building a 2002

Update!!!

2008-07-06T17:51:00.000-07:00

Yeah, not much of an update. Im still alive. I still have the 02. Im in the process of moving all my stuff 3 thousand miles, so I havent had much time to keep the updates coming. Expect some activity in August. Thank you, come again.

Half step forward

2008-04-20T17:59:00.000-07:00

Block is back from the machine shop with a clean bill of health. Unfortunately, we had to put the head down. Since getting the block back its been painted and crank installed with ARP hardware. Used plastigage with standard size bearings to check clearances. Amazingly the crank has seen zero wear in the past thirty years. Clearance for all journals right around the min. spec.

Block treatment: thermal clean, magnaflux, decked, bore/hone.

Crank treatment: cleaned, magnaflux, measure, polish.

Cylinder head installed just for mockup.

MegaSquirt

2008-04-13T08:41:00.000-07:00

No, its not Ron Jeremy's latest film. Its the DIY engine management from B&G.

Hit a couple glitches with assembly and testing, but all is up and running now. I feel very edumacated. Engine should be assembled in the next couple weeks. Then i need to do some wiring and set up the (aheemmmmmm) ford ignition system, and hopefully fire it up. Month maybe?

Blank MII V3.0 main board:

Partially assembled:

Completed board:

Completed board, relay board, and stimulator:

Megasquirt Megatune software, still not porn:

The engine is out getting all the machine work done. Lots of good stuff to come.

Roll center

2008-03-19T17:41:00.000-07:00

In an attempt to regain proper control arm travel and angle, Ive installed Massive Lee's 32mm roll center spacers. If you ever have the chance to order something from Massive I guarantee you wont be disappointed. Everything Ive gotten from him has been a perfect fit and finish.

Its pretty pathetic when you look at a picture of your suspension and think, "I need to dust that, wait, is that a fingerprint?".

Redneck engineering.

2008-03-19T17:31:00.001-07:00

As of now, the plan is to make my own turbo manifold flange. Im using 3/8" steel.

Normally you would use the exhaust manifold gasket as a template for the flange. Since the gaskets for this head are not one piece, I had to come up with something else.

After a lot of daydreaming about other stuff, I figured out a solution. Take some painters tape, apply to ports, rub tape with greasy gloves. This left a perfect stamp of the ports on the tape. Then remove the tape and apply to steel. Cut away.

Picked up a 1" hole saw to start the ports.
Its times like this I wish I had a bandsaw.

I got head

2008-03-19T17:27:00.000-07:00

Picked up an E21 head. Just got it disassembled for now. Will be sending it to the machine shop to have the surface checked.

This car might have had some intake restrictions:

Lumens

2008-02-17T16:15:00.001-08:00

Sort of finished one taillight. One of the circuits in the brake light is inop due to me running out of the proper resistor. I plan on setting up the other light in stock form for a side by side comparison. I will also be getting new lenses that will be less faded letting more light through.

Accident avoidance

2008-02-17T11:10:00.000-08:00

In an effort to avoiding becoming a statistic of another 02 being rearended, Ive decided to upgrade the rear light assemblies. The stock brake lights are very dim, and dont do an excellent job of alerting tailgaters (high school girls trying to text message a fellow chearleader about a crush she has on the quarterback) that I am coming to a stop. My old roommate John from Jersey would be proud of the lumens my new taillights will be throwing out.

Ingredients for taillights: Lots of LEDs, resistors of a specific value, pc board, steady hands.

For this board it is four parallel circuits, each with 5 LEDs in series. A 1/4watt, 39 ohm resistor keeps each circuit within spec. I used a simple LED calculator to determine the proper schematic based on the factory LED specs.

Obviously not completely done, but you get the idea:
The luminous intensity of the white LEDs is 13000mcd, versus 8000 for the red ones. I will be using white ones for the brake lights, red for running lights, white for reverse, and orange(5000mcd) for turn signals. Im no electronics expert, so if you see something sketchy speak up!

