wow. congrats on the project, awesome pics

 

Dude, that thing is gonna be a rocket!

 

You have any pics of how you relocated the PS pump?

 

Long time since last update...the car is about finished now. Its soooo much fun to drive!

Here you go - pic showing how I did the ancilaries. Its working ok so far. The PS pump is a bit difficult to get to but I hope I wont need to!
http://www.flickr.com/photos/7197859@N04/5775295402/http://www.flickr.com/photos/7197859@N04/5775295402/ by http://www.flickr.com/people/7197859@N04/, on Flickr

The car now has CCW wheels on with 295 rubber at the rear:
http://www.flickr.com/photos/7197859@N04/5658576156/http://www.flickr.com/photos/7197859@N04/5658576156/ by http://www.flickr.com/people/7197859@N04/, on Flickr

Brakes are complete...I used 135i calipers and front discs off a Z4m and rears off a E60 (5 series).
http://www.flickr.com/photos/7197859@N04/5722899304/http://www.flickr.com/photos/7197859@N04/5722899304/ by http://www.flickr.com/people/7197859@N04/, on Flickr

I made a new strut brace that connects to the bulkhead tying everything together well.
http://www.flickr.com/photos/7197859@N04/5740735211/http://www.flickr.com/photos/7197859@N04/5740735211/ by http://www.flickr.com/people/7197859@N04/, on Flickr

I have been tuning the engine with HP tuners and have it going pretty good now. I have not driven it too hard yet but did have a race with a BoxterS last week - over v quickly lol. Fuel consumption is not so good and I hope that will get a bit better as the engine runs in.

There have been a few snags but all have now been sorted except for the gear linkage which is vibrating a bit not quite sure what to do about that. It stops if I keep my hand on the shifter. The car is reasonably quiet to drive. The honeycomb mod to the inlet quietened down the induction a lot. I did fit two pieces of honeycomb on either side of the MAF and may take one out to let some more noise out. Its perhaps a little too quiet at the mo. Anyways its time to drive the car now and have some fun

 

Do you tune original GM pcm box with hp tuners? Please, tell as some examples of your tuning adjustments (idle problems, afr, problems with tuning...)?
Fuel consumption is bad? Do you can compare it to old engine? Which is mpg?

I am currently in preparation for this project with same engine in e36 and this idle problems scary me allot!!!

 

Did you ever get the stalling issue 100% sorted? I remember that the location of the MAF, distance from TB and distance from filter, are crucial.

 

The stalling is 99% sorted. I added honeycomb material on both sides of the MAF, and retuned the MAF curves in HPT. There isnt enough room in the inlet in the installation to get the MAF located in accordance with the GM installation guide. I think the honeycomb does a good job of keeping the air going straight. The idle is usually fine and holds steady at 850rpm. I get the occasional stall when bringing the car to rest between gears - maybe once every 30 miles miles. I'm not sure what do to about that but I can live with it anyway.

I have had the car running for a few months now and all is good. I have a had a few minor teething problems - a few small leaks - as to be expected. The fuel consumption is getting better - up to 18 MPG (UK galls) on the last tank full. Performance is great. The diff is 3.15 ratio so its revving low at cruise and there isnt much giddy-up in 6th as a consequence. The engine seems to need 3000rpm before it comes on the cam and flies

 

How's the brakes? I've fitted AP Racing callipers front & rear to my e46 conversion & the pedal feels horrid & the rears almost don't work

 

Have you got them bled ok? My brakes are working great so far. I haven't done any really heavy stops yet though - only a couple hundred miles done.

I was careful to get the caliper sizing right. The brakes have slightly more rear bias than before, to match the engine/trans being more rearwards than the BMW lump. I had to change the brake master cylinder from the M type to the non-M (with smaller front piston) otherwise the balance would have been dangerously rear biased.

I have a spreadsheet that works out the brake balance, where you can play around with disc/caliper/cylinder sizes and see the effect. If you want a copy send me a pm.

 

Very cool swap, and the outcome is a very cool little car! You did an outstanding job of engineering on this, one of the more impressive that I've seen so far. I hope you enjoy your Z-LS3 a lot.

Bill B.

 

Yes mate that would be awesome, they bled & some on the E46 the M has a smaller rear output than 325ci

 

Sorry for reviving a dead thread, but is there any place the Cad files of the engine and transmission used in your drawings are posted? Were they your measurements and drawings?

 

I sent the CAD file to Kyle and if anyone else wants it just ask.

Right...a little help is required. I just put the car through its second MOT and its failing on emissions. I have some leaks formed in the headers around the collectors, probably in the centre area between the 4 pipes. The collectors were made diy so perhaps the welding was not good enough :-( The leaks are causing the o2 sensors to read lean and its therefore running about 5% rich.

To fix it I'm thinking I could:

Anyone have any bright ideas?

Cheers, Mark

http://www.flickr.com/photos/7197859@N04/4960631362/http://www.flickr.com/photos/7197859@N04/4960631362/ by http://www.flickr.com/people/7197859@N04/, on Flickr

 

So how'd you make out with the emissions/MOT issue?

Tipsy