Pi22 yUP - The next phase

[Duncodin]

Interesting

Morning,

. .
. .

Trying to visualise it

View attachment 327525

. . .
. . .

I've been lurking - I do like where you're going with it. I love my M44. Actually I'm more than happy with my performance but your conversion is super interesting.

Couple of questions

1. Will it fit under the standard bonnet or are you planning on a power bulge?

2. What kind of power are you planning on getting from your M44?

3. I assume you're replacing all the plastic pipes and hoses - me too - you wouldn't per chance have a shopping list and a source? I know if I try to order them all I'm bound to (a) forget one and/or (b) order the wrong one.

4. Your happy new year picture - What's your dram? Local?

 

[RB2]

Howdo @Duncodin

It should all fit under the bonnet, I think it'll actually end up a little lower and further over once mounted with the kit, I've added a photo in the thumbnails of one installed. It will have additional pipe work for an intercooler. I'll probably go for an electic fan to help with the pipework spacing. A power bulge would be great though

Quoting the kit makers website, they're supposed to make 250 to 300 bhp with proper fuelling and a pulley but we will see, I'd be delighted with 250, Standard the SC only does 7 ish psi, it'll do 12 psi with the pulley, so not daft pressures. It pumps about 0.7L per revolution. The pulley is on the list.

I'll have a look for the email I bought the hoses with but I just use the realoem.com website and order what's needed. It's a really handy site.

I think that one was a Glencadam PX casc from Brechin, very tasty but I often go for the heavy peat.

The SC instal is a bit of fun and a learning process for myself but I'll keep posting the lessons and results.

 

[RB2]

A box of bits arrived today after some customs delays. Glad to see the red is a pretty close match. I'll try and have a mock up this weekend to get my head around it.

 

[RB2]

The pipework makes sense now (I think), the part I couldn't see before was how it tied into the inlet but the plate the charger sits on covers the original route and the kit utilises the hole left by the disa valve. I'll need to trim back a little of the casting on the original inlet and the edge of the throttle body.

 

[RB2]

 

[RB2]

A little bit if progress, I started chasing out the threads as they came full of powdercoat. There was also a lip on the cast of the inlet that would clash with the inlet elbow, which needed ground back.

I then noticed that the "ports" between the two parts didn't really match. I am hoping with wasn't a mistake but I've opened it up as much as I dare to be a close match to the inlet.





I've been using RTV gasket sealer for the mating surfaces, hopefully that does the trick against the boost. In the mean time I've started taking bits to work as I have access to a sand blaster and decent parts washer.

I am still just mocking up on this engine for now, but I recieved the belt tensioner the kit required from opie oils, so that's fitted. I need to make a tool so I can get the fan off.

The car itself received a new cheap ICV, as it started the oscillation in the idle again. I have cleaned it in the past, so just replaced it to be done with it. It then got a quick polish and I set about fitting the oem centre consol from the breaker, getting rid of the aftermarket double din horror.

 

[elevensies]

looks great

 

[RB2]

Tried it in a test today. All the old fail points are sorted but this time emissions got it. They suggested a cat cleaner but they also do a 200 cell cat, so I've opted for that. It's back on the 25th for the cat and an alignment. Almost there

 

[RB2]

My rocker cover was ready to collect, so not all bad news today. I did say it was going to be red overload. I need to work out the dimensions for the COP conversion bracket.

 

[IainP]

From the net

www.bmwz3diysweebly.com
I think

 

[RB2]

From the net
View attachment 328659
www.bmwz3diysweebly.com
I think

That's fantastic, thanks for that Iain.

 

[RB2]

Well the 25th is upon us, so I gave it a bit of a bull up in preparation. Hopefully the new cat is the last bit to be able to get it out for a spin.

Very happy with the returned to standard interior but I am missing a blank in the consol. I need to work out which plug was which for thr asc button and the clock. Both look identical. If anyone has a spare blank to fill the gap send me a message, that would be very appreciated.

In the meantime I've started to strip the other engine. I am going to attempt a full rebuild on it. This will be my first attempt at going this full into one so it'll be a learning curve.

More parts for the works parts washer.

 

[spurs fan in a coupe]

Looks amazing, great commitment, if you need a banking plate let me know.

 

[RB2]

One perk of my job is access to superb parts washers.

Before

Quick scrub

Then into this beast

After the beast

I left the seals in for some protection from beed blasting. After blasting and another quick dip to get the grit off.

Then home early to get the car to the test centre. The sun was out so rude not to have the roof down.

 

[RB2]

Success, finally, for the first time in 11 years my little zed is road legal.

 

[Duncodin]

Success, finally, for the first time in 11 years my little zed is road legal.

View attachment 330067

Well done! I went back and read the whole thread again. Amazing. I wish I had just half of your enthusiasm.

 

[Scooblitz]

Success, finally, for the first time in 11 years my little zed is road legal.

View attachment 330067

Very well done. A lot of effort.

 

[RB2]

Thanks guys, now I just need to get home and stretch it's legs. Roll on next weekend

 

[RB2]

I finally made it home and managed to get pi22 up to the station for a fresh tank of fuel. Noticed afterwards that the coolant hose had collapsed once cooled. The radiator and cap are new. I jacked the front up to bleed it, and tried to massage the pipes, wondering if its an airlock. The radiator didn't get hot, now wondering if the thermostat could be stuck closed. The car doesn't overheat and sits pretty much in the middle. No sign of any leakage.

I was hoping to get some fun out of this engine without spending more on it until the next one is ready but I am thinking I might need to do the thermostat.

I also recieved a blank for the dash from our in house Spurs fan, which helps my ocd massively. Thanks mate.

I am going to take it to work tomorrow, hopefully it's trouble free and I can hit the hills with it over the weekend.

 

[RB2]

Finally out for a bit of a run. It sounds fruity enough for the little 4 pot.