Mike's Cabrio Build

[greyV8pete]

Re: Mike's Cabrio Build

Excellent news Mike. You are always welcome to drop in for a cuppa even if the SW Meets don't coincide with your travels. Peter.

[Mike]

Re: Mike's Cabrio Build

Dual Mass Flywheels

As part of my engine/gearbox swap, I have taken time to address the issue of a Dual Mass Flywheel (DMF) v Single Mass Flywheel (SMF). I had a vague notion that DMFs often fail, and are very expensive, but are smoother than a SMF: and that the SMFs are lighter and allow an engine to rev more responsively.

Like most petrolheads the idea of a installing an SMF whilst the engine is out had some appeal - it would go faster! But if I'm honest, I did not fully understand how DMFs work , or moreover, why they are so widely used in modern cars.

These two short videos went a long way to answering my questions:

https://www.youtube.com/watch?v=DbvP5EvpUbA

The last 20 seconds of this animation makes the point very well:

https://www.youtube.com/watch?v=YnaXB8q3uzQ

Having seen the "why" I have decided that, as I am not building an out and out track day car, I will stay with the M54's DMF in my Cabrio and forego the last ounce of additional acceleration.........

I just hope I feel, and appreciate, the smoothness!!

[greyV8pete]

Re: Mike's Cabrio Build

That's a really interesting bit of info Mike. Makes me feel less bad about the cost of having one replaced on my old Audi when the clutch was done a couple of years ago! Peter.

[Mike]

Re: Mike's Cabrio Build

It may be Halloween today , but I enjoyed a very spooky coincidence last week.

Since replacing my 3.14 diff with a 3.38 diff I felt there was more noise and vibration coming from my rear drive train, and through the chassis into the cabin. At cruising speeds over 50mph the 3.38 diff sounds as though the gears were running dry inside a large can, and under hard acceleration, it appears noisey and vibrates through the chassis.

I was not certain what the causes were, but guessed it would be due to either a worn diff, and/or my home made rear diff mount.

Last week, while surfing the net, I spotted an advert for a brand new, never used, Ford 7 1/2" 3.36 diff being offered secondhand at a realistic price:



I decided opportunities like this do not come along often, so (with guilt) bought it.

Rather spookily and completely out of the blue, an MOC member made contact the very next day to ask if I would be prepared to sell my 3.14 diff - What spooky, but perfect timing! - of course I was delighted to oblige.


As part of my deliberations on the cause of the noise/vibration I considered the possibility that my "Koala" twin rear diff mount was achieving the complete opposite of what I had intended - more noise and vibration, rather than less! It dawned on me that although I had copied both Ford and BMW's twin rear diff mount, I had not picked up the fact that they both only had a single front mount.

As I had retained Marlin's twin front mount, I had inadvertently created a 4 point fixing.

Rather like chairs, I now suspect a 3 point mount will always find a balanced equilibrium, whereas my four point fixing will vibrate (rock) when unequal point loads are applied, just as a four legged chair does.

I have decided that as I have to pull my diff mount out to swap over diffs I am going to fit a single billet aluminium diff mount. The Sierra Coswoth guys rate them highly, and a couple of MOC members who used them also advise no problems.






So I'm going to give one a go................

[greyV8pete]

Re: Mike's Cabrio Build

Mike. Have sent you a PM about front diff bushes. Peter.

[cameronfurnival]

Re: Mike's Cabrio Build

interesting stuff Mike - we look forward to seeing the result

[Mike]

Re: Mike's Cabrio Build

Earlier this year I bought an E46 330i Coupe CAT D insurance write off with only 64000 genuine miles on the clock - I've checked its history on-line and its service record.

BMW 330 1.JPG

- It was a write off due only to the damage you can see - a slightly creased bonnet.


BMW 330 64k .JPG

My intention was to break the car for its engine and sell off the remainder to get my outlay back.
However, after I had towed it back home the only damage I discovered was a slightly creased bonnet, and that the steering wheel airbag had been triggered: it was far too good to scrap. I suspect the front wings had been replaced previously as there is no rust whatsoever.

So, I bought an E46 coupe bonnet and slam panel in the same colur from ebay for £70,and had the car back on the road looking good as new!
Getting it through an MOT cost a little more than I expected as not only had the steering wheel airbag to be replaced (ebay £25), but also the two seat belt pre-tensioners had gone off (2 x £15 ebay), along with the main battery cut off (£25 ebay). In all another £120 including the garage re-setting the dashboard CEL warning lights, and an MOT.
But for less than a grand and I was on the road with a very good car


Over the past 7 months I've covered over 6,000 trouble free miles in what we affectionately came to know as "Chugabug".

However, my original plan was to remove the engine, and the confidence I gained from using this silky smooth low revving engine re-inforced my determination to see this plan through: but I couldn't scrap a perfectly good car. So, I am going to swap a spare M54B30 engine I bought "from under the railway arches" some time ago - it was going to provide the rotating internals (crank, con rods, and pistons) to swap into my current M50 block to create a stroked M50B30 - but it can go into the E46 to make someone a good cheap car.

