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Sportster build update

JazzMan

JazzMan

Member
Joined
Sep 27, 2005
Messages
49
Location
Hampshire, UK
I'm building a kit car with my brother, we've only just started really. We've got a build site here: www.msportster.co.uk which we will be updating as and when we make progress :)

Its a Marlin Sportster - www.marlinracing.co.uk It's based on a BMW 325i

Here's a few pictures:















Engine:

M20 2.5ltr Straight 6 - 170BHP stock

Modifications & Customisations:

8mm Magencor HT leads
Custom exhaust system
Cold air Intake
Big bore throttle body
Wild Zone chip
3.91 LSD
AVO Road sport dampers for the rear
Custom rear springs
5 stud conversion (E36/E46 Wheels)
Z4 3.0 or Z3 1.8 gear lever (short shift)

:)

Small update today:



Installed the fuel lines so the car's ready to have the engine put back in. Also recieved the seats from Cobra and the intake system:



 
Nice dude, its coming along nicely.
 
tidy!

but why a new thread?
 
Yes, the intake did set me back a bit, but it was the only way to properly shield the engine heat from the intake without using the stock airbox which is bigger and does not fit under the bonnet. It will still be fun trying to fit this one!

I put the engine/gearbox back in yesterday and with the replacement Z4 3.0ltr shift lever I ordered it has really dramatically shortend the shift of the box which is nice. There is about 5 cm total movement at the top from 1st to neutral to 2nd - same again with the rest of the gears :)

I'll post new pics in this thread from now on, some forums I've been on get a bit niggly about bumping old threads :)
 
Put the E36 wheels with Bridgestone RE720's on this weekend. The clearance at the back is now much better with the stud adapters. They look good too! Rain has stop us taking the car outside to get good pictures.



Also now under construction an adpater plate to fit the steering column. The steering feels very good even on the spot.

 
what resources do you have?

i mean, do you have a full equiped workshop, or can you make parts at work after hours? doesn't look like a project every basic handyman can do
 
bone said:
what resources do you have?

i mean, do you have a full equiped workshop, or can you make parts at work after hours? doesn't look like a project every basic handyman can do
Click to expand...

I've got a full socket set, angle grinder, drill. Nothing really specialist. I've pick up a few things like a right angle drill adapter, pipe cutter, riveter, break bars, torque wrench. The one thing I do have is a lathe. Most bits come from Marlin and only need minor modification. Anyone can do this as long as they have some mechanical skill. I started with no knowledge of how cars worked underneath. All I had done before starting the project was swap wheels over and chech coolant levels!
 
what are the performance figures on it now?
 
bartboy9891 said:
what are the performance figures on it now?
Click to expand...

The stock E30 325i had a 0-60 of around 8 seconds. Weighed a lot more though - a bit over 1200Kg I think! Weight of the Sportster should be around 750-800Kg. Stock BHP was 170BHP, with chips and mods I would hope to get that up to around 180 ish (would be nice)
 
This is what I like seeing. Also knowing that I'll hopefully start my projects soon. Keep up the good work :).
 


3 Empty bottle of gear/diff oil! Changed the oil in the LSD and the gearbox today. 3ltrs was just enough. It came down to the last few ml!

Also test fitted the prop shaft. Fits nicely and loads of room for the gear lever linkages.







Also taken out the pedal box to spray the metal underneath. Going to bend the brake pedal into a better place while its out.
 
The holiday season has given us time to sit next to the car and think about how and where to run things. The intake is going to be a rather interesting one. I'll let the pictures do the talking once all the bits turn up from Rally Design.

Ordered are silicon hoses, ducts, oil cooler and pipes. After further consideration we're moving the rad further forward, placing the oil cooler in front and getting a "sucker" fan instead. The current position places the rad too close to the engine for me to be comfortable with.

Also up for work is the steering column. After enlarging the hole on the bulk head we were able to mount it using the bracket already in the car. However after spending some time sitting in the driver seat we both agreed we didn't like the alignment and have decided to customise it. Using the brake we already made and the now enlarged hole I think we have a steering position that suits our personal taste.

The brake pedal - after several hours of going nowhere trying to bend it, it's time to call in a professional. This stuff is too thick for our weedy gas burner and vice to bend.

The Rally Design order came today, so we've been able to start putting the intake together!

Here are some pictures:


Oil cooler


Intake system


Steering column bracket test fit
 
Top notch.

Is there a rough time on when you'll have it finished?
 
Haven't seen this tread yet. Very nice project you have there. I really like you have chosen a BMW inline-6 :thumbsup: Dream of doing something similar one day...
Can i ask what kind of expererience you have with putting cars together? Are you both, or one of you a mechanic, or just lerned it along the way?
 
Were both learning as we're going. The most I had done on a car before the project was change the wheels and add oil and coolant!

It help a lot taking the donor car to bits before hand as it gave an overview of where things go and how they work.

Estimated build completion is sometime this summer, probably nearer the end :)

I've got a staight six in my daily driver, its such a nice engine it made sense using one for the sportster too. The nice thing is that its a single donor kit so we only needed to break one car to get most of the bits we needed.
 
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