#ZedShed Dino’s Track toy 2.8 (6-Speed Gearbox Conversion)

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
She’s back! @Dino D 6 years ago we first saw this Zed, back then though we only replaced bushes and never did any powder coating or bearing removals. So now she’s back for a total nut n bolt overhaul with all the shinny black bits.

It’s worth mentioning this car has become a very track focused 2.8.We’ve also done track days together and she’s amazing. Some of the mods include bucket seats, s50 manifolds along with M50 inlet manifold. Raised rev limiter and welded oil pump nut. Increased rear diff ratio from 3.15 to 3.38. These are just the mods that come to mind.

So again assuming the position with the bum in and getting her in the air.
64C9D035-6147-47A9-97C1-F38107CA20B0.jpeg

high enough to slide the gearbox out.
972EDF05-1B1D-4F4D-93DA-EB85D7191F31.jpeg

I can confirm these seats are very comfy.
7AF7F95E-C851-4D3A-881F-DC22328FAA58.jpeg

with the wheels off we can see how she’s faired over the last 6 years.... not great.

BC coilovers still in great condition, we fitted these 6 years ago. I love Dino’s home made brake ducts that actually make a huge difference on track.
D2FD2CEF-E676-4794-8B53-DCE45F3FD298.jpeg

All this hardware will be removed and replaced
E0F27F8A-E084-4F90-99A7-A04CFFC0390D.jpeg

88EEF20D-536D-4E71-B1D4-AB4F5949531C.jpeg

Looking pretty rough.
4BF1CA90-858C-491B-8785-7840A4D6260E.jpeg

not sure these swing arms have much life left in them. Luckily Dino provided a spare set just in case.
7F747D4F-ABAC-4F30-A329-CAB818D534A1.jpeg

We are also replacing the sills compliments of @Sean d old ones are pretty good shape just with a few dings.
B745BDCD-E168-42DA-A9F8-FEEC53CB9B48.jpeg

EC08E8EA-FC27-4396-B78A-364717523D32.jpeg

CBAC599C-8E99-43C9-8C0C-B6D97491AE4F.jpeg

and the sills themselves are in good shape considering the age and miles.
B3074A75-E576-4AF6-A76B-C6A8F8D41A60.jpeg

4C6D1F7E-8C29-4645-8591-F45E35C5001F.jpeg

D76C3FB3-1C6E-4142-A017-22E8019D2D54.jpeg

3B59AF92-FFA4-44AC-879B-2A5726E16DE9.jpeg

this is the worst one. Not to shabby.
1D8EF0EA-0920-4DDE-B6D1-9759BA975E2C.jpeg

First large bit of hardware to remove was the exhaust, Dino tells me this has only just been fitted, the finish is lovely, one of the best sounding 2.8’s I’ve ever heard.
369D82C3-1057-4EDE-9460-FEB8123FF954.jpeg

paired up with a set of S50 manifolds from the Z3M boy she’s loud!
2CBFD43F-45DF-4E3B-A9A7-593828FD9BB0.jpeg

Think this rear roll bar is beyond powder coating. Luckily we have plenty of pre coated roll bars in stock.
B902D8ED-64DD-4983-9612-F98B3608351D.jpeg

Photo limit reached.
 
Last edited:

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
She put up a fight, removing the subframe we had to cut the beam plates because the bolts were all seized. 4/5 hours in and she’s all apart.
B52EFA3C-1DCE-4619-8C89-25859AE612C7.jpeg

C27CF5BD-6D9C-4418-8A37-9A34C8CB81AC.jpeg

33A34DC2-5FD8-4106-B6FB-9FDD79835AFD.jpeg

35034546-246C-441B-90AD-F8A3D37BD596.jpeg

this is what’s left of the beam plates. Luckily I managed to get all 4 bolts out once the beam was down. Combination of an angle grinder and hammer.
13D084BE-BFD2-4651-B3E9-718FA454D508.jpeg

thought while I was under her I would remove the old straps.
8202A077-5F22-4D36-B7D5-D44E1A28BBCB.jpeg

C2D6354C-FF20-44DD-91AE-213CDCCA2E8B.jpeg

so two people and 5 hours in were at this stage. Not to bad for the first day.
336FA6AA-8F57-4F74-B448-D2A7A5A69187.jpeg
 

Tom Holland

Regular Member
Joined
Jun 28, 2017
Messages
20
Green with envy, good luck with all the work you are undertaking. If you should be wanting to sell those sills.... Great stuff
 

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
Green with envy, good luck with all the work you are undertaking. If you should be wanting to sell those sills.... Great stuff
I have new sills to fit so @Dino D might not have any need for the old ones.
 

Dino D

Zorg Guru (V)
British Zeds
Joined
Mar 28, 2014
Messages
4,130
Location
Kent
Model of Z
2.8 Manual
So crusty and crispy all at the same time.
My palpitations have calmed down a bit now after seeing those picso_O

Not a moment overdue by the looks of it.
 