2008-02-17T11:03:00.000-08:00

After getting an estimate for dropping off a dirty assembled motor for rebuilding, Ive decided to do all the work myself i can. Hopefully Ill be dropping the block off this week at the machine shop.

Rollaaaa

2008-02-10T14:18:00.000-08:00

Finally, its an official roller. Rear suspension is "done".

Coilover sleeves arent against their perch cause its jacked in the air again.

Hopefully next update will be of this engine fully rebuilt.

Once the engine is rebuilt:

-install engine with transmission, modify tunnel to accept transmission.

-mockup steering rack, design steering column.

-measure driveshaft length and send out to get shortened/balanced.

-install pedals according to final steering wheel position, bend brake lines.

-install seats according to ^^^

-get engine running.

-burnout.

Support out back

2008-01-24T16:37:00.000-08:00

Finally made it to the metal place where they sell, uh, metal. This rear suspension cage(?) is going to be completely assembled out of car in order to get full welds. Still need to weld on the upper coilover mounts and one of the sideplates. It will then be welded into the car at both ends and the bottom. I was going to triangulate the hell out of it. Then I decided to keep it simple, as i think this will be plenty strong. It looks really heavy, but its actually under 15 pounds(arm scale method).

As of right now, it looks like my plans of running the coilovers inverted is going to happen.

Obviously i chopped off the old upper mount area. I also moved the upper mounting point forward a couple of inches to help maintain the original geometry as I moved the lower mount forward as well. Coolest part is that the ride height should be able to be adjusted from the trunk!

On Deck.

2008-01-24T16:34:00.000-08:00

With the suspension coming to a close, the engine is on deck. Basically a full rebuild with stock components. Forged pistons will be added to handle the boost. Stroke will stay stock, bore will be determined once cylinders have been checked.

Give me fuel, ...

2008-01-20T16:43:00.000-08:00

Got the basket for the fuel cell fabricated. I know it looks like a strange design, but i had to accomodate the bottom feed/return line hookups. It supported me jumping up and down on it, so unless we switch back to leaded fuel, it should be plenty strong. I still need to fabricate a strap to go over the cell to hold it down. If i dont get more steel this weeek, dont expect a progress report anytime soon. The angle iron on all four corners holds it in place nicely. I have a hard time getting it out even without an over strap.

Rear Legs

2008-01-16T16:50:00.000-08:00

I have got to get this rear suspension done. Ive been working on this suspension for so long, and the end is so near.

After much debating, I think ive figured out how the rear lower mount is going to go:

First i welded some flat stock and wrapped it around the circumference of the control arm bearing area. This is to distribute the stress of the mount assembly. Then i welded on the mount so that the strut can go through the complete travel without the heim joint binding. I plan on mounting the coilovers inverted as long as space allows. I need some "cage" material before i can attack the upper mounts. Hopefully Ill get to that this weekend. (yes, i removed the wheel bearings before welding)

Shameless plug

2008-01-16T16:45:00.000-08:00

If you have the chance to do business with kelleyracingcompany.com do it.

I ordered my pedal assemblies, battery box, shock mounts, rear coilover sleeves, rear shocks, and some other stuff. Theyre an excellent company to deal with.

Battery box:

I wasnt sure what i was going to need for fabricating the rear coilover mounts, so I ordered them all. Hopefully I have my design figured out before the return policy expires.

Stopping power.

2008-01-16T16:38:00.000-08:00

Wilwood brake pedal with dual master cylinders and balance bar. Only a few components left before the brake system will be complete. Also pictured is the Wilwood floor mount clutch pedal.

ARP wheel studs for the rear. Plenty long, plenty strong. These are intended for a Lexus IS300, but fit absolutely perfectly. Im sure these are the ones Ireland engineering sells. But if you want to get them on time, right part, and without being treated like shit, order them from Jegs or Summit.

Slammed

2008-01-16T16:36:00.000-08:00

Fully tucked. First thing to cause interference was actually the control arm hitting the floor board. I hope to never see this kind of compression, but its nice to know the room is there.

Rollin dirrrty

2008-01-06T12:59:00.000-08:00

Well it looks like a roller. Unfortunately the rear suspension is not done and its being held up by jackstands.

When fully drooped tires are hitting the outside of the rear fender. Luckily, that can easily be trimmed.

All slow, No go

2008-01-06T12:54:00.000-08:00

Lee's Massive kit installed(minus the front rotors for now). Everything went in perfectly, although i think i installed the parking brake assembly every way but the right way. Once i finally figured out the proper sequence(bracket>rotor>then spot caliper) it fit perfectly.

Obviously need some longer studs for the rear

Unsprung weight

2008-01-06T12:52:00.000-08:00

A slight upgrade in braking since 1973.

Rollin on dubs -5

2007-12-23T17:25:00.000-08:00

Finally decided on some wheels.

Rota RB w/gold centers and polished lip: 15x8, 4x100, et+04, 67.1 hub bore with rings to bring it down to 57.1

Tires to be:Hankook rs2 225/45/15

Also finally figured out what to use for the rear suspension.

Bilstein 2" large body race shocks, 230/78 linear valving with coilover sleeves and upper perch for 2.5" inside diameter coil springs. 10inch, #200 springs on order.

Next up:

Install complete Massive/Wilwood brake assembly.

Mount tires and drop car on wheels to check for clearances(with fingers crossed).

Fabricate mounts for rear shocks. Reinforce rear strut towers to support upper strut mounts.

Roll car back and forth just because i can.

Fabricate mounts for, and install, wilwood pedal assembly.

saga continues

2007-12-09T10:46:00.000-08:00

Welded on some flat stock to complete the triangle bolt pattern of the e36.

Still need to fill in the old holes, then shes done.

Before:

After:

End of day

2007-12-08T13:39:00.000-08:00

The day ended with rear end installed, front suspension almost complete.

A shot of the fronts, need to get some paint on those seam welds.

Steering rack needs to be mocked up. But i couldnt set the front suspension height because the wheels i have for mockup are way too narrow.

I was hoping to get it on four wheels today, guess Ill have to settle for one.

Low...ri...der. is a little........

2007-12-08T13:28:00.000-08:00

I finally got my rearend together, literally.

I needed to get this put up so i can determine what stroke shock i will need.

max drop is 25", fully tucked is 15" but i will never see any of these extensions. I figured 22" was a safe fully drooped. Still with me? Im gonna go with a 7 inch stroke.

Obviously these arent the wheels im going to be using. This is max tuck without hitting. A little unsafe for mass. roads.

Yes, i have adjustable camber in the rear, so hopefully some of this will go away instead of my tires.

Ha, the I cant imagine how this would look driving down the street. I guess if i wanted an idea i could go check out some hondas in dochesta. You can kinda noticed i started the blending on the rear fenders.

Finallyyyy

2007-12-08T13:10:00.000-08:00

So, i had to wait over two months for my kmac camber plates. Then they got lost by ups. Then ups claimed they found them in the woods by my house. Done laughing? So a week later i finally got them. Completely crap. Looks like something that came out of a freshman shop class. I had to send them back and find another solution.

So I believe kmac and ireland are the only ones that make plates for the 2002(i think ground control might, but my roommate had a horrible experience with them). I refused to give in to buying something more from ireland. My roommate had bought some e30 ones from Vorshlag. Unfortunately they dont make them for the 2002. So i ordered the ones for the e36 with camber and caster adjustments. Hopefully i can make them work(fast forward-theyre already installed, so theyll work)

Heres some pics of what had to be done:

Camber plates with crazy good engineering and machine work.

Everything fit beautifully with correct parts to accomodate my 2.5 springs and inverted bilsteins

A little geometry with levels, straight edges, etc.I forgot to mention, the e36 bolt pattern and center offset is completely different. So i had to drill two new holes, and them im going to weld a plate to support the third hole. Soon to come.

Markings for new holes

And installed