I am much happier to be swapping over the entire M54B30 into my Cabrio, even if it has created more work, as it develops much more low down torque due to its DISA inlet manifold (variable runner lengths to suit engine rpm), and Dual variable valve timing. I also hope it will be more efficient, and the emissions will be much better having two CATs built into the exhaust manifold (assuming they will fit inside the Cabrio bonnet!).

I have to say modern engines are so b****dy complex that the process has been a lot more work than I anticipated! - but I'll get there......................

M54 being removed from E46 330i 3.JPG



M54 being removed from E46 330i 2.JPG


The additonal work is due to the fact that my E46 was a Yr 2000 model, whereas the spare engine came from a 2004 model. I'd wrongly assumed they would be the same, but oh no!..... the coil packs are different, as are their connecting cables and the valve cover beneath them, so I have had to swap the entire engine wiring harnesses and valve cover from one to the other.


M54 being removed from E46 330i 4.JPG

The coil-on-plugs (COPs) from the Yr 2000 engine are completely different from the ones above.

[copperleaves11]

Re: Mike's Cabrio Build

Dogon. Wait until the details of the hydrogen cell and energy recovery systems are released shortly.Fossil fuels; that's so last year.

[Mike]

Re: Mike's Cabrio Build

Mike
I'm now confused!
I thought you had the engine you wanted mated to the 6 speed and about to be trial fitted to the spare chassis. Exactly how many engine/box combinations have you got? I have to admit that if I had that much space to work in I would get sidetracked . Time to move apace Mon Amie before the fossil fuels run out!!!!

Have another read Alan - its all there!
I am swapping the previous engine of unknown history with this one, which I have driven for the past 7 months/6000 miles, and know it runs beautifully.

Don't worry about the fossil fuel - I have it on very good authority that there is plenty of oil to see us and our children through our lives. My best mate is head of a very large geological consultancy in Calgary (where they specialise in oil extraction) and he is really depressed as the US is producing so much shale oil, and looks set to continue for decades, that his consultancy is having to shed around 25% of their workforce: there is so much oil around that it is not worth them searching for more at the moment.

[Mike]

Re: Mike's Cabrio Build

Dogon. Wait until the details of the hydrogen cell and energy recovery systems are released shortly.Fossil fuels; that's so last year.

Nah! - they don't make the right noise.

I did consider nicking Maz's DB9 V12 engine (510BHP!) to drop in my Cabrio when he visited this weekend - when he woke up and saw this from his bedroom window he thought for one moment that I had actually done it!


Aston Martin DB9 V12.JPG

[westy]

Re: Mike's Cabrio Build

Hi Mike
will swapping the engine cause paperwork problems as the car had passed the iva with a different engine rating?
I am only asking as I have been thinking of swapping out my 2.0 ford for something more exotic! and am worrying that it will need another iva test.

Westy Steve

[copperleaves11]

Re: Mike's Cabrio Build

Westy. If you swap your engine, you only need to have the DVLA change the engine capacity and number on the V5. Details of the new engine number, capacity and a receipt of purchase, if possible from the vendor was all that was required in my case. I changed from 3.5 RV8 to BMW 2.5 . David

[scott h]

Re: Mike's Cabrio Build

Hi Mike
will swapping the engine cause paperwork problems as the car had passed the iva with a different engine rating?
I am only asking as I have been thinking of swapping out my 2.0 ford for something more exotic! and am worrying that it will need another iva test.

Westy Steve

This is something that concerns me with my Berly rebuild. I have changed from a V8 to Vauxhall red top. I hope the worst will be to provide an engineers report but it would be ideal if it was just paper work.

[Mike]

Re: Mike's Cabrio Build

Hi Mike
will swapping the engine cause paperwork problems as the car had passed the iva with a different engine rating?
I am only asking as I have been thinking of swapping out my 2.0 ford for something more exotic! and am worrying that it will need another iva test.

Westy Steve

Hi Steve

This is something I have looked into, and David (Copperleaves) has said, I believe all that is required is to notify DVLA and change the V5. The only bit I am unsure about is the emission rating. I very deliberately chose my M50 engine as a pre August 96 engine as this avoided the higher emissions requirements.
My M54 engine is Yr2000, so will need to meet more stingent emission regulations - ie it will require the CATs fitted.

Other than that I am reasonably confident it will be straight forward.

Would you like a very good BMW M50 2.5 litre straight 6 and 5 speed gearbox and propshaft by any chance? It had covered less than 70k miles when I bought it, and I saw the car and engine running before I bought it.
- its a reasonably straight forward plug and play engine swap.

Mike

[dbazdavies]

Re: Mike's Cabrio Build

this is the link guys

https://www.gov.uk/change-vehicle-details-registration-certificate/changes-youll-need-to-update

seems they are getting keen on any changes especially when changing to Historic !!!