Zag2

Zorg Addict
British Zeds
Joined
Oct 30, 2020
Messages
112
Location
Reading, UK
Model of Z
BMW Z3 2.8
Nice to see the internal moterwerx upgrades on the gear knob and handbrake, same as mine! Love the feel of them (on a warm day :D)

I'm also wondering where you got the manifolds done?

Also what engine brace is that? I've been looking for a shiny one for a while! :)

Great work as always Lee.
 
  • Thank You!
Reactions: Lee

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
Another mega day today. Started off stripping down the rear end assembly then moved up to the front.

Rear trailing arms in poor condition, wonder why it’s always the drivers side that takes the most battering.
460C42E8-CFA6-4C82-B7BA-6F310D1776FC.jpeg

it was clear these wheel bearings had been played with before, all the bearings fell out when we removed the hub.
96AFD8D2-86C1-4658-A398-CB6FB8B46CF5.jpeg

0A53C143-8842-4CC4-9295-C45A4635BFDC.jpeg

we came across some interesting fixes. Metal cable tie’ing a brake line to the abs sensor.
839CF951-98D0-42FF-8EE4-F257B21B353C.jpeg

Both half shafts looking sorry for themselves. Diff end joint on both feeling very slack.
78E44D19-F6A9-4E61-B138-DAF8FB6C0569.jpeg

I also noticed Dino has a like for unique brands and track focused parts, the rear pads on the calliper side have no retaining clip, this is causing the rear pad to wear unevenly.
C40CC403-7A64-44BE-A753-AB8413FC91D6.jpeg

8A8BA22C-4C3F-470C-8D1B-BB426BFA2B07.jpeg

The old diff bush looked a little sorry for itself, this is being replaced anyway due to the retaining plates rotting away. Everything is looking like it’s suffering from a very damp climate, look between the bush Ali diff ring.
CD8FFF58-4E7A-4787-B9CC-D371A9841155.jpeg

After the tear down we looked at the new arms we pre powder coated ready for Dinos build, he got these arms from a written off figi. These have come up really nice.
66975FF6-A9F6-49E6-B280-C71DE07E889C.jpeg

4EABF93C-A3DA-4966-86BE-C3686BE3BE64.jpeg

Now moving up to the front, things got interesting. Dino must have a very friendly MOT tester.

Front brake cooling ducts, personally really like these and they work very well.
B4455B4A-742E-4739-96F6-67443130FA6B.jpeg

front Drop links way past it.
D04B9A91-E2B5-4094-9176-06AEAAD656CD.jpeg

Also the front calliper dust shields appear to have been melted, think this must be from Dino chasing me at Brands :)
98D4C7A3-5C19-4996-BBAE-093E454C0115.jpeg

Again Dino loves a mod, brass bushings for the sliders.
B06144C0-9862-49F4-92FD-4614BF5E36C3.jpeg

Toe rod ends also removed alone with wishbones. All those ball joints I could spin by hand, crazy.
2077AADA-3622-4334-BF12-B3520C7DE44E.jpeg

Must say the front coilovers although on the wrong sides are in great condition still.
9D69B51D-04D5-4DFC-9754-855D29EA1C24.jpeg

So this just leaves the subframe to come off. Ran out of time today.
6C851880-55C2-4482-9B69-96E15034BE2A.jpeg

both sides now clear.
8D8533B7-0436-44B4-9548-FBD1F1F8B63A.jpeg

We are doing some sneaky little extras. The Diff is being re built professionally by a local Transmission company, were planning to set up a deal between the Zedshed and them for continued business going forward.

We have a 6 speed gearbox going in aswell. Most of the RnD for this has been done behind the scenes so fingers crossed were nearly there.
4D9CB20D-0E69-4FF6-838B-AA21A8FCDB4E.jpeg
 

Dino D

Zorg Guru (V)
British Zeds
Joined
Mar 28, 2014
Messages
4,130
Location
Kent
Model of Z
2.8 Manual
Silly question incoming but does the extra cog really make the box so much bigger than the 5sp?
 

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
Little update today.

finished off removing the rest of the hardware so everything could be dropped off at the coaters today.
0FE2EA63-1877-4766-802F-8B03A7BB2617.jpeg

8EE8F9B5-CDCF-48D0-829A-140D83F7C026.jpeg

The underside looking crazy without the subframe.
6D490B25-3C41-475D-9098-AF4475EF8985.jpeg


42857C54-3280-4846-8D98-9A47AF2D39D8.jpeg

0F9870F4-5DE4-472A-8822-3F4AD927D97E.jpeg

I also got a few photos showing the S50 manifolds in place on this M52 engine. plenty of clearance.
4628819A-C1E5-44D8-9D9E-85B83A9DBFE0.jpeg

3B7DCC12-B43A-46B2-A049-61388ACEB3AF.jpeg

We also started stripping down the front knuckles/hubs so they can be painted. Had to get some serious tools out. 46mm socket for the bearing.
CEABB464-4D1A-4CF9-A8B1-25C9C5229708.jpeg

24C2F902-0D08-40AE-92ED-8E1B94FBD740.jpeg

hour later both stripped and slightly less rusty.
D1BF581B-FA0B-4F8D-8DDF-01D05E3C9531.jpeg

3D942C96-86E4-4612-8C2A-482BAD28E4D5.jpeg

Shocks got a partial strip down and re grease so hopefully they’ll last a few more years.
D843866F-C85F-4F1E-BB46-850931D74BDC.jpeg

We also unwrapped the new subframe beam. Looking pretty compliments of Traceys Feji.

