radiator.
I also realized today why I threw away my coil plug brackets. I need new ones as the drivers side would have hit the inverted exhaust manifold.
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Nice going with the inverted manifold.
I'm unfamiliar with the CARB rules. Do they require using stock manifolds, as opposed to the custom headers that most people (including me) use?
Diving in at the shallow end!
CARB requires stock manifolds or CARB approved manifolds. There are some aftermarket manifolds that have gone through the process and received CARB approval. But they all have the same issue of interfering with the steering shaft, brake booster, etc. The interference is even greater due to the CAT that comes right after the manifold.
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Todays Progress: Ordered a cheap oil cap. Plugged some sensors to wiring harness. Did some research on EVAP.
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Today’s progress was installing the fuel line. I used braided PTFE from the filter to to fuel rail. I am going to make a custom bracket to hold the throttle cable and fuel line from running each other and to also ensure they remain on the exact path intended so they don’t run other parts, like the drivers side header.
Overall, this was my first time make a PTFE line and it turned out as good as I can expect.
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