689D06D2-70A9-4807-A9A9-4A874D95853A.jpeg

BDCB726A-DD95-4E39-8A3C-770A1E6568E5.jpeg

Then finally a drop off at the powder coaters. There’s all Dinos parts and a Z4 going through the same process. Plus @Althulas is having his M springs changed from yellow to red. On our way back we dropped the Diff into BK transmissions who are rebuilding it, this diff really clonks, he said it will likely need a new crush sleeve and bearing set. Looking forward to hearing the outcome and what price he’s going to do for us going forward.
1D41EFE1-1EB7-4B26-A86B-7C6A20E9417A.jpeg

so Dinos car is left looking like this...
FA126D8F-CB53-4B88-BDA1-CFA57A90394B.jpeg
 

Dino D

Zorg Guru (V)
British Zeds
Joined
Mar 28, 2014
Messages
4,130
Location
Kent
Model of Z
2.8 Manual
^That song ‘levitating’ comes to mind seeing it ‘floating’ in space like this.

This must be record time to strip a Z3 of ALL it’s rubbing gear!
 

D0nni

Zorg Addict
Supporter
British Zeds
Joined
Jun 24, 2020
Messages
169
Location
N.Ireland
Model of Z
2.8
Serious work lads. definately showing your trade here. I'm still working on one while you've have pushed 5 or 6 cars through in the same space of time :whistle:
 
  • Haha
Reactions: Lee

Bazza

Zorg Guru (IV)
Supporter
British Zeds
The West Country
Joined
Oct 15, 2013
Messages
2,055
Location
Verwood Dorset
Model of Z
2.8 Roadster
Wow got your work cut out with Dino's machine, he will be flying round the track after the Zed shed has worked there magic
 
  • Agree
Reactions: Lee

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
Wow got your work cut out with Dino's machine, he will be flying round the track after the Zed shed has worked there magic
Long as he’s not coming past me :) we know he can’t at the moment we can see all his brakes have been on fire at some point. =))
 

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Messages
3,887
Location
Basingstoke
Model of Z
Z3 Roadie 2.8TU
Only a little update tonight. It’s been a day of collecting powder coated items and lots of de rusting.

I’m amazed in less than 24/h they’ve done all the coating. So today we de rusted the chassis and sealed everything in.

Before
4372AB76-5F0C-415C-9197-B8F330158174.jpeg

After
1E502221-2477-489A-8F64-1E22C8DF20C1.jpeg

and some other shots after the flappy wheel treatment. All still very solid.
783FC4D3-4D5C-4DD8-9606-03EEB538EEC2.jpeg

6A3B6B14-38BE-4623-BE2E-CF5B75A5534D.jpeg

then a treatment of under seal.
86E4F0A0-C162-44A9-916D-CE96855D39F6.jpeg

All the main areas covered.
D7982BB1-243D-46EF-B3DD-FA64BFF30383.jpeg

D864A5F9-2841-4A79-83BA-0F02DDBE684E.jpeg

C33D7B71-913E-45C5-8FB7-37E5742214DE.jpeg

4FE7BD1B-619F-4226-9071-1AC65CA4EAED.jpeg

while under the car I noticed the reason why the Speedo kept intermittently cutting out in the wet. So tomorrow I’ll solder and heat shrink a fix.
0342D632-BEB9-463E-BC4E-FA74CBBFA4A6.jpeg

Another really pants job was removing two snapped bolts. Both swing arms were on a car that left the road and snapped off both shock bolts. If I had a pound for every bolt I’ve drilled out in the last few weeks. Nice M12x1.5 to drill.
84749DCA-40EE-470F-999A-FB2E3EC44209.jpeg

took me a good hour to fix this.
83484BF0-41CA-490B-BD97-C5A59B6FF756.jpeg

no pressure as this could write the arm off...
EABD3A27-3ACE-41AE-9C08-8BF438A1586A.jpeg

only one more to do tomorrow :)

We also collected the springs for Althulas and these look amazing. Really pleased how red powder coat came out also the cost was £30 for all four springs, think we might start doing more colours. Dino we could try a pink subframe =))
4620242A-531F-4388-8D0F-02B13150025E.jpeg
 